GB2306539A - Frame assemblies for doors and windows - Google Patents

Abstract

In order to provide efficient protection against ingress of water, a resilient member 17 is provided extending across a gap 15 between the inner frame 2 and outer frame 1 for sealing the gap. In order to prevent the inner frame 2 being pushed through the outer frame 1, a removable fixing member (23, Fig 3) may be provided which has an abutment against which the inner frame rests. When the inner frame is fixed in position, the removable fixing member can be removed. The outer frame may be in the form of a U-shaped member with the top secured during storage by a connecting member (33, Fig 4). The connecting member can be disconnected during insertion of the frame assembly into a wall and reused as a continuous fixing member for fixing an inner frame to a wall.

Description

FRAME ASSEMBLIES FOR WINDOWS AND DOORS The present application relates to frame assemblies, for example for windows and doors, for inclusion in openings in walls.

The invention has arisen in the field of thermoplastic frame assemblies for inclusion in brick or block work walls during construction of the wall, but can find application more generally. Block or brick walls are now constructed universally with a cavity between an inner (usually block work) and outer (often brick work) leaf. Great care has to be taken to ensure that loss of heat and ingress of water does not occur around the frames of windows in such walls.

To improve the thermal resistance it is common to include a so-called "cavity closer" usually comprising an extruded thermoplastic member for closing off the cavity around the periphery of the opening. GB 2228033A describes such a cavity closer.

Water ingress is usually prevented by settable sealing compositions such as silicone and/or compressible foam plastic strips. These, however, are not always correctly applied, leading to leakage.

Extruded thermoplastic frame assemblies also offer systems in which a cavity closer can be readily included in a wall and a window frame subsequently placed in the cavity closer in a simpleoperation. Such a structure is shown in GB 2255124.

Most prior art designs involve some form of abutment projecting from the cavity closer against which a window or door frame rests when in position in the opening. It has the disadvantage that the window or door frame can only be inserted in one direction into the opening.

The inventors of the present invention have sought further improvements to the design of frame assembly to make the design more flexible and to improve and simplify the construction procedure in a number of respects.

The inventors of the present invention have realized that the abutment on the cavity closer can be dispensed with. In order to prevent the window or door frame from being pushed right through the opening, the present inventors have designed a removable strap for temporarily holding the window or door frame in position.

It is normal practice to provide that the outer frame is generally U-shaped, with the side arms joined at the top by a connecting member. The inventors of the present invention have realised that this connecting member is suitable for reuse as a fixing member for fixing the inner frame to the wall.

In a first aspect the present invention provides a frame assembly for inclusion in an opening in a wall, the frame assembly comprising an outer frame for contacting the wall and an inner frame, the outer shape of the inner frame generally corresponding to and being smaller than the shape of the innermost part of the outer frame, so that the inner frame can be positioned in the outer frame with a gap therebetween, a resilient member being provided, of size greater than the gap, on the inner or outer frame, for lying within and sealing the gap when the inner frame is in position in the outer frame. The gap should lie generally in the plane of the opening.

The first aspect of the invention is concerned with a frame assembly in which the inner frame can be passed right through the space inside the outer frame when the inner frame lies in the plane of the opening. The terms "outer frame" and "inner frame" are intended to include all parts integral with or permanently fixed to the outer frame or inner frame respectively, except the resilient member. For example a sill could be included in the inner or outer frame. The present invention is used in contrast to frame assemblies in which an abutment is provided on the inner periphery of the outer frame, which the inner frame cannot pass. A relatively efficient permanent sealing member may be formed on such an abutment, but the present inventors have decided to dispose of the abutment altogether.

The first aspect of the invention is particularly suitable where the inner and/or outer frame is constructed of a thermoplastic material, such as PVCu.

Such a thermoplastic material may have a relatively high coefficient of thermal expansion so that a relatively large gap between the inner and outer frame may appear.

The resilient member can bridge this gap to provide resistance to ingress of water between the frames.

As is common, opposing faces of the outer frame and inner frame will usually be provided for receiving a sealant, in the form of a settable sealing composition and/or compressible foam sealing strip which may be placed in position when the inner frame is in position in the outer frame.

The resilient member preferably comprises a generally flat strip. It may be of a very resilient material, for example an elastomeric material such as rubber. For example, it could be of EPDM or PVC nitrile rubber. It may be constructed of the same material as is normally used for sealing gaskets in this art. It may be of size in the range 0. 5-2cm, preferably about lem in length. It may be in the form of a strip, preferably substantially coextensive in length with the gap between the inner and outer frame. It may have a part at one end for attachment to a groove or similar structure formed on the inner or outer frame surface. It is normal for the inner and/or outer frame to be provided with such a grove for various reasons and this embodiment allows a standard inner and/or outer frame to be modified in a simple fashion.Alternatively, where the inner and/or outer frame is an extruded member, the resilient strip may be coextruded of a different material so that it is integrally included in the structure of the inner or outer frame.

According to a second aspect, the present invention provides a frame assembly, for inclusion in an opening in a wall, the assembly comprising an outer frame for contacting the wall and an inner frame, the outer shape of the inner frame generally corresponding to and being smaller than the shape of the innermost part of the outer frame, so that the inner frame can be positioned in the outer frame, wherein a releasable fixing member is provided, releasably fixed with respect to the wall, inner frame and/or outer frame and having an abutment part projecting therefrom for preventing the inner frame from passing through the outer frame when the inner frame lies in the plane of the opening, the releasable fixing member being disconnectable from the wall, inner frame or outer frame and subsequently removable.Preferably, the releasable fixing member is fixed to at least one but not all of the wall, inner frame and/or outer frame.

Preferably, the abutment part comprises a part extending in the plane of the opening inwardly of the innermost part of the outer frame, if the releasable fixing member is fixed to the outer frame, or outwardly of the innermost part of the outer frame if the fixing member is fixed to the inner frame.

Again, the second aspect of the invention is concerned with a frame assembly in which it would be possible to pass the inner frame through the outer frame when the inner frame is orientated in the plane of the opening, if the releasable fixing member were not in position. The terms "outer frame" and "inner frame" include any part integral with or permanently fixed to the outer frame or inner frame respectively but not parts releasably fixed thereto for subsequent release, nor a resilient member as in the first aspect of the invention.

Preferably, movement of the inner frame through the opening is simply prevented by abutment of the abutment part against one of the inner frame, outer frame and/or wall to which it is not releasably fixed to. However, it is envisaged that the releasable fixing member could be releasably connected to all parts, for added security, for example in windy conditions.

It is simpler if the releasable fixing member is releasably connected to one of the inner or outer frames. It can then be preassembled with the inner and/or outer frame.

The releasable fixing member may comprise connecting means, for example a screw or snap-fit member for connection to the inner frame, wall and/or outer frame.

One end of the strap may be bent generally through a right angle to define an abutment.

Preferably, the releasable fixing member is removably connected to the inside of the outer frame. In a preferred embodiment, the releasable fixing member comprises a strap having a first end for releasable connection to the inner frame, wall and/or outer frame, a longitudinally extending part, and an abutment at the other end. Preferably, the longitudinally extending part is for lying against and extending over the outer frame in a gap formed between the inner and outer frames, the strap being removable by releasing it and withdrawing it through the gap.

The length of the releasable fixing member may be chosen so that, when the inner frame is placed in position from a given direction, it is arrested by the releasable fixing member in a defined position for giving optimum thermal resistance.

In a cavity wall construction comprising an inner leaf and an outer leaf separated by a cavity, it is found that optimum thermal resistance is provided when the inner frame bridges the outer leaf and the cavity, preferably coming to rest with at least one third of its length over the outer leaf of the wall. The releasable fixing member may be of sufficient length to provide this.

In a particularly simple embodiment, such a releasable fixing member is releasably fixed for example, by screwing, to an inwardly facing part of the inside of the outer frame and a part which will not be covered by the inner frame when the inner frame is in the defined position.

The releasable fixing member may simply comprise a removable angle piece for connection to the outer frame.

There may be a plurality of such releasable fixing members, for connection to different parts of the outer frame, inner frame and/or wall to provide good support for the inner frame over the whole of its periphery.

The second aspect of the invention also provides a releasable fixing member for use with a window or door frame, having the features of the releasable fixing member defined above.

In a preferred embodiment, the releasable fixing member is detachably fixed to the outer frame by attachment means which allow rotation of the releasable fixing member from a storage position to a position for use.

According to a third aspect, the present invention provides a frame assembly for inclusion in an opening in a wall, the assembly comprising an outer frame for contacting the wall and an inner frame for fitting within the outer frame, the outer frame comprising a bottom part and two side parts connected together by a connecting member extending across the tops of the side parts, the connecting member being releasably fixed to the side parts, the connecting member comprising first connecting means for connection to the inner frame after release of the connecting member from the side parts and second connecting means for connecting to the wall after release of the connecting member from the side parts.

In this aspect, a connecting member used to stabilise the shape of the outer frame before it is placed in position in a wall is reused in an advantageous manner.

As it is already dimensioned correctly for the outer frame, the connecting member is well suited to form a longitudinally extending connecting member for fixing the inner frame to the wall and is easily stored with the outerframe. In effect, two functions are combined in one article.

The connecting member is preferably releasably fixed to faces of the side parts which are vertical when the outer frame is in position in the opening, so that a wall may be built on top of the outer frame with the connecting member still removably connected.

Preferably, the connecting member has a plurality of connecting means and/or continuous connecting means for connecting the connecting member to the inner frame and/or wall.

The connecting member may comprise a longitudinally extending member of generally L-shaped cross section.

In all aspects of the invention, it is preferred that the inner frame should be connected to the wall and not only (preferably not at all) to the outer frame. Thus, it can be arranged that high stresses involved in holding the inner frame in position when it is finally fixed are not transferred to the outer frame, which may be relatively weak. For example, fixing straps could be provided for attachment to the wall at one end and to the inner frame at the other end.

All aspects of the present invention are particularly suited for use with a cavity wall construction.

A preferred method of using the first, second and/or third aspect of the invention involves the following steps.

The wall will be constructed upto the level of the lower edge of the opening. The outer frame, or the bottom component of the outer frame is placed in position on the top of the wall. The outer frame defines the size of the opening which is intended to be used. This allows a window or door to be constructed as a standard unit in a factory and the wall to be constructed around the outer frame on site so that the opening is the right size. The wall is constructed around the frame so that it extends to the sides of the outer frame. When the top of the outer frame is reached, the connecting member (if any) is removed and a standard lintel of known design is placed across the top of the opening to bear the weight of the wall subsequently built on top.

The outer frame may be secured to the wall by any suitable known means, such as screws. Preferably, however, brick ties of known design are provided fixed to the outer frame for inclusion in layers of mortar between bricks or blocks during construction of the wall. The outer frame preferably comprises a part for extending into and closing the end of a cavity in a cavity wall construction, i. e. it is a cavity closer. Preferably, the part for engagement in the cavity is filled or partly filled with insulating material to increase the thermal resistance. The cavity closer may comprise a surface or means for connection to a damp proofing course provided against an inner leaf or outer leaf of the cavity wall.

Once the outer frame is included in the wall, the inner frame may be placed in position in the outer frame at a suitable time. The first and second aspects of the invention are concerned with inner frames which may be inserted from any direction.

When inserting from within the building, releasable fixing means according to the second aspect of the invention may be placed in position (if they are not already in position) to prevent the inner frame being pushed right through the opening.

The resilient member (if present) of the first aspect of the invention will be deformed when the inner frame is placed in position in the outer frame so that it lies across and seals the gap between the inner and outer frame to provide a high level of protection against water ingress.

As is known in the art, the gap between the inner and the outer frame may be sealed from the outside by inserting a compressible foam backing strip and/or settable liquid sealing composition such as a silicone seal.

In order to secure the inner frame against subsequent removal, it is preferably fixed in place by fixing it to the wall, preferably to the inner leaf of the wall, for example using fixing straps provided at points along the periphery of the inner frame, for connection by nails or screws or similar fixing means of any suitable known type to the wall. The connecting member of the third apsect of the invention may also be used. After the inner frame is fixed to the wall, the releasable fixing member of the second aspect of the invention may be withdrawn, for example from the outside.

If the inner and/or outer frame is constructed from polymeric material such as PVCu, it will be necessary to design the inner and/or outer frame to allow for thermal expansion. For example, the means for fixing the inner frame to the wall should be designed to allow for movement of the inner frame. For example, the fixing means may be designed to allow for a limited amount of sliding or resilient deformation in a direction parallel to the plane of the opening. The resilient member of the first aspect of the invention and the silicone seal or compressible foam backing strip should be designed in a manner known in the art to accommodate movement due to thermal expansion.

Preferably the brick ties are made from injection moulded plastic. They may fit into a groove in the outer frame. They may lie against the frame when stored and be twistable through 90 50 that they can lie in courses between bricks.

Different sizes of cavity can be accommodated by returning the inner leaf of the block work or brick work to the cavity closer in the manner known in the art.

The releasable fixing member may be positionable to prevent the inner frame being pushed through the opening when inserted in a first direction and be repositionable to allow the inner frame to be pushed into the opening from the other direction. Alternatively, when placing the inner frame in the opening from the other direction, the releasable fixing member may be removable, and the inner frame may then be prevented from being pushed through the opening by an alternative releasable fixing member or by plaster work formed on the inner or outer leaf of the wall. For example, an edge may be provided for attachment to the wall or outer frame and defining the position upto which plaster should be applied and providing an abutment surface for the inner frame when inserted in the opposite direction to normal.

The present invention will be further described by way of example only with reference to the accompanying drawings in which: Figure 1 shows a vertical cross section of a frame assembly according to the first aspect of the present invention, Figure 2 shows a vertical section of a frame assembly according to the first aspect of the present invention with the inner frame inserted in the reverse direction to figure 1, Figure 3 shows a frame assembly according to the first and second aspects of the present invention, Figure 4 shows a frame assembly according to the third aspect of the present invention with the connecting member in place on the frame, Figure 5 shows a frame assembly according to the third aspect of the present invention with the connecting member in place as a fixing strap.

Figure 1 shows a vertical cross section through the frame assembly according to the present invention. The frame assembly comprises an outer frame 1 and an inner frame 2. Both are constructed of extruded PVCu material. The inner frame 2 comprises standard parts and profiles for reinforcement, connection to seals, trims, glass panels etc in a manner which is known in the art.

The outer frame 1 is in the form of a cavity closer which lies in a cavity 3 formed in a brick wall comprised of an outer leaf 4 comprised of bricks and an inner leaf 5 comprised of blocks.

The cavity closing part of outer frame 1 comprises insulating material 6 to improve its thermal insulation properties. In order to allow ready insertion of the insulating material, the outer frame 1 is made of two extruded parts which can be snap fitted together at the joints shown at 7.

The outer frame 1 is fixed with respect to the leaves 4 and 5 of the wall by brick ties 8. The brick ties 8 slot into recesses 9 formed in the cavity closing part of outer frame 1. The brick ties 8 are mortared into layers of mortar between bricks or blocks in a manner known in the art.

The inner frame 2 is shown fixed to the inner leaf 5 by a steel fixing strap 10. The fixing strap 10 is fixed by suitable means such as screws to the inner leaf 5 at position 11 and firmly engages suitable parts 12 formed in the profile of inner frame 2. The fixing strap 10 comprises a resiliently deformable longitudinally extending portion 13 which allows movement in the plane of the opening due to thermal expansion of the inner frame 2 to be accommodated.

In the manner known in the art, a primary seal against ingress of water is provided by inserting a compressible foam backing strip 14 in a gap 15 provided between the inner and outer frames 2 and 1.

Further sealing is provided in the known manner by injecting a layer of settable sealing composition, such as a silicone composition or mastic 16.

In accordance with the first aspect of the invention, the possibility that the seal provided by the seals 14 and 16 will be deficient is countered by providing a resilient member 17. The resilient member 17 comprises an extruded rubber component which is very soft. For example, it may be PVC nitrile, or EPDM or similar gasket material. It may be Alcrin (TM) or Mavillex (TM).

It is slotted into a suitable recess 18 formed on the inward facing face of the outer frame member 1.

The resilient member 17 is constructed so that it extends generally normal to the inner face 19 of the outer frame 1. In figure 1, the inner frame 2 is shown as inserted from the direction of arrow A. The size of resilient member 17 is greater than the gap 15 provided between the inner frame 1 and outer frame 2 so that the resilient member 17 is bent and lies across the gap 15 between the inner frame 2 and outer frame 1, sealing the gap.

Figure 2 shows the frame assembly of Figure 1 with the inner frame 2 inserted in the wall of figure 1 from the opposite direction. The same components are used and like reference numerals denote the same components. As the inner frame 2 has been inserted into the opening in the opposite direction, the resilient member 17 is seen to be deformed in the opposite direction to figure 1.

Figure 2 also shows an angle piece 20 secured to the outer frame 1 for defining a stop against which the inner frame 2 rests. The angle piece 20 provides a level up to which plaster 21 is applied on the inside of the wall.

Recesses 22 can be formed in the plaster work 21, for example by placing wooden blanks against the places on the leaf 5 where the recesses 22 are to be formed. The recesses are provided to hold the fixing straps 10 when the inner frame 2 is placed in position. The recesses 22 can be plastered over later when making good. A trim piece may be inserted between the inner frame and the plaster work to give a clean finish.

Figure 3 shows the frame assembly of figure 1 during insertion of the inner frame 2 into the outer frame 1.

As the same components are used as in figure 1, they are given the same reference numerals in figure 3. However, the sealing foam 14, silicone seal 16 and fixing member 10 have not been applied yet. The inner frame 2 is shown having been inserted in the direction of arrow A. It is prevented from passing right through the opening in outer frame 1 by a releasable fixing member in the form of a strap 23 releasably fixed to the outer frame 1 by screws 24.

It should be noted that the resilient member 17 is of such resilience that it is deformed (in a manner not shown) by the releasable fixing means to allow the releasable fixing means to pass over the surface 19 of the outer frame. The strap 23 has an abutment part 25 which bears against the outer face of the inner frame 2. By releasing the screw 24, after the fixing member 10 as shown in figure 1 has been inserted and fixed, the strap 23 can be removed in the direction of arrow A by pulling it through the gap 15 between the inner and outer frame.

Figure 4 shows a frame assembly according to the third aspect of the invention.

An outer frame 26 is shown, which may form the outer frame of a frame assembly according to figure 1-3. Also shown are brick ties 27 which may function in the same manner as the brick ties 8 shown in figure 1 and releasable fixing members 28 which may function in the same manner as the strap 23 of figure 3.

The outer frame 26 comprises a bottom part 29 and two upright parts 30. The outer frame 26 is intended to act as a cavity closer in the manner shown in figure 1. To this end, insulation 31 is provided in the cavity closing part. Capping members 32 are provided for closing the ends of the upright parts 30 to prevent ingress of water. A connecting member 33 comprising L-section metal strip is releasably fixed, e.g. by screws, to vertically oriented inwardly facing facing surfaces of the tops of the upright members 30. The connecting member 33 allows the outer frame 26 to retain the desired shape during storage and during construction of a wall (not shown) around the outer frame 26.

A wall can be constructed upto a given level. Then, the cavity closing part of the bottom section 29 is placed in the cavity of the wall and the wall built up around the uprights 30 with their cavity closing parts within the cavity of the wall constructed. The connecting member 33 remains fixed to the upright parts 30 until an inner frame is inserted in the outer frame 26. The top of the opening defined by the outer frame 26 can be closed by a lintel of known design placed on top of the brick work and outer frame 26. According to the third aspect of the invention, the connecting member 33 can be reused in a novel way.

Figure 5 is a vertical section through a wall comprising two leaves 34 and 35 with a cavity 36 betweeen them. The bottom part 29 of the outer frame 26 is shown received in the cavity 36 and fixed by brick ties 27. An inner frame 37 is shown in place in the outer frame 26.

The inner frame 37 corresponds to the inner frame 2 of figures 1-3, and includes a sill 38. The sill is fixed to the leaf 34 of the wall by the connecting member 33 by connecting means (for example screws engaging the connecting member with the sill at 39 and the wall at 35).

The present invention has been described above purely by way of example, and modifications can be made within the spirit of the invention. The invention also consists in any individual features described or implicit herein or shown or implicit in the drawings or in any combination of such features or any generalization of any such features or combination.

Claims (12)

CLAIMS:

1. The present invention provides a frame assembly for inclusion in an opening in a wall, the frame assembly comprising an outer frame for contacting the wall and an inner frame, the outer shape of the inner frame generally corresponding to and being smaller than the shape of the innermost part of the outer frame, so that the inner frame can be positioned in the outer frame with a gap therebetween, a resilient member being provided, of size greater than the gap, on the inner or outer frame, for lying within and sealing the gap when the inner frame is in position in the outer frame.

2. A frame assembly according to claim 1, wherein the inner and/or outer frame is constructed of thermoplastic material.

3. A frame assembly according to claim 1 or 2, wherein opposing faces of the outer frame and inner frame are provided for receiving a sealant, in the form of a settable sealing composition and/or compressible foam sealing strip.

4. A frame assembly for inclusion in an opening in a wall, comprising an outer frame for contacting the wall and an inner frame, the outer shape of the inner frame generally corresponding to and being smaller than the shape of the innermost part of the outer frame, so that the inner frame can be positioned in the outer frame, wherein a releasable fixing member is provided, releasably fixed with respect to the wall, inner frame and/or outer frame and having an abutment part projecting therefrom for preventing the inner frame from passing through the outer frame when the inner frame lies in the plane of the opening, the releasable fixing member being disconnectable from the wall, inner frame or outer frame and subsequently removable.

5. A frame assembly according to claim 4, wherein the releasable fixing member is removably connected to the inside of the outer frame.

6. A frame assembly according to claim 4 or 5, wherein the releasable fixing member comprises a strap having a first end for releasable connection to the inner frame, wall and/or outer frame, a longitudinally extending part, and an abutment at the other end.

7. A frame assembly according to claim 6, wherein the longitudinally extending part is for lying against and extending over the outer frame in a gap formed between the inner frame and outer frame, the strap being removable by releasing it and withdrawing it through the gap.

8. A frame assembly according to claim 6 or 7, wherein the length of the strap is such that when the inner frame is placed in the position from a given direction, it is arrested by the releasable fixing member in a defined position.

9. A releasable fixing member for use with a window or door frame, having the features of the releasable fixing member defined in any of claims 4 to 8.

10. A frame assembly for inclusion in an opening in a wall the assembly comprising an outer frame for contacting the wall and an inner frame for fitting within the outer frame, the outer frame comprising a bottom part and two side parts connected together by a connecting member extending across the tops of the side parts, the connecting member being releasably fixed to the side parts, the connecting member comprising first connecting means for connection to the inner frame after release of the connecting member from the side parts and second connecting means for connecting to the wall, after release of the connecting member from the side parts.

11. A frame assembly according to claim 10, wherein a plurality of connecting means and/or continuous connecting means for connecting the connecting member to the inner frame and/or wall are provided.

12. A frame assembly substantially as herein described with reference to figures 1 to 3, and 4 or 5.