EP2426303A2

EP2426303A2 - Metal reinforced plastic window frame

Info

Publication number: EP2426303A2
Application number: EP11179957A
Authority: EP
Inventors: Ryszard Florek
Original assignee: Fakro PP Sp zoo
Current assignee: Fakro PP Sp zoo
Priority date: 2010-09-06
Filing date: 2011-09-02
Publication date: 2012-03-07
Also published as: PL392318A1; PL219804B1

Abstract

Plastic window frame with rails in the form of multi-chambered plastic profiles, connected by welding at oblique ends, which in at least side rails (1), has reinforcing and stiffening inserts (61, 62), preferably made of a low thermal conductivity material, bound with the profile chamber walls using adhesive.

In addition to the known steps, the frame manufacturing method involves inserting reinforcing and stiffening inserts (61, 62) into the rail, together with injecting adhesive through the supply holes (14).

Description

The invention refers to a window frame with multi-chambered plastic profile rails welded together at their oblique ends. The invention also refers to the manufacturing method of a window frame with multi-chambered plastic profile rails. The frames according to the invention are used mainly in the sashes of roof windows, especially those with the hinges attached to the side rails of the sash frame.
Window frames are known with rails made of multi-chambered plastic profiles connected by welding at their oblique ends, so that these rail connections form the window frame corners. Rail profiles usually have one chamber larger than the other chambers, where the reinforcing section is placed, which is usually a metal channel section. The largest chamber of the rail profile is located near the profile's neutral axis of bending and the reinforcing section is placed so that its cross section is situated on both sides of the neutral axis of bending of the profile cross-section. By selecting the length and the thickness of the section arms, the position of its neutral axis of bending is affected, and indirectly, the position of the rail's neutral axis of bending.
Plastic window frame with rails in the form of multi-chambered plastic profiles reinforced with metal sections, positioned inside multi-chambered plastic profile, is provided with reinforcing and stiffening inserts in at least one rail, which are embedded in the plastic rail profile chambers and are connected with the walls of the chambers by means of adhesive. The reinforcing and stiffening inserts, preferably of a low thermal conductivity material are located mainly in extreme chambers of rail profile, positioned farthest from the profile cross-section neutral axis of bending, on at least one side of this axis. There are typically four rails in the window frame, made of multi-chambered plastic profiles, which are permanently connected at their oblique ends, mainly by welding. The length of each reinforcing and stiffening insert is less than the length of the rail on the inner side of the window frame. Within the meaning of this invention description, window frame means both the frame and the sash frame. The frame is fitted with hinges that connect it to the second window frame, more precisely, one hinge assembly (fixed) is mounted on the frame (casing) and the second one (movable) is mounted on the sash frame. There is also a solution involving intermediate connecting assembly, between the casing and sash hinges. These window assemblies are responsible for the two window opening modes.
Reinforcing and stiffening inserts are placed at least in side rails, or at least in the hinged rail. Depending on the type of window and its opening modes, the rails may be identical. For example in the roof window opened by rotating about a horizontal axis positioned close to half the length of the window, or slightly above, hinges connect the side casing rails and sash rails. Also in the turn window, one sash side rail is connected by hinges to the frame (casing) side rail. However, in awning windows, hinges are mounted on the upper rails, and in tilting windows, hinges are mounted on the lower rails. If not occurring in all rails, the reinforcing and stiffening inserts are preferably placed in those rails, which carry the greatest load.
The reinforcing and stiffening insert fills at least half of the chamber cross-section in which it is placed and fills the chamber entirely, preferably maintaining the necessary clearances. Preferably, the reinforcing and stiffening insert is made of wood and has longitudinal cavities especially in the corners. These cavities accommodate the excess adhesive binding the insert the chamber walls in which the insert is placed. There can be just one reinforcing and stiffening insert in the rail but there also may be two such inserts, positioned on both sides of the rail cross-section neutral axis of binding. The reinforcing and stiffening inserts can have a maximum length equal to the length of the rail on the inner side of the window frame or may also be shorter, located in the zone of greatest rail load by bending moment. With two inserts in the rail, it is also possible to differentiate their length.
If the frame according to the invention is the sash frame of roof window, then its plastic rail profiles have shoulder to provide support for the window glass pane, and on the outer side of the window, these profiles have bearing surfaces for glass pane clamping strips, which are attached to rail profiles using mainly threaded fasteners. The reinforcing and stiffening insert of the window sash frame is positioned directly at the bearing surface for clamping strips, which holds the glass pane in the frame. Fasteners securing the glass pane clamping strip, preferably screws, are embedded in the reinforcing and stiffening insert, and through the wall of rail multi-chambered profile, these fasteners either pass through the threaded hole, made when screwing the threaded fastener in the reinforcing and stiffening inserts, or through a smooth hole with a diameter slightly larger than the threaded fastener screwed into the insert.
The reinforcing member is usually a channel section, preferably with its cross-section distributed on both sides of the rail cross-section neutral axis of binding.
The section is located in the largest rail profile chamber, and the size and shape of its arms are preferably chosen so that the section cross-section neutral axis is as close as possible to the rail cross-section neutral axis of binding.
The method of manufacturing plastic window frame with rails in the form of multi-chambered plastic profiles is characterized by the fact that reinforcing and stiffening insert is placed in the chamber at the face surface together with adhesive in order to bind the reinforcing and stiffening insert with chamber walls. The method of manufacturing the window frame also involves well known rail production techniques by oblique cutting of multi-chambered plastic profiles and then connecting the resulting rails by welding their oblique ends to from the window frame. If necessary, the squeezed out beads in the joints are cut off at the window frame corners.
Before placing the reinforcing and stiffening inserts in the rails, holes are made in the chamber walls through which the adhesive is injected as the insert slides into the chamber. The number and spacing of holes depends on the clearance between the insert and the chamber walls.
If the reinforcing and stiffening insert is to be placed only in the part of the rail length, especially in its middle, the insert is pushed inside the chamber by means of the pusher.
In the first plastic window frame manufacturing method, the reinforcing and stiffening insert is introduced into the trimmed rail chamber before welding to other window rails. Welding of rails to connect them in a window frame is performed after setting of the adhesive connecting the insert with the rail chamber walls in which it is placed. This manufacturing method is used in the production of the new window frames.
In the second manufacturing method, reinforcing and stiffening insert is introduced into the side rail chamber, located on the rim of the sash frame, after the welding of the rail to other window frame rails, placing the insert above the surface of the bottom rail. This method can be used both in the production of new roof window frames, as well as to reinforce used frames.
In the third manufacturing method, after welding the rails of the window frame, the reinforcing and stiffening insert is introduced into the chamber through the access hole made in the transverse rail. The access hole is located on the extension of the chamber axis, and after the reinforcing and stiffening insert is inserted the access hole can be sealed. This method is mainly used to reinforce the existing frames, and also during window repair and modifications.
The reinforcing and stiffening inserts glued to the window frame rails made of multi-chambered plastic profiles, reinforce and stiffen the rails, and consequently the entire window frame. Benefits arise mainly due to the location of reinforcing and stiffening inserts in the extreme chambers, which increases the rail cross-section moment of inertia, increasing its rigidity and flexural strength. The location of reinforcing and stiffening inserts directly under the glass pane clamping strip bearing surface increases the reliability of strip fastening.
Plastic window frame and its manufacturing method are shown as embodiments in drawings, where individual figures show:

Fig. 1 -: view of part of the roof window sash frame when inserting the reinforcing and stiffening insert into the rail.
Fig. 2 -: roof window sash frame rail cross-section with two reinforcing and stiffening inserts.
Fig. 3 -: view of roof window sash frame side rail when inserting the reinforcing and stiffening insert.
Fig. 4 -: section through part of the roof window sash showing side rails of Figure 2 with seals, glass pane and hinge.

The invention is also presented in the examples that are not shown in the figure, but described by identifying common features and differences compared to the examples shown.
Example 1 Roof window sash frame is made of multi-chambered plastic profiles manufactured by extrusion. The sash frame is composed of two side rails 1, the upper rail 2 and the lower rail 3. Side rails 1 are made of profile with shoulder 11 on which the seal 12 is placed to support glass pane mounted in the sash frame. In addition to shoulder 11 and seal 12, in the side rail multi-chambered profile 1 there is a two-chamber rim, protruding above the shoulder 11 surface and above the pane seal 12. In the assembled frame, the side rim 13 limits the lateral movement of the glass pane mounted in a window sash frame, along the sash frame.
Upper rail 2, made of identical multi-chambered plastic profile, has a shoulder 21 with a seal 22 for glass pane and a two-chambered rim, which is its upper rim 23 in the assembled frame. Lower rail 3 is made of a reduced height profile, so that the seal 31 is the highest placed element of the rail, while the lower rail 3 differs from the side rails 1 and upper rail 2 in that it has no rim. Side 1, upper 2 and lower 3 rails have diagonally cut ends, and the resulting rail contact surfaces are welded in order to connect the rails into a complete window sash frame. The weld 4 between the side rails 1 and the upper rail 2 covers the entire height of the rails, together with their rims 13 and 23, while the weld 41 between side rails 1 and the lower rail 3 only reaches the height of the lower rail. Hinge assemblies 5 are attached to both side rails 1 roof of window sash frame. Hinge assemblies are designed to open the window by turning the sash about a horizontal axis, located just over half of the sash height.
In each of the two roof window sash frame side rails 1, in multi-chambered profile chamber, located in the side rim 13, the farthest away from the rail neutral axis of binding, there is a reinforcing and stiffening insert 6, having the form of a wooden strip of rectangular cross-section. Figure 1 shows the insert (for illustrative purposes) in the position when being inserted into the side rail profile chamber 1, while in the assembled window frame, reinforcing and stiffening insert 6, which is shorter than the length of the rail 1, measured on the inside of the window frame, fits entirely between the obliquely trimmed ends of the side rail 1. Reinforcing and stiffening insert 6 is bound with the walls of the chamber by means of adhesive, injected in the chamber through the supply holes 14. Inside the side rails 1, in the largest plastic profile chamber, the known metal sections are placed (shown in more detail in the second example), which reinforce the rails. These sections are attached to the profile side wall using screws 15 from the outside of the sash frame. For a larger frame width, a similar section is placed inside the upper rail.
Side rail profile chamber 1, the most distant from the rail neutral axis, is also the chamber located in the side rim 13, directly below the bearing surface of the clamping strip, holding the glass pane in the sash frame. The location of reinforcing and stiffening insert 6 in the rails profile chamber 1 allows threaded fasteners to be embedded in the insert to fasten the pane clamping strip to window sash frame.
Example 2 Roof window sash frame is composed of multi-chambered plastic profiles, which are identical and identically connected as in the first example of the invention. Inside the side rail profile 1 (cross-section - Figure 2) there are two reinforcing and stiffening inserts, of which the glazing insert 61 is placed in the chamber, situated in the side rim 13 of the rail, next to the shoulder 11 and seal 12. Additional insert 62 is placed in the chamber on the opposite side of the rail profile. Both chambers with the inserts are the furthest away from the rail's neutral axis of binding. Inserts 61 and 62 are bound with the walls of the chambers with adhesive, injected into the interior of both chambers through supply holes 14, which, for the chamber containing the glazing insert 61, are located on the outside of the window and at the glass pane, alternately in one and the other chamber wall (Figure 3). For the chamber with an additional insert 61, holes are inside the side seal channel 16. Glazing insert 61 has corner cavities 63 and the additional insert 62 has corner chamfers 64 - both provide space to accommodate any excess glue.
Inside the largest rail chamber there is metal channel section 17 with on of its arms curved. C-section 17 is attached to the side rail outer walls 1 using screws, and on the outer side surface of the rail hinge assembly 5 is mounted - as in the first example.
In the assembled roof window sash the supply holes 14 are concealed by glass pane 7, and its clamping strip 71 and with side seal 72 (Fig. 4), which enhances the window aesthetic appearance. Clamping strip 71 is attached to the rails 1 with screws 73 embedded both in the rail walls and the glazing insert 61. Supply holes 14 can be also used to pass screws through the chamber wall.
Example 3 Roof window sash frame is composed of multi-chambered plastic profiles, which are identical and identically connected as in the second example. Just the same, within the side rail multi-chambered profile there are two reinforcing and stiffening inserts: glazing insert, placed in the chamber located in the rail side rim, and the additional insert. In the upper rail 2 there is a glazing insert, placed in the chamber located at the rail upper rim 23, next to the seal 22 on the shoulder 21.
Example 4 Roof window sash frame is composed of multi-chambered plastic profiles, which are identical and identically connected as in the second example of the invention. Inside the side rail multi-chambered profile 1 there are two reinforcing and stiffening inserts (Figure 2): glazing insert 61 placed along the rail's entire length and an additional insert 62 placed in the middle section of the rail, on both sides of the hinge. The supply holes for additional insert are distributed only along its length.
Example 5 Manufacturing process of a roof window sash frame, whose structure is shown in the first example, begins with cutting of multi-chambered plastic profiles, fitted with a rim, to the desired length of the side rails 1 and the upper rail 2 and cutting of multi-chambered plastic profile without a rim to the desired length of the lower rail 3. All rails are cut obliquely at an angle of 45° to obtain surfaces where the rails are welded to combine them into a complete frame. Before welding, known metal sections are inserted into the largest chambers of the two side rails, and in the case of the broader frames, into the upper rail and then fastened with screws to the outer wall of rail profile. After welding, if a need arises, the plastic beads squeezed out of joints of the window frame corners are cut off.
In the sash frame side rails 1, in the walls of the chamber located at the side rim 13 the farthest from the rail cross-section neutral axis, supply holes 14 are made alternately in the wall of the chamber located on the outer side of the window and in the side wall of this chamber. These holes are distributed along the entire length of the planned location of the reinforcing and stiffening insert 6 (the figure shows the extreme holes only). Supply holes 14 can be made in the frame after welding, but it is better to make them in side rail 1 before welding.
In each of the two side rails 1 connected by welding to window sash frame, located in the side rim 13 of the rail profile chambers farthest away from the rail neutral axis, a reinforcing and stiffening insert 6 is inserted at the lower rail 3 by moving the insert above the lower rail. When inserting the reinforcing and stiffening insert 6 into side rail profile chamber 1, adhesive is injected into the rail profile chamber through the supply holes 14 in succession, so that individual portions of the adhesive are injected before head of the insert. Given the existence of a clearance between the reinforcing and stiffening insert 6 and the chamber walls, adhesive is evenly distributed along the chamber and the insert.
Example 6 Manufacturing of a roof window sash frame, whose structure is shown in the second or third example, begins with cutting of multi-chambered plastic profiles to the desired length of the rails: side rails 1, the upper 2 and lower rail 3 - as in the method presented in the fifth example. Then in the side rails 1, in the walls of the chamber located at the side rim 13, the farthest from the rail cross-section neutral axis, supply holes 14, are made alternately in the wall of the chamber located on the outer side of the window and in this chamber wall at the glass pane side. These holes are distributed along the entire length of the planned location of the glazing insert 61 (the figure only shows the extreme holes). Manufacturing a frame of the third example, the supply holes 14 are also made in the upper rim 23 of the upper rail. In side rails 1 supply holes 14 are also made for the chamber with an additional insert 62 passing through the channel 16 from the side seal. Subsequently, inserted into the side rails 1 from the face surface side, are reinforcing and stiffening inserts: glazing 61 and additional 62 inserts while gradually injecting the adhesive through supply holes 14, as the the insert is slid in. Similarly, the glazing insert 61 is placed in upper rail, if one is installed there. Then, known metal sections 17, are inserted into the largest chambers of the two side rails, and in the case of the broader frames, into the upper rail and then fastened with screws 15 to the outer wall of rail profile. Rails prepared as outlined above are welded at the oblique ends, resulting in a complete frame. After welding, if a need arises, the plastic beads squeezed out of joints of the window frame corners are cut off.
Example 7 Manufacturing of a roof window sash frame with some of the reinforcing and stiffening inserts shorter (design shown in example 4) is similar to the method presented in the sixth example. Supply holes for shorter reinforcing and stiffening inserts are made only along their actual location, and inserts are introduced into the chamber by means of the pusher, which is then withdrawn.

Claims

Plastic window frame with rails in the form of multi-chambered plastic profiles, permanently connected at their oblique ends, reinforced with primarily metal sections, placed inside multi-chambered plastic profile, fitted with hinges to connect it to the second window frame, especially roof window sash frame, where the rail profiles also have shoulder to support glazing and bearing surfaces located on the outer side of the window, for clamping strips holding glass pane, fixed to multi-chambered rail profiles using chiefly threaded fasteners, is characterized in that in at least one rail (1, 2, 3) in the plastic profile chambers, especially the extreme ones, located farthest from the rail cross-section neutral axis of binding, on at least one side of this axis, there are reinforcing and stiffening inserts (6, 61, 62) preferably made of a low thermal conductivity material, which are bound to the chamber walls with adhesive, whereby the length of each insert is not greater than the length of the rail of the inner side of the window frame.
Window frame as described in claim 1, characterized in that the reinforcing and stiffening inserts (6, 61, 62) are placed at least in side rails (2).
Window frame as described in claim 1, characterized in that the reinforcing and stiffening inserts (6, 61, 62) are placed at least in the hinged side rails.
Window frame as described in claim 1, 2 or 3, characterized in that the reinforcing and stiffening insert (6, 61, 62) fills at least half of the chamber cross-section in which it is placed and fills the chamber entirely, preferably maintaining the necessary clearances.
Window frame as described in claim 1, 2, 3 or 4, characterized in that the reinforcing and stiffening inserts (6, 61, 62) are placed both sides of the rail cross-section neutral axis (1, 2, 3) of binding.
Window frame as described in claim 1, 2, 3, 4 or 5, which is the sash frame, characterized in that the reinforcing and stiffening insert (6, 61, 62) is placed directly at the bearing surface for clamping strips (71), holding the glazing (7) in the frame.
Window frame as described in claim 6 characterized in that the fasteners holding the clamping strip (71) preferably screws (73) are embedded in the reinforcing and stiffening insert (6, 61, 62).
Window frame as described in claim 1, 2, 3, 4, 5, 6 or 7, characterized in that the reinforcing and stiffening insert (6, 61, 62) is located in the rail (1, 2, 3) only in areas subjected to the greatest bending moments.
Window frame as described in claim 1, 2, 3, 4, 5, 6, 7 or 8, characterized in that the reinforcing and stiffening insert (6, 61, 62), preferably made of wood, has longitudinal cavities (63) especially in its corners.
Window frame as described in claim 1, 2, 3, 4, 5, 6, 7, 8 or 9, characterized in that the reinforcing section (17) is a channel section, preferably with its cross-section distributed on both sides of the rail cross-section neutral axis of binding.
Manufacturing method of the plastic window frame with rails in the form of multi-chambered plastic profiles, involving making rails by oblique cutting of multi-chambered plastic profile ends and then binding these oblique rail ends to obtain a window frame and, if necessary, cutting off the beads squeezed out in the corner joints of the window frame is characterized in that at the front surface of the rail multi-chambered profile (1, 2, 3) a reinforcing and stiffening insert (6, 61, 62) is introduced into the chamber together with adhesive to bind the reinforcing and stiffening insert to chamber walls.
Window frame manufacturing method as described in claim 11, characterized in that the reinforcing and stiffening insert (6, 61, 62) is introduced into the chamber of a cut rail (1, 2, 3), before it is welded to other window frame rails.
Window frame manufacturing method as described in claim 11, characterized in that the reinforcing and stiffening insert (6, 61, 62) is introduced into the chamber of a cut rail after it is welded to other window frame rails, especially through the access hole made in transverse rail, located on the extension of the chamber axis.
Window frame manufacturing method as described in claim 11, 12 or 13, characterized in that in the rail chamber walls (1, 2, 3) where a reinforcing and stiffening insert would be introduced (6, 61, 62), supply holes (14) are made thorough which adhesive is injected during insertion of the insert.
Window frame manufacturing method as described in claim 11, 12, 13 or 14, characterized in that the reinforcing and stiffening insert (6, 61, 62) is moved inside the chamber by means of a pusher.