EP1444414A1

EP1444414A1 - Combination for a window and method for making such a combination

Info

Publication number: EP1444414A1
Application number: EP02787429A
Authority: EP
Inventors: Allan Edvardsen; Carsten Fredlev Nielsen
Original assignee: VKR Holding AS
Current assignee: VKR Holding AS
Priority date: 2001-11-12
Filing date: 2002-11-12
Publication date: 2004-08-11
Also published as: EA200400677A1; PL209667B1; WO2003042481A8; CN1328469C; WO2003042481A1; CN1592815A; PL370701A1; EA005757B1

Abstract

A combination for a window and a method for making such a combination, comprising a frame structure and a sash structure corresponding thereto, where the frame structure comprises a number of frame profiles (120), and the sash structure comprises a number of sash profiles (130), where at least one profile for the frame structure and one profile for the sash structure comprises one or more unit slats (100), where the unit slats for the frame respectively the sash have substantially identical cross sections, and where at least one frame or one sash profile comprises at least two unit slats, and each of the sash profiles comprises at least one unit slat.

Description

Combination for a window and method for making such a combination

The present invention relates to a combination of a frame and sash structure for a window, in particular a window for mounting in an inclined roof surface, comprising a frame structure and a sash structure, each comprising top, bottom and side portions, where the sash structure is hinge connected to the frame structure for rotation about an axis parallel to the top and bottom portions.

Windows of the kind mentioned in the introduction are well known and are widely used. In principle, such windows can be manufactured in a very sim- pie manner from identical profiles for the frame structure and the sash structure (hereinafter also designated the frame and the sash) respectively. It is thus known from EP 0 445 663 Al to manufacture a wooden profile from several wooden slats glued to- gether, where some of the slats are arranged perpendicularly to the others which makes the profile particularly stable, and furthermore, for the hidden parts of the profile, slats can be used which would otherwise have to be discarded. It is however a dis- advantage that the finished profiles are relatively bulky.

Another example of such a structure with identical profiles for sash and frame respectively is disclosed in EP-A-0 133 769. As it appears from this application, the aim is to simplify the production process and reduce the storage costs, especially to allow a frame or sash to be manufactured locally by a craftsman from ready made, identical profiles for frame and sash respectively.

In order to ensure optimum useful qualities for such a window, the above-mentioned "simple" window has gone through a development, especially with a view to securing good weather protection and consequently long life for frame and sash elements made from wood, as well as good sealing qualities between the parts movable relative to one another in order to minimize the heat loss through the window structure. These wishes have entailed that today partly comprehensive flashings for rough' protection of the window structure are used, partly a complicated system of sealing elements is used often as a system of two or three sealings "on top of each other" . These sealing elements are generally • made in the form of elastic sealing profiles,^' which either abut on a fixed part of the frame or sash structure itself or on other sealing profiles. In order to be able to fasten these sealing profiles, the frame and sash structures have been manufactured with increasingly complicated fastening systems, either with elements made as an integrated part of the frame or sash profiles such as key slots, or as independent elements for fastening hereon. This again has ^• caused that the different profiles, i.e. profiles for top, bottom and side portions for the frame and sash structure respectively, have been designed differently, which again has entailed a complicated and costly production process. The circumstances described above mainly relate to the functional qualities of the window, but an almost equally important field is that of wishing for an attractive appearance, which in practice means smooth, uniform surfaces on all visible frame and sash surfaces .

For the manufacture of frame and sash today mainly woods with a relatively large number of natu- ral irregularities are used, especially knots when using conifer wood such as pinewood and fir. In order to hide these irregularities, it has long been known to saw the timber into relatively thin slats, which have afterwards been classified according for in- stance to whether one, two or three surfaces are "flawless" and thereby free of unwanted irregularities. Hereafter, the individual frame and sash profiles have been put together such that the flawless surfaces have been placed according to the visible surfaces on the finished frame or sash structure, while the other surfaces are hidden, either on the backside of the profile or inside the profile. Dependent on the actual structure, the individual slat will have one, two or three visible sides and will thus need a number of flawless surfaces corresponding thereto .

With this background, it is an object of the invention to provide a structure for a combination of a frame and sash structure for a window enabling a rational and thus cost favourable production, but enabling at the same time to the largest degree possible to secure an optimum functional design of each component, i.e. both the different profiles for the frame and the different profiles for the sash. The present invention is based on the recognition that the profiles for the top, bottom and side portions for a roof window can be made of substantially identical slats for the frame as well as for the sash.

As it appears from the introduction, it has previously been attempted to simplify the manufacturing process for a window structure either by using identical top, bottom and side portions or by constructing the profiles from a number of slats. Both these methods are founded on the basic idea of simplifying or improving the production of an existing product, i.e. a combination of a frame with a sash placed therein. As it has not been possible to produce a well-functioning window, which has been optimised with regard to useful qualities, as well as tightness and heat insulation, made from identical profiles for the frame as well as the sash, these two part components have thus far been considered as separate units, which it has separately been attempted to rationalise the production of.

As opposed to the prior art described above, the present invention does not take its point of de- parture in the finished product, but in one of the basic components, that is the slat itself from which frame and sash are built. More specifically, the present invention is based on the recognition that as well frame as sash can be constructed, entirely or partly, from identical slats, whereby both production, classification, handling and stocking of the slats are simplified. The invention is thus based on the recognition that the largest rationalisation gain is obtained by an efficient production of the basic profiles for frame and sash respectively, whereas advantageously, the ultimate profiles can be made individually with modern production equipment. It is evident that the elaboration construction-wise of the individual profiles of the window and the choice of slat structure is adjusted to one another in such a way that the basic profiles correspond as much as possible to the finished profiles, whereby it is en- sured that the least possible amount of material is removed. This circumstance is very significant as the material costs make up a major part of the total costs when manufacturing a roof window with wooden frame and sash. From the above, it appears that the original "identical" slats will be processed and will thus formally no longer be identical, which is why, in the following, the expression "substantially identical slats" will be used for the finished profiles, whereby it should be understood that a person skilled in the art without difficulty will be able to realise that the slats only differ from one another in so far as smaller quantities of material have been removed corresponding to for instance slots or other forms of processing. More specifically, it will be possible to define that the individual, substantially identical, slats each comprise a given minimum percentage of the cross-sectional area for a reference cross section surrounding the cross section of the units slats in question. In preferred embodiments, the cross- sectional area constitutes at least 70%, preferably at least 80%, and most preferably at least 90%.

When it is stated in the following that a frame respectively a sash profile comprises one or more unit slats, this means that the individual profile can furthermore comprise additional slats of a different shape. This will typically be an advantage when the frame or the sash for structural reasons comprises a "protruding" element, which is most appropriately provided by placing a slat with a shape corresponding thereto .

Corresponding to a first aspect of the inven- tion, the combination is characterised in that each of the frame profiles comprises at least two unit slats, and each of the sash profiles comprises at least one unit slat . The number of unit slats forming part of the respective profiles are subjected to mu- tually conflicting requirement, as a large amount of units slats will increase the cost of handling and gluing together of the slats, and a large number of glue lines will occur, which will among other things impair the product visually, while a small number of unit slats will increase the risk of a slat having to be rejected due to defects, which increases material consumption.

In a preferred embodiment, both frame and sash top, bottom and side portions each comprise at least two respectively at least one unit slat. In a particularly preferred embodiment, the sash structure is hinge connected to the frame structure for rotation about an axis parallel to the top and bottom portions . According to an embodiment, each of the frame profiles comprise at least three unit slats, and each of the sash profiles comprise at least two unit slats .

A further optimisation of the number of unit profiles is obtained by the fact the frame profiles comprise n no. of unit slats and the sash profiles comprise n+1 no. of unit slats, where n is a positive integer preferably not exceeding the value of 4. Hereby account is taken of the increased cost related to handling and gluing together of a large number of slats, whereby a large number of glue lines will furthermore occur, which among other things impairs the product visually.

If a stronger frame and/or a bulkier frame is required, for example in connection with fitting a roof window in a roof structure comprising a roof covering with a relatively large distance between top and bottom surfaces, it is alternatively suggested that the sash profiles comprise n no. of unit slats and the frame profiles comprise n+2 no. of unit slats, where n is a positive integer preferably not exceeding the value of 4. For instance, when it is stated that the frame, respectively the sash, comprises at least two respectively one unit slat, this obviously includes embodiments where the frame and the sash do not comprise further slats. Corresponding to another aspect, the invention concerns a method for the manufacture of a combination of a frame structure and a sash structure corresponding thereto for a window, comprising the steps of providing a number of slats, producing one or more basic frame profiles, making frame profiles of one or more of the basic frame profiles, assembling frame profiles to form a frame structure, and producing one or more basic sash profiles, and making sash profiles of one or more of the basic sash profiles, assembling sash profiles to form a sash structure, comprising the additional step of in constructing at least one of the basic frame profiles and one of the basic sash profiles using one or more unit slats, where the unit slats for the frame, respectively for the sash, have identical cross sections, and where at least one basic frame or sash profile comprises two^' unit slats. Preferably at least one of the basic frame profiles comprises at least two unit slats, and at least one of the basic sash profiles comprises at least one unit slat.

The basic profiles preferably have a length corresponding to a number of frame or sash profiles, so that these can be made in long lengths, which will subsequently be cut up to the desired length for a given window size. By arranging with overlap, basic profiles of any desired length can be manufactured. Assembly of the slats into basic profiles will typi- cally take place by means of gluing. Assembly^' of the finished profiles for frames will take place in the traditional way, i.e. by a finger joint.

In a preferred embodiment, the basic profiles of the frame, respectively the sash, are constructed identically with identical respective cross sections for the top, bottom and side portions of both the frame and the sash.

As it appears, the invention concerns frame structures constructed by slats, but here it has to be mentioned that the term slat in this connection does not cover very thin leaf-like "slats" , which are used for the manufacture of plywood. In order to make this clear, it could be determined that the slats corresponding to the invention have a thickness (i.e. a minimum cross section dimension) of at least 5 mm, preferably at least 10 mm. In a preferred form, the slats can be designated as being rod-shaped.

In the following, the invention will be de- scribed in more detail with reference to the drawings, in which

Fig. 1 shows a fundamental embodiment for a typical roof window, Fig. 2 shows the general principle corresponding to the invention,

Fig. 3 a cross section through a frame profile and a sash profile for a roof window,

Fig. 4 shows in cross section a frame respec- tive a sash profile, on which a number of slats have been drawn, and

Fig. 5A-5I examples of shapes of basic profiles for a frame, respectively a sash.

With reference to Fig. 1, the basic elements for a roof window will be described. Such a window comprises a frame structure 1 defining an opening and comprising a top portion 2, side portions 3 and a bottom portion 4 and a sash structure 11 hinged in relation hereto, in which sash structure a pane of glass 15 is framed between a top portion 12, side portions 13 and a bottom portion 14. In the following, the expression top, side and bottom sash and the expression top, side and bottom frame will also be used to designate the top, side, and bottom portions, and likewise, the expressions frame and sash will be used for frame and sash structure . In the embodiment shown in Fig. 1, the window also comprises various flashings 5 which are not a part of this invention. The frame can rotate about an axis parallel to the bottom portions and with the hinges (not shown) located between the top and bottom portions, i.e. centre hung as opposed to a top-hinged window.

Fig. 2 shows the general principle correspond- ing to the invention, i.e. how a unit slat can be used to establish three different configurations for a combination of a frame and a sash. More specifically, Fig. 2 shows a unit slat 100 in section as well as three combinations also in section, for a frame and a sash corresponding thereto. The expression "unit" exclusively refers to the cross section as the length of the individual slat depends on the specific use. In all three embodiments, the frame profile 131, 132, 133 is the same, whereas the sash profile varies. In a first embodiment, the sash profile 121 consists of four unit slats placed in a stack, in a second embodiment the sash profile 122 consists of four unit slats placed in pairs side by side, and in a third embodiment, the sash profile 123 consists of two unit slats placed in combination with two slats 110 having a different cross section. In Fig. 2, the slats are shown in two "qualities", either hatched or non-hatched, where the former shows a slat with one or more surfaces without defects (such as knots) , and where the latter shows a slat where there are no special requirements as to the appearance of the surface. Depending on the structure, it might be necessary that a given flawless surface be surrounded by flawless surfaces on one or both sides. Whether a given surface is free and thereby visible on the finished window depends partly on whether a surface represents a front or a back, partly on whether the side is to be covered in another way, just like there might be different requirements to the degree of perfection depending on how visible the surface is on the fitted window. As it appears, slats belonging to more than just two categories will often be an option.

Fig. 3 shows a cross section (corresponding to the side portions in Fig. 1) , a frame profile 20, a sash profile 30, a pane 15, a mounting frame 16 and a flashing 5. This invention only concerns the frame and the sash whereas the flashing elements are only shown for illustration. It is noted that the figure is schematic, only stating the main components for a roof window. The frame profile comprises a front sur- face 21, a back surface 22, an inside face 23 and an outside face 24, just as the sash profile comprises a front surface 31, a back surface 32, an inside face 33 and an outside face 34. Each of the profiles comprise a number of key slots 25 in the form of none or one or more on each of- the four surfaces. It is noted that the frame profiles 20 as well as the sash profile 30 has a general configuration corresponding to the examples shown in Fig. 2, which will be described further below. Fig. 4 shows a frame, respectively a sash profile 120, 130 with a sectional configuration corresponding roughly to the one shown in Fig. 3, on which profile a number of slats 101-106 have been drawn corresponding to the first configuration of basic profiles 121, 131 shown in Fig 2. As it can be seen, the basic profiles correspond to a large degree to the finished profiles. In particular, it is seen that the three top slats (in fig. 4) of the frame profile and the two slats for the sash profile are substan- tially identical, whereas so much material has been removed at the lowest frame slat 104 that it cannot directly be said to correspond to the others. This is however entirely in conformity with the first aspect of the invention, which solely indicates that a frame profile comprises at least two unit slats (here: three) , and a sash profile comprises at least one unit slat (here: two), where the unit slats for the frame, respectively the sash, have a substantially identical cross section. With regard to the "technical" definition of the invention, it furthermore appears that a reference cross section is made up by the remaining part of the second slat 102 of the frame, and that the cross section of the other unit slats 101, 103, 105, 106 make up at least 70% hereof. Even though the reference cross section for the embodiment shown corresponds to the actual cross sections, this is not necessarily the case, as the ref- erence cross section will often have a larger area than corresponding to the "largest" of the actual cross sections.

It must be emphasized that the above discussion regarding what can be perceived as being substan- tially identical for the ready-made profiles, and thereby slats, is not relevant for the method according to the invention, as here it is exclusively the slats in their unmanufactured form which is relevant. Seen in this light, all the slats 101-106 shown here would therefore be unit slats according to the second aspect of the invention.

In figs. 2 and 4 a single type of slat configuration is shown (that is four slats for the basic profile of the frame and two slats for the basic pro- file of the sash) , but it will obviously be possible to vary the invention with regard to both form and number and position of the slats in the basic profiles, as shown in fig. 5A-5I. More specifically, Fig. 5A shows an embodiment where the frame profile consists of only two slats and the sash profile of only one slat; as it appears, the slats 112 can also have a square cross section. Fig. 5B shows an embodiment where both frame and sash profiles are identical (apart from the orientation of the slats) and each consist of two slats. Fig. 5C corresponds to the configuration shown in fig. 3, whereas Fig . 5D shows an embodiment where the frame consists of differently oriented slats. Fig 5E shows an example where a relatively large number of narrow slats 113 are used, which can be advantageous if knotless surfaces are difficult to come by. Fig. 5F and 5G show examples where slats 114 with non- parallel surfaces are used, and Fig. 5H and 51 show examples where the unit slats have been complemented with elements 115-118 having another configuration. The latter will of course increase the complexity of the manufacturing process, but can be advantageous in reducing the material consumption.

Corresponding to another aspect, the invention also concerns a method for the manufacture of a frame structure and a sash structure corresponding thereto for a window. As mentioned in the introduction, for the manufacture of frame and sash for windows, often woods with natural irregularities are used, especially knots when using conifer wood such as pinewood and fir. After conversion of the logs at the sawmill into the desired slat dimension (typically with a rectangular cross section) , a quality classification of each slat is carried out, according for instance to the number of flawless' surfaces, which are suitable for use as visible surfaces on the finished win- dow. A "perfect" slat will typically have one (wide) flawless surface with one or two flawless adjacent edges. After classification, the slats, can now be laid up according to the desired configuration as to dimensions and location of faultless surfaces for the frame or sash in question. Typically the slats are arranged with overlap into relatively long structures, which are afterwards assembled into basic profiles by gluing under pressure. Corresponding to the invention, both basic frame and sash profiles comprise one or more unit slats, but preferably both basic profiles are constructed primarily from unit slats, most preferably exclusively from unit slats.

Claims

P A T E N T C L A I M S 1. A combination for a window comprising a frame structure and a sash structure corresponding thereto, where the frame structure comprises a number of frame profiles (120) , and the sash structure comprises a number of sash profiles (130) , where at least one profile for the frame structure and one profile for the sash structure comprises one or more unit slats (100) , where the unit slats for the frame respectively the sash have substantially identical cross sections, c h a r a c t e r i z e d in that each of the frame profiles comprises at least two unit slats, and each of the sash profiles comprises at least one unit slat.

2. A combination according to claim 1 where the frame structure and sash structure both comprise top, bottom and side profiles.

3. A combination according to claims 1 or 2 where each of the frame profiles comprises at least three unit slats, and each of the sash profiles comprises at least two unit slats.

4. Combination according to any of the claims 1-3 c h a r a c t e r i z e d in that the frame profiles comprise n no. of unit slats and the sash profiles comprise n+1 no. of unit slats, where n is a positive integer preferably not exceeding the value of 4.

5. A combination according to any of the claims 1-3, c h a r a c t e r i z e d in that the sash profiles comprise n no . of unit slats and the frame profiles comprise n+2 no. of unit slats, where n is a positive integer preferably not exceeding the value of 4.

6. A combination according to any of the claims 1-5 where the respective profiles of the frame structure and the sash structure respectively are substan- ^• tially identical.

7. A combination according to any of the claims 1-6 where the respective profiles of the frame structure and the sash structure respectively are constructed primarily from unit slats, preferably exclusively by unit slats.

8. A combination according to any of the claims 1-7 where the sash structure is hinge connected to the frame structure for rotation about an axis parallel to the top and bottom portions.

9. A method for the manufacture of a combina- tion of a ' frame structure and -a sash structure corresponding thereto for a window, comprising the steps of:

- providing a number of slats,

- producing one or more basic frame profiles, - making frame profiles (120) of one or more of the basic frame profiles,

- assembling frame profiles to form a frame structure and - producing one or more basic sash profiles,

- making sash profiles (130) of one or more of the basic sash profiles, assembling sash profiles to form a sash structure, c h a r a c t e r i z e d in constructing at least one of the basic frame profiles and one of the basic sash profiles using one or more unit slats

(100) , where the unit slats for the frame, respec- tively for the sash, have identical cross sections, and where at least one basic frame or sash profile comprises two unit slats.

10. A method according to claim 9 where the frame structure and the sash structure each comprises top, bottom, and side profiles, and where the basic profiles for the top, bottom and side portions of the frame and the sash respectively are built with identical cross sections.

11. A method according to claims 9 or 10, where the basic profiles have a length corresponding to a number of frame or sash profiles.

12. A method according to any of the claims 9- 11, further comprising the step of connecting the frame structure to the sash structure with a hinge device so that the frame structure can rotate about an axis parallel to the top and bottom portions relative to the sash structure.