EP2660415A1

EP2660415A1 - Window element or window or door frame element

Info

Publication number: EP2660415A1
Application number: EP13166366.8A
Authority: EP
Inventors: Bent Ahlmann Larsen
Original assignee: Barsmark AS
Current assignee: Barsmark AS
Priority date: 2012-05-03
Filing date: 2013-05-03
Publication date: 2013-11-06

Abstract

Window element or window or door frame element suitable to be built into a building's wall, where said element consists of a box structure which box structure is open in two opposing ends, and which in use will have a top plate, a bottom plate and two side plates connecting said top and bottom plates at their free side edges, where each plate along its edges is provided with structural frame members made from a polyurethane based material, and where the volume between the structural frame members is filled with an insulating material, and that means are provided along what in use will be facing the outside environment of the building for fastening either a glass pane or a sash frame, and that along the edges of the element which will be facing the interior of the building means are provided for integrating the element with the walls surface.

Description

Field of the Invention

The present invention is directed to a window element or window or door frame element suitable to be built into a buildings' wall, as well as a method of installing such a window element or window or door frame element into a building's wall.

Background of the Invention

In the art it is common practice to see windows as a separate element which has to be integrated in the building in order to provide light and air, etc. Traditionally, a building will have an outer wall, for example made from bricks separated from an inner wall by an insulation layer where the inner wall may be made from for example a skeleton of timber and gypsum boards, concrete panels or the like. The amount of insulation depends partly on the type of building, partly on the geographical location of the building and on the building codes present in the country where the building has to be erected.
Typically, the wall construction will be designed such that there will be no thermal bridge between the outer and inner walls. This is important in order to maintain the good insulation properties and thereby lower the energy consumption needed in order to heat the building. Typically, outer wall constructions according to the latest Danish building codes will have a thickness from 360 mm to typically 480 mm or more, and as such the walls are quite substantial. In the openings where windows, doors and the like are to be mounted the distance between the inner side of the outer wall and the outer side of the inner wall will be minimized for example by mounting an element such that only a gap of 20-30, maybe 50 mm is left between the front and rear walls. The window frame elements will typically have a dimension of 100-160 mm in the direction of the wall thickness when mounted such that it will be possible to mount the window frame spanning the gap between the front and rear walls whereby the gap will neither be visible from the inside nor the outside. Needless to say, this procedure is quite labour-intensive and also requires that the window, i.e. the glass of the window, is positioned at a certain position in order to bridge the gap thereby withdrawing the glass from the façade. A further disadvantage with the traditional way of combining windows into buildings is the fact that the gap between the front and rear walls is not suitable to fasten the window frame, and as such the window frame must be fastened, either by special brackets or directly into either the front wall or the rear wall or the special member arranged to bridge part of the gap between the front and rear walls.

Object of the Invention

Consequently, there is a desire to rethink the window and doorframe constructions relative to the buildings in a manner that the window/doors become more integrated in to the building and where easier installation is achieved and at the same time a more stable, rigid and improved insulating construction may be provided.

Description of the Invention

The invention provides a solution to this problem by means of a window element or window or door frame element suitable to be built into a building's wall, where said element consists of a box structure which box structure is open in two opposing ends, and which in use will have a top plate, a bottom plate and two side plates connecting said top and bottom plates at their free side edges, where each plate along its edges is provided with structural frame members made from a polyurethane based material, and where the volume between the structural frame members is filled with an insulating material, and that means are provided along what in use will be facing the outside environment of the building for fastening either a glass pane or a sash frame, and that along the edges of the element which will be facing the interior of the building means are provided for integrating the element with the wall's surface.
By providing a complete element spanning from the front side of the façade to the rear side of the rear wall an effective bridging of the gap between the front and rear walls is achieved and furthermore all finishing work in connection with integrating the window including frames and sash frames etc. is solved by a single integrated element. Furthermore, by making the window element or window or door frame element from a polyurethane-based material and filling the spaces between the structural elements with insulating material an element having much better insulating properties than what is traditionally available is provided and as such the overall insulating properties of the window is improved. With respect to the amount of labour necessary as the element is a complete, finished unit, the necessary labour is much less in that the single element may be fitted not making it necessary to have all the different routines which are necessary with the traditional way of mounting windows.
In a further advantageous embodiment of the invention the inside or the outside or both the inside or the element is provided with a covering plate or veneer, where said plate may be a composite material, a polymer material, a naturally occurring material, a surface coating, a metal such as aluminium, copper, or zink and where the veneer may be selected among any type of veneer. With this embodiment it is possible to provide the finish which is desired in the window opening such that no further work needs to be carried out in connection with finishing of the window structure, as it is already pre-made and integrated in the element.
In a still further advantageous embodiment the polyurethane-based material comprises regenerated polyurethane and fibres selected from one or more of the following fibre types: glass, polyester, polypropylene.
In a still further advantageous embodiment the insert is made from a polymer material comprising regenerated polyurethane and fibres selected from one or more of the following fibre types: glass, polyester, polypropylene.
The insulating material arranged between the structural frame members may in a further advantageous embodiment be selected among the following: expanded polystyrene, glass-wool, rock-wool, polyurethane foam, cork, vacuum insulation (silicium dioxide).
As there is no structural requirements to the insulating material due to the fact that the structural frame members provide all the structural integrity needed for the window element or window or door frame element, the insulating material may be selected freely with due respect to the insulating properties etc. A preferred vacuum insulating material is Poreextherm Vacupor® NT-B2-S.
In a still further advantageous embodiment of the invention the opening which in use is towards the interior of the building is larger than the opening facing the outside environment. In this manner it is ensured that the light which enters through the window is received on the inside the best way possible. Especially with the very thick wall constructions needed in order to address the requirements of the building codes, the openings in which the windows are mounted may become relatively small although the area is the same, but due to the increased wall thickness they appear smaller. By widening the inside opening the light entrance opening will appear larger and as such provide more light to the inside room.
The invention is directed both to a window element and a window or door frame element. The window element is considered to be a non-opening window structure such that in a further advantageous embodiment the structural members provided along what in use will be facing the outside environment of the building are shaped as a glass receiving frame or a sash frame receiving frame. The window or door frame elements are by the nature of a door and an opening window constructed such that a sash frame may be arranged in the window or door frame element such that it will be possible to open the window and the door respectively.
In the art it is well-known to provide the appropriate contours for the frame elements in order to achieve safe closure and avoid water, wind and moisture penetration through the window construction, i.e. the opening between the window frame and the sash frame. The skilled person will design these mutually engaging frame members in a manner providing the traditional closure features.
The invention is also directed to a method of installing a window element as described above wherein

a frame element having a distance between the open ends substantially corresponding to the thickness of the building's wall into which the window is to be installed, is selected;
where the height and width of the window element corresponds to the opening provided in the building's wall into which the element is to be mounted;
where the window element is arranged in the opening, and fastened to the building's walls.

Above the invention has been described with reference to various embodiments, but it is also construed within the scope of protection afforded by the claims that a plurality of window elements or window or door frame elements may be grouped together in order to create a section of a façade comprising a plurality of windows and or doors.

Description of the Drawing

The invention will now be explained with reference to the accompanying drawings wherein

Figure 1: illustrates a typical traditional construction
Figure 2: illustrates cross-section through a wall
Figure 3: illustrates the structural members of an element without sides
Figure 4 and 5: illustrate connection between element and window glass
Figure 6: illustrates an element according to the invention wherein a sash frame is arranged.

Detailed Description of the Invention

In figure 1 is illustrated a typical traditional construction having a double wall construction in which a window is mounted. The wall comprises a front wall 1 in this embodiment in the shape of a brick wall and a real wall 2 illustrated as a concrete panel. Between the two walls is arranged insulation 3. As this invention is directed to a novel and inventive manner in which to arrange a window in an opening in a wall, the further aspects of the wall are not relevant and therefore ventilation, membranes etc. are not illustrated. In opening 4 where it is desirable to install a window frame in this embodiment, a non-opening window construction 5 is illustrated. In the traditional construction the insulation 3 is allowed to completely separate the front wall 1 and the rear wall 2. This is typically done by placing a piece of relatively hard insulation 6 such as for example expanded polystyrene.
Furthermore, in order to bridge the gap between the front wall 1 and the rear wall 2 a cladding member 7 is typically arranged which may also double as window sill or interior cladding in the window opening. The window construction 5 is fastened either to the plate 7 or fastened by means of a screw 8 to the front wall 1. The frame 9 of the window in this embodiment has a wood rear part and a composite front part and has a dimension such that it will bridge the gap filled with polystyrene 6. Normally, the window frames 9 are mounted suspended in the opening such that screws will attach the window to the opening along the sides and an expandable foam material, for example based on polyurethane or other resilient insulation material, will be placed between the frame 9 and the wall 1 in order to provide insulation. In this embodiment only resilient joints 10, 11 are illustrated.
As will appear from the description above, the process of installing a window in an opening in a wall structure is a complicated process, and it does severely restrict where the window frame shall be placed in that the window frame 9 shall bridge the thermal barrier 6 in order to maintain the high insulation properties of the overall construction.
Turning to figure 2, however, a cross-section through a wall corresponding to the wall described with reference to figure 1 is illustrated wherein a window element 20 according to the invention has been installed in the opening 4. As is evident from figure 2 the element 20 is arranged substantially flush with the inner side of the rear wall element 2 and in this embodiment is pulled slightly back from the front side of the front wall 1. Naturally, the dimensions of the element 20 may be such that the element is flush with the rear wall and the front wall or is withdrawn with respect to one or the other.
In the cross-section of the element it is illustrated that structural members 21 are arranged along the edges of the element 20. This will be more clearly explained with reference to figure 3. It is, however, clear that the structural members 21 in combination with the insulating plates 22 which are arranged between the structural members 21 thereby creating the box form illustrated with reference to figure 4 provide high structural stability such that no other means are needed when installing windows and doors.
Turning to figure 3 the element is illustrated without sides such that only the structural members 21 are visible. In this embodiment the structural members 21 form a rectangular box such that by further introducing insulating plates 22 as illustrated in figure 2 the box will be an open-ended box where the front 24 and rear 25 of the box will be open, whereas the other sides will be closed and eventually become part of the building's walls.
Advantageously the structural members may be made from a polyurethane-based material, such as for example an extruded hard foam. One preferred material is marketed under the trade name PT200. The preferred material is available from the Barsmark A/S, Denmark under the trade name PT200. Further, derivatives of this material having higher or lower densities are also available, but particularly PT200 has shown exceptionally good characteristics when incorporated in a composite structural member for the use within the scope of the present invention.
During the manufacturing process of PT200 regenerated polyurethane is pulverized and as already mentioned above fibres are added to the mixture together with a binder which typically is an isocyanate. The mixture is hereafter consolidated by being exposed to relatively high pressure and heat resulting in a very strong and hard polymer material which may be machined with ordinary tools, has good insulating properties and shrinkage and moisture characteristics substantially corresponding to wood which makes the material especially suitable for incorporation in constructions of the type mentioned above.
The regenerated polyurethane will usually or mainly be derived from discarded or waste stemming from polyurethane insulation production. The polyester and/or polypropylene usually stems from for example car seats and the like. The polyurethane is pulverized or divided into very fine particles and fibres are mixed into the mix before it is shaped into a stiff and hard polymer material. The fibres are added in order to provide better ductility and cohesion in the material such that when mounting for example window frames to a construction, fastening devices such as screws and the like will exhibit higher withdrawal strength than what is achievable when the same screws are attached in the wood part. Therefore, the polyurethane material provides added security when mounting the finished frames in the constructions.
The material may alternatively be made from an extruded polymer material in the shape of a hard foam. Although as already mentioned above PT200 is the preferred material, almost the same advantages may be derived with a hard foam.
The PT 200 material in normal densities (500 kg/m3) will have a u-value around 0,076 W/m2K, and for density 400 kg/m3 approx. 0,06 W/m2K, whereas polyurethane foam (density 50 kg/m3) can be designed with u-value of 0,0226 W/m2K and expanded polystyrene a u-value of 0,04 W/m2K (naturally depending on the densities). A further suitable product is sold by the tradename "CompacFoam", also available from Barsmark A/S. This product has an u-value for density 100 kg/m3 of 0.04 W/m2K.
As should appear from the description of the preferred material above the PT200 material in addition to providing structural capabilities of the window element also provides excellent insulation such that excellent thermal capabilities are also present which compared to the traditional construction described with reference to figure 1 provides for a much better construction. Naturally, the insulating material 22 arranged between the structural members 21 may also be for example PT200 material, but for reasons of economics it may be more advantageous to use other materials such as expanded polystyrene, mineral wool or the like.
Turning briefly to figure 4 an embodiment is illustrated where the structural member 21 is provided with a suitable profile 21' in order to accommodate a window pane in this embodiment a double glass construction 26. The glass 26 is fitted with a glass list 27 in a traditional manner. Naturally, the profile may also be shaped as illustrated with reference to figure 5 which is completely corresponding to the example explained above with reference to figure 4. The only difference is that the window 26 extends substantially perpendicular to the side of the element.
The invention has now been explained with reference to a few embodiments, but it should be understood that other embodiments are also possible within the scope of the appended claims, for example suitable cladding may be applied to the interior and exterior sides of the element prior to installation, other insulating materials may be used especially for the infill-elements between the structural members 21 and it is also contemplated that more elements may be assembled to form larger window sections in a building where the window elements provides the structural stability necessary for such window facades.
In fig. 6 is illustrated the inventive window element 20 arranged in an opening in a building, as described above with respect to fig. 2. In the part of the element facing the outside is arranged a sash frame 28, which by means of hinges (not illustrated) may be opened. Naturally the cross section in fig 6 could also be a horizontal cross section through a door where the door is designed to open outwards.
The outermost parts of the profiles 21 are provided with a cladding 29, in this embodiment with an aluminium cap, in order to provide a desired (cosmetic) finish. The profiles, when made from PT200 may also be provided with a paint or lacquer finish directly.
As is evident from the above, and in particular fig. 2 and 6, the present invention provides a finished window or door element which only needs to be fastened to the aslready provided aperture in the building. Hereby a substantial saving in labour cost is achieved. Furthermore when the element is manufactured from the materials suggested above, superior insulating properties, without compromising structural integrity, are provided.
Although only rectangular elements have been described, it will naturally also be possible to utilise the inventive concepts and achieve the advantages presented with the present invention, with elements having different shapes.
As the elements exhibit superior insulating properties, and will typically be manufactured from unorganic materials, it is possible to integrate ventilation channels in the elements providing ventilation from the outside ambient environment to the inside environment. The feature of having superior insulation in combination with unorganic materials, assures that no or very little condensation occurs in the ventilation channel. Should condensation occur anyway, this will not harm the construction as the elements are made from unorganic materials. Typically the ventilation channels are provided in the lowermost section of the element.
Furthermore, for logistical reasons it may be advantageous to transport the elements in a "knock-down" fashion, and assemble the window or door elements on site. In that manner transportantion cost is also minimised. For the assembly of knock-down assemblies a host of different systems exists which may be selected accordng to the task.

Claims

Window element or window or door frame element suitable to be built into a building's wall, where said element consists of a box structure which box structure is open in two opposing ends, and which in use will have a top plate, a bottom plate and two side plates connecting said top and bottom plates at their free side edges, where each plate along its edges is provided with structural frame members made from a polyurethane based material, and where the volume between the structural frame members is filled with an insulating material, and that means are provided along what in use will be facing the outside environment of the building for fastening either a glass pane or a sash frame, and that along the edges of the element which will be facing the interior of the building means are provided for integrating the element with the walls surface.
Window element according to claim 1 wherein the inside or the outside or both inside and outside of the element is provided with a covering plate or veneer, where said plate may be a composite material, a polymer material, a naturally occurring material, a surface coating, a metal such as aluminium, copper, or zink, and where the veneer may be selected among any type of veneer.
Window element according to claim 1 wherein the polyurethane based material comprises regenerated polyurethane and fibres selected from one or more of the following fibre types: glass, polyester, polypropylene.
Window element according to claim 1 or 3 wherein the polyurethane based material is made from a pulverized regenerated polyurethane material, which material is shaped into a hard polymer material under pressure or where the polyurethane based material is made from an extruded polymer material in the shape of a hard foam.
Window element according to any of claims 1 to 4 wherein the insulating material is selected from one of the following: expanded polystyrene, glass-wool, mineral wool, rock-wool, cellulose based materials, polyurethane foam.
Window element according to any of claims 1 to 5 wherein the opening which in use is towards the interior of the building is larger than the opening facing the outside environment.
Window element according to claim 1 wherein the structural members provided along what in use will be facing the outside environment of the building are shaped as a glass receiving frame or a sash frame receiving frame.
Method of installing a window element according to any of claims 1 to 7, wherein:
- a frame element having a distance between the open ends substantially corresponding to the thickness of the buildings' wall into which the window is to be installed, is selected;

- where the height and width of the window element corresponds to the opening provided in the buildings' wall into which the element is to be mounted;

- where the window element is arranged in the opening, and fastened to the buildings' walls.