GB2135375A

GB2135375A - Window frames

Info

Publication number: GB2135375A
Application number: GB08402750A
Authority: GB
Inventors: John Walter Augustine Cox
Original assignee: Individual
Current assignee: Individual
Priority date: 1983-02-17
Filing date: 1984-02-02
Publication date: 1984-08-30
Also published as: GB8402750D0; GB2135375B

Abstract

A kit of parts for a window frame comprises upright members, the lengths of which are predetermined and transverse members which are cut to size on site. Location of the uprights (13) with respect to the transverse members (15) may be governed by location means such as notches 18 and projections 17. Corner joint arrangements are described. No metal- cutting or -working tools are required and the kit is intended for D.I.Y. assembly. The frame members can be made of plastics, such as self-skinning rigid polyurethane foam. <IMAGE>

Description

SPECIFICATION Window kit, method of making a window and a window made thereby This invention relates to windows and more specifically to a window kit, a method of making a window, and a window made from such a kit or by such a method.

At present, most existing houses have timber windows. If these are not given adequate and regular maintenance during their life, they can become draughty and ill-fitting owing to warping or rotting of the timber where it is unprotected from weathering. Some houses and many commercial buildings have steel-framed windows but these also need maintenance to prevent rusting. The current trend for both new and replacement windows has been towards aluminium or plastics.

Both aluminium and plastics windows are usually made from complex extruded sections of specialist manufacture, which are welded or otherwise fabricated into the exact size required by fabricators, to special order from firms of installation contractors or builders. Installation contractors deal direct with the public, estimating and measuring, ordering and installating replacement windows.

There has been no scope fo "do it yourself" aluminium or plastics windows for several reasons. Firstly, window sizes vary enormously so it would be uneconomic for builders' merchants or do-it-yourself outlets to stock a sufficient range of ready-made windows. Secondly, the corner jointing of such windows by welding requires specialist equipment and so windows cannot be made up at present by the final customer. Finally, precision is needed in constructing the frame if an openable sash is to be fitted, and the sash must also be sized to suit. A certain area of window must be openable to comply with the Building Regulations on room ventilation.

It is an object of this invention to provide a window kit which enables a reasonably competent householder or handyman to construct satisfactory replacement windows.

Further objects of the invention are the provision of a method of making a window and a window made from such a kit or by such a method.

According to the invention there is provided a window kit comprising a pair of first frame members; and a pair of second frame members; the first frame members alone being of a predetermined length and having termination portions; the second frame members being capable of being cut to length to suit the size of a window opening, the kit comprising corner jointing means which include said termination portions, whereby the first and second frame members can be assembled to form a frame having a size in one dimension predetermined by the length of the first frame members and a size in another perpendicular dimension based on the cut length of the second frame members.

The second frame members may be provided with location means equidistantly spaced along at least one end portion of the second frame member for locating a first frame member and preferably along its entire length and at closely spaced positions.

The termination portions of the first frame members may be provided with location means adapted to cooperate with the location means on the second frame members.

The second frame members may be provided, at least adjacent each end, with formations adapted to form a further part of said corner jointing means.

Said formations may comprise transverse slots for receiving a part of the corner jointing means afforded by the termination portions of the first frame members.

Alternatively, said formations may comprise a plurality of spaced apart holes, or weakened portions adapted to be perforated to form holes.

The holes or weakened portions may also form part of said location means. The formations may be provided throughout the length of the second frame member.

Said part of the corner jointing means afforded by the termination portion of the first frame member may comprise a fixing plate engageable within said slot of the second frame member. The fixing plate may be apertured to receive a fixing such as a bolt and nut, after assembly with the second frame member.

Said first part of the corner jointing means may comprise a fixing stud engageable within a hole of the second frame member.

The kit may further comprise a pair of sash uprights; a pair of sash transverse members; and sash corner jointing means; whereby an openable sash can be constructed, the size of the sash in one dimension being such as to fit within the frame in the dimension predetermined by the length of the first frame members.

The first frame members may be frame upright members; the second frame members may be frame transverse members and the frame uprights may be of a predetermined length such that, when secured to the frame transverse members to form a frame, the overall height of the frame is equivalent to the height of an integral number of courses of brickwork.

The first and second frame members and/or sash uprights and transverse members may be rigidified by stiffening strips which may each comprise a stiff sheet metal strip.

The stiffening strips may form part of said corner jointing means.

The stiffening strips may be arranged to provide lateral locating projections on some at least of the frame members, to locate the finished frame in a wall opening of a building.

The first and second frame members and/or sash uprights and transverse members may be of plastics material, which may be a rigid, selfskinning, dense polyurethane foam.

With the exception of their termination portions, the first frame members may have the same configuration as the second frame members.

The invention also provides a method of making a window frame comprising the steps of selecting a kit according to any preceding claim of which the first frame members have a predetermined length suitable for forming a frame having a size in one dimension equal to one dimension of a window opening; cutting the second frame members to a length substantially equal to the other dimension of the window opening; locating the first frame members relative to the second frame members using said location means; and securing the first and second frame members together using said corner jointing means to form a window frame.

The method may further include the step of locating one or more additional first frame members within the frame so defined by the use of the location means and securing said additional first frame member or members to the second frame members by jointing means.

The method may include the step of locating one or more additional second frame members within the frame so defined.

The method may further include the steps of making up a sash from a pair of sash uprights and a pair of sash transverse members, and hanging said sash within the frame by means of hinges, so that the sash at least substantially abuts first or second frame members at each of its sides.

The method may finally comprise securing one or more glazing sheets within the frame (and sash, if provided).

The invention also provides a window made from a kit, or using a method, as set out in the foregoing statements of invention.

A window kit and a window made therefrom and embodying the invention will now be described in more detail by way of example only, with reference to the accompanying drawings, in which: FIGURE 1 is a perspective view of a window made from a kit embodying the invention; FIGURE 2 is a detail view showing assembly of a frame upright and a frame transverse member; FIGURE 3 is an exploded perspective view of a first form of corner jointing means; FIGURE 4 is an exploded perspective view of a second form of corner jointing means; FIGURES 5 EF 6 are diagrammatic illustrations of "two-bay" windows made from a kit embodying the invention; FIGURES 7, 8 8 9 are diagrammatic illustrations of "three-bay" windows made from a kit embodying the invention.

FIGURE 10 is an exploded perspective view, similar to those of Figures 3 and 4 of a modified form of kit having greater rigidity.

Referring firstly to Figure 1 of the drawings, there is illustrated a window comprising a frame generally indicated at 10 and a hinged sash generally indicated at 11. The window has two bays, one of which is occupied by the sash 11 and the other of which is occupied by a fixed light 12.

The frame 10 comprises three frame uprights, two of which are illustrated at 13, and which form the sides of the window frame. The third, shown at 14, forms a central mullion, separating the two bays 11,12.

The frame is completed by upper and lower frame transverse members 15, to which the frame uprights 13 and 14 are secured by jointing means, illustrated in more detail in Figures 3 and 4.

Each of the frame uprights and frame transverse members has a generally similar configuration. However, the frame uprights alone have termination portions 16 (Figure 3) or 31 (Figure 4). The termination portion 16 is the type which is used to form the window shown in Figure 1, which will now be described in more detail.

Each of the frame uprights has a termination portion 16 which includes a tapering pyramidal projection 17, forming part of a location means used to ensure that the uprights 13, 14 are correctly positioned relative to the frame transverse members 15 so as to be capable of receiving a sash 11 as an accurate fit. The tapering notches 18 are provided in a forward edge of the frame transverse members 15 to locate the projections 17. The basis on which these notches are provided will be further discussed below. The notches are shown greatly exaggerated in Figure 1 of the drawings.

The frame transverse member 15 has an arcuate channel 19 defined in its lower edge as shown in Figure 3. From the channel 19, a more or less continuous slot 20 extends throughout the length of the frame transverse member 1 5. Crossbridging members 21 extend between the forward and rearward parts of the frame transverse member to maintain its structural integrity, the member being formed as a repetitive or modular moulding in a synthetic plastics material.

The termination portion 16 of the frame upright has an arcuate rib 22 which can be located within the channel 19. Embedded in the termination portion, there is an upstanding metal plate 23 having an aperature 24 for receiving a fastener assembly 25. The upstanding plate 23 passes into the slot 20 when the rib 22 is engaged within the channel 19.

The fastener assembly 25 comprises a hook bolt 26 having an externally threaded upper end, on which is received an internally threaded nut 27.

The hook bolt 26 is slipped into the aperture 24 of the plate 23 and the frame upright 13 or 14 is slid into position along the frame transverse member 15 with the hook bolt in situ. The projection 17 is engaged with an appropriate notch 18 for location. A separate apertured metal plate 28 can be dropped onto the hook bolt 26 and the nut is then added and tightened down to trap the plate 28. The apertured plate 23 is therefore drawn upwardly to hold the frame upright 13 in a firm joint with the frame transverse member 15. It is seen that the member 15 has a pair of shoulders 29, 30, against which the loose plate 28 can seat.

For a single-bay window, only four corner jointing means of this type need to be provided.

Where one or more mullions is provided to form a multiple-bay window, these will be slid into place and secured before the outer corner joints have been completed.

Figure 2 merely illustrates the way in which the frame upright and transverse members fit together to form a neat joint.

Figure 4 shows an alternative corner jointing means. This does not utilise inter-fitting projections 17 and notches 18 as with the embodiment shown in Figure 3. Instead, the transverse frame member is provided with a plurality of equally spaced circular weakened portions 32, corresponding to the spacing of the notches 18 in the previously-described embodiment.

The termination portion 31 of the frame upright is again provided with an arcuate rib 22 but, instead of the plate 23, an upstanding externallythreaded stud 33 is provided. The stud 33 can be aligned with a selected one of the weakened portions 32, which can readily be punched through to permit the stud to be inserted.

Assembly is completed by means of a loose apertured plate 28 as in the previously-described embodiment, and a nut 27, which is tightened down onto the stud 33.

One advantage of this construction is the reduction in the number of loose components to be assembled and another advantage is that the notches 18 are no longer required and so are not visible on the face of the window when assembled.

One important advantage of the window kit is that the frame uprights will only be needed in a predetermined range of heights for use in brickwork. The heights will be such that the frame constructed using the kit has an overall height equal to an integral number of courses of brickwork, that is an integral multiple of 75 mm. It will be appreciated that, because the upper and lower frame transverse members add to the height of the window, the calculation of window height will be made including an allowance for the thickness of the frame transverse members in the assembled window.

It is not possible to such a simple rule of thumb for predicting the width of window openings; great variation occurs in this dimension. For this reason, the kit includes a pair of frame transverse members which can be cut off to a desired length, so as to provide a window having the appropriate width.

Where a two-bay window is to be constructed, for example a window such as that shown in Figure 1, the kit will be provided with two end uprights 13, one central mullion 14, all of them of the predetermined height, and two frame transverse members 15, which can be sawn or otherwise cut off to length.

The kit will also include the components for one openable sash 11, these components comprising simple sash upright and sash transverse members.

The sash uprights will of course be provided in a range of sizes suitable for fitment within a frame having a height equivalent to a specific number oF brick courses. However, it is not necessary to provide the sash transverse members in a very large range of sizes, in spite of the great variation in the width of windows, because the person selecting the kit will have a choice of a one-bay, two-bay, three-bay or possibly four-bay window, equipped with the appropriate number of sash components to comply with the Building Regulations on ventilation.

Sashes will need to be provided only in a limited range of widths. In order to ensure an exact fit, the frame uprights can only be secured to the frame transverse members at predetermined positions, defined by the co-operating projections and notches 17 and 18, or by the co-operation of the studs 33 and weakened portions 32 as described above.

The sash components of a kit are all of predetermined size and merely need to be screwed together. Standard hinges and other window furniture are provided.

The versatility of the kit can be increased by having the same configuration for both the upright and the transverse members. This also reduces tooling costs. If desired, a two-bay window can be divided horizontally rather than vertically Dy an intermediate transverse member. For example, Figure 5 shows a two-bay window constructed from a pair of uprights 1 3 and a pair of transverse members 15. This is divided by an intermediate transverse member 34, the openable sash being diagrammatically illustrated at 11, at the top of the window, with its hinge axis horizontal.

Of course, since similar sections are used for the first and second frame members, there is nothing to prevent the first members from being used horizontally and the second members vertically. The use of brick coursing as a guide for standard lengths of the first frame members is only valid in brick-built or brick-faced buildings and not necessarily in concrete or tirnber frame buildings. However, since most housing is of brick or brick-faced construction, the use of sizes compatible with standard brick coursing provides a useful advantage and reduces the range of stocks to be carried by a supplier.

In the window shown in Figure 6, the uprights 13 and frame transverse members 15 are used as before but an extra frame member is used as a mullion 14. The sash 11 is hung to pivot about a vertical hinge axis, rather than the horizontal axis shown in Figure 5.

For a larger window opening, a three-bay kit is provided. This includes uprights 13, transverse members 15, two intermediate frame members and one openable sash.

Figure 7 of the drawings shows the kit assembled to provide a central openable sash between a pair of mullions 14. Figure 8 shows the same components rearranged to provide a single mullion 14 and an intermediate transverse member 34, positioned below a top-hung sash 11.

Figure 9 illustrates the same components again, this time arranged with the sash 11 at one side, between an upright 13 and a mullion 14, the remaining frame member being provided as an intermediate transverse member 34 between a pair of fixed lights 12.

The window can be glazed in any suitable manner, for example using an elastomeric weatherstrip to secure the glass. Each window opening, whether of a fixed light 12 or a sash 11, has a double-sided adhesive weatherstrip secured in an inner rebate, the position of which is shown in Figure 3 and Figure 4 at 35. The glass is presented to the outer adhesive face of the weatherstrip so as to be stuck securely in position.

A further weatherstrip having a single adhesive face is then stuck to the face of the glass and finally, a timber bead is secured over this weatherstrip to trap the glass in position.

The kit is capable of being manufactured in a number of different materials but a preferred material is a self-skinning polyurethane foam of relatively high density and rigidity. Such a material can be provided with the necessary fixings as described and can also be drilled for installation of, for example, hinge fittings and other window furniture. The external smooth skin of a self skinning foam provides excellent weather resistance. It requires substantially no maintenance.

It will be appreciated that a suitable window sill can be provided with the kit and can be cut to size and screwed to the window when it has been assembled.

It is envisaged that the frame transverse members will have the notches 18 or weakened portions 32 provided at closely spaced intervals throughout their length. However, the kit could be constructed with these features provided only at one end portion of the transverse member, one upright of the frame then being secured in a fixed predetermined position. Desirably the weakened portions or notches are provided at 20 mm.

separations.

Referring to Figure 10, the frame members shown are modified to provide greater rigidity during assembly and building in of the frame. At each end of the frame member 1 5, a rigid sheet metal stiffening strip 40 is positioned in a seating 41 of the frame transverse member 1 5. The strips 40 may be overlapped in the centre of the frame member, so that the necessary range of widths can be provided without needing specially-cut strips 40. A cover strip 47 is secured by screws passing through openings 48 to trap the overlapped central portions of the strips 40.

The strip is also located by means of an aperture 42, which receives the stud 33 (or fastener assembly 25), preventing longitudinal movement of the strip 40 once the assembly has been completed.

The end portion 43 of the strip 40 projects beyond the frame transverse member, to provide a location tag for locating the window frame in an opening in a wall into which it is being inserted.

A similar strip 44 is provided at each end of the frame upright members, the ends 45 being apertured at 46 and bent at right angles to the longidutinal direction of the strip 44, and being trapped between the frame transverse member and its own stiffening strip 40 in use. Again, the strips 44 can be overlapped centrally of the frame upright member. However, because the uprights are provided in a specific length for each kit, the strips 44 may also be of a specific length to suit.

Once the frame has been assembled and built into the wall of a building, it is quite rigid.

However, it may be desirable to provide stiffening means to prevent excessive flexing during assembly and during insertion into the wall opening, which could result in a poor fit.

Claims

1. A window kit comprising a pair of first frame members; and.a pair of second frame members; the first frame members alone being of a predetermined length and having termination portions; the second frame members being capable of being cut to length to suit the size of a window opening, the kit comprising corner jointing means which include said termination portions, whereby the first and second frame members can be assembled to form a frame having a size in one dimension predetermined by the length of the first frame members and a size in another perpendicular dimension based on the cut length of the second frame members.

2. A kit according to claim 1 wherein the second frame members are provided with location means equidistantly spaced along at least one end portion of the second frame member for locating a first frame member.

3. A kit according to claim 2 wherein the second frame member has such location means equidistantly spaced along its entire length.

4. A kit according to claim 2 or claim 3 wherein the location means are provided at closely spaced positions.

5. A kit according to any one of claims 2 to 4 wherein the termination portions of the first frame members are provided with location means adapted to cooperate with the location means on the second frame members.

6. A kit according to any preceding claim wherein the second frame members are provided; at least adjacent each end, with formations adapted to form a further part of said corner jointing means.

7. A kit according to claim 6 wherein said formations comprise transverse slots for receiving a part of the corner jointing means afforded by the termination portions of the first frame members.

8. A kit according to claim 6 wherein said formations comprise a plurality of spaced apart holes, or weakened portions adapted to be perforated to form holes.

9. A kit according to claim 8 wherein the holes or weakened portions also form part of said location means.

10. A kit according to any one of claims 6 to 9 wherein the formations are provided throughout the length of the second frame member.

11. A kit according to claim 7 wherein said part of the corner jointing means afforded by the termination portion of the first frame member comprises a fixing plate engageable within said slot of the second frame member.

12. A kit according to claim 11 wherein the fixing plate is apertured to receive a fixing such as a bolt and nut, after assembly with the second frame member.

13. A kit according to claim 8 wherein said first part of the corner jointing means comprises a fixing stud engageable within a hole of the second frame member.

14. A kit according to any preceding claim and further comprising a pair of sash uprights; a pair of sash transverse members; and sash corner jointing means; whereby an openable sash can be constructed, the size of the sash in one dimension being such as to fit within the frame in the dimension predetermined by the length of the first frame members.

15. A kit according to any preceding claim wherein the first frame members are frame upright members; the second frame members are frame transverse members and the frame uprights are of a predetermined length such that, when secured to the frame transverse members to form a frame, the overall height of the frame is equivalent to the height of an integral number of courses of brickwork.

16. A kit according to any preceding claim wherein the first and second frame members and/or sash uprights and transverse members are rigidified by stiffening strips.

17. A kit according to claim 16 wherein the stiffening strips each comprise a stiff sheet metal strip.

18. A kit according to claim 16 or claim 17 wherein the stiffening strips form part of said corner jointing means.

19. A kit according to any one of claims 16 to 18 wherein the stiffening strips are arranged to provide lateral locating projections on some at least of the frame members, to locate the finished frame in a wall opening of a building.

20. A kit according to any preceding claim wherein the first and second frame members and/or sash uprights and transverse members are of plastics material.

21. A kit according to claim 20 wherein the plastics material is a rigid, self-skinning, dense polyurethane foam.

22. A kit according to any preceding claim wherein, with the exception of their termination portions, the first frame members have the same configuration as the second frame members.

23. A method of making a window frame comprising the steps of selecting a kit according to any preceding claim of which the first frame members have a predetermined length suitable for forming a frame having a size in one dimension equal to one dimension of a window opening; cutting the second frame members to a length substantially equal to the other dimension of the window opening; locating the first frame members relative to the second frame members using said location means; and securing the first and second frame members together using said corner jointing means to form a window frame.

24. A method according to claim 23 further including the step of locating one or more additional first frame members within the frame so defined by the use of the location means and securing said additional first frame member or members to the second frame members by jointing means.

25. A method according to claim 23 or 24 and including the step of locating one or more additional second frame members within the frame so defined.

26. A method according to any one of claims 23 to 25 and further including the steps of making up a sash from a pair of sash uprights and a pair of sash transverse members, and hanging said sash within the frame by means of hinges, so that the sash at least substantially abuts first or second frame members at each of its sides.

27. A method according to any one of claims 23 to 26 and comprising the further step of securing one or more glazing sheets within the frame (and sash, if provided).

28. A window made from a kit according to any one of claims 1 to 22, or using a method according to any one of claims 23 to 27.

29. A window kit substantially as hereinbefore described with reference to, and as illustrated in, Figures 1, 2, 3, and 5 to 9 of the accompanying drawings.

30. A window kit substantially as hereinbefore described with reference to, and as illustrated in, Figures 1, 2, 4, and 5 to 9 of the accompanying drawings.

31. A window kit substantially as hereinbefore described with reference to, and as illustrated in, Figures 1, 2, 10, and 5 to 9 of the accompanying drawings.

32. A method of making a window substantially as hereinbefore described with reference to the accompanying drawings.

33. A window substantially as hereinbefore described with reference to, and as illustrated in Figures 1,2 and 3, or Figures 1, 2 and 4, or Figures 1, 2 and 10 of the accompanying drawings or as modified by any one of Figures 5 to 9.