GB2353316A

GB2353316A - Reinforcement member for a hollow extruded plastics frame section

Info

Publication number: GB2353316A
Application number: GB9919831A
Authority: GB
Inventors: Michael Gordon Austin; Trevor Alan Moss; Donald William James Mason
Original assignee: EVEREST Ltd
Current assignee: EVEREST Ltd
Priority date: 1999-08-20
Filing date: 1999-08-20
Publication date: 2001-02-21
Anticipated expiration: 2019-08-20
Also published as: GB9919831D0; GB2353316B

Abstract

A hollow extruded plastics frame section, for example used for door and window frames, includes a reinforcement member (1) having a base (3) and a portion (9) projecting from the base. A further part (19) is provided which projects from the portion (9) and is intended to cause the reinforcement to jam within the frame section. Preferably, the projecting portion includes an aperture (17), which may be rectangular, and the edge (21) of the further projecting part has a surface continuous with the edge (23) of the projecting portion.

Description

2353316 Improvements to Plastics Door and Window Frames The present

invention relates to door and window frames made of plastics extrusions.

Door and window frames constructed from extruded plastics sections are known. Normally a number of these extruded plastics sections are welded together to form a frame. A known problem is that extruded plastics sections are not suitable for load bearing and lack the rigidity necessary for use in long sections. Hence, the plastics extruded sections are normally formed with at least a hollow part to the section, into which metal reinforcement may be fitted.

The metal reinforcement increases the structural integrity of the window and ensures that good screw retention is provided for attaching the door or window hardware, (for example hinges). A problem with fitting reinforcement to extruded plastics sections is that although external dimensions of such a section may be closely controlled in manufacture, it is more difficult to control internal dimensions of hollow parts in such sections. Hence, between different lengths of extruded plastics sections the internal dimensions may vary.

According to the invention there is provided a hollow extruded plastics frame section having a reinforcement, the reinforcement comprising a base and a portion projecting from the base in a direction away from the base, the portion having a part projecting further from the base in the said direction, the part formed so as to cause the reinforcement to jam within the plastics section.

A benefit of this is that a length of reinforcement may be more easily inserted and retained in the extruded plastics section.

In an embodiment of the invention, the part projecting further comprises an aperture in the portion, the aperture being formed by displacing a displaced portion.

The aperture may be rectangular. This is particularly the case in an embodiment where portion projecting from the base forms a side wall and the aperture is formed by a shearing action of a punch shearing the side in a plane coincident with the plane of the portion. A benefit of ensuring the displacement is coincident with the side, is that a width dimension of the length of reinforcement is unchanged.

The aperture may preferably have three sides formed in the upstanding side wall, and the fourth side formed at a join between the side wall and the base. A benefit of this is that the aperture may be formed by a tool approaching the length of reinforcement in a perpendicular direction from a side opposite to that from which the side walls extend from the base, the tool shearing the side wall in a direction away from the base. A further benefit is that a simple press tool may form two opposing apertures, one in each of the side walls, in one operation. A further benefit is that the tool may be adapted to also crop a length of the length of reinforcement in the same operation.

In another embodiment of the invention, the aperture is formed by making a slit in the portion projecting, the slit being opened by displacing a displaced portion of the portion projecting in a direction away from the base preferably in a plane coincident with the plane of the portion projecting.

A further embodiment may have an aperture where the aperture has a curved side, and the displacement is by a combination of bending and shearing in a direction away from the base in a plane coincident with the plane of the side.

An alternative embodiment may not have apertures in the side walls, and the deformation may be obtained by a reduction in the thickness of the side wall.

Preferably the displaced portion forms a displaced edge of an edge of the portion projecting such that the displaced edge is displaced in the said direction away from the base. The benefit of this is that there is a local increase in the height of the length of reinforcement.

Preferably the displaced edge has a surface continuous with the edge. A benefit of this is that there are no transverse steps that may cause the length of reinforcement to snag or catch on an edge of the extruded plastics section on - 2 insertion into the extruded plastics section. A further benefit of this is that the length of reinforcement may be inserted in either direction.

Preferably a dimension of the displacement is such that when the reinforcement is inserted into a length of extruded plastics section, the displaced edge causes the reinforcement to be retained in the extruded plastics section.

Preferably the reinforcement has a second portion projecting from the base in the same direction as the portion projecting. In an embodiment of the invention, where the portion projecting is a side wall, the second portion projecting is a second side wall projecting from the base.

Preferably the reinforcement has more than one said part projecting further in one or both of the portion projecting, and more preferably where there are two portions projecting at least one said part is in each of the portions projecting. A benefit of this is that the reinforcement may be supported more evenly within the extruded plastics section. 15 Preferably the there are said parts substantially opposite each other in the portions projecting. A benefit of this is that torsional forces that might produce distortion by twisting of the length of reinforcement are minimised. Specific embodiments of the invention will now be described by way of example 20 with reference to the accompanying drawings in which:Figure 1 is a perspective view of a length of reinforcement according to the invention; Figure 2 is an end view of a length of plastics extrusion fitted with the length of reinforcement shown in Figure 11; Figure 3 is a plan view of a long length of reinforcement similar to that shown in Figure 1; Figure 3A is a side view of the long length of reinforcement shown in Figure 3; Figure 4 is a perspective view of a tool for producing the reinforcement shown in Figure 1 showing the detail of the punch and anvil parts of the tool, together with the length of reinforcement shown in Figure 1 that has already been formed; Figure 5 is a perspective view of a length of reinforcement according to a second embodiment of this invention; Figure 6 is a perspective view of a length of reinforcement according to a third embodiment of this invention; and Figure 7 is an end view of a length of reinforcement with a first alternative profile; Figure 7A is an end view of a length of reinforcement with a second alternative profile; and Figure 713 is an end view of a length of reinforcement with a third alternative profile.

From Figure 1, a length of reinforcement 1 is preferably made of folded sheet material. A suitable material for example would be steel or aluminium. The length of reinforcement comprises a base 3 with an external surface 5 and sides 7 and 9 connected to the base at rolled corners 11 and 13. The side 7 is provided with a retention shape 15. The retention shape 15 comprises a sheared hole 17 and a displaced portion 19. An curved edge 21 of the displaced portion 19 is preferably continuous with a cut edge 23 of the side 7 at blending curves 25 and 27. A second retention shape 16 is also visible in Figure 1, and is similar to retention shape 15. The second retention shape has a curved edge 22 similar to the curved edge 21. A benefit of the retention shapes 15 and 16 being formed in the sides 7 and 9 is that there are no holes or cut-outs in the base 3, which could prevent a screw inserted into the base 3 from being securely retained.

Figure 2 shows the length of reinforcement 1 fitted to an extruded plastics section 201 so as to jam in the section. The extruded plastics section 201 comprises an external profile 203 and an internal hollow portion 205. The internal hollow portion 205 is preferably substantially rectangular in shape and has a upper surface 207, a lower surface 209, and two sides 211 and 213. The internal hollow portion 207 has an internal height 21-1 between the upper surface 207 and the lower surface 209. The extruded plastics section 201 may also have additional hollow portions 215 and 217 and 219. Additional hollow portions such as 217 may be used to provide drainage chambers. Preferably the hollow portion 205 is arranged in use to be sealed such that water ingress is prevented. The external profile may include extruded details to provide additional features, such as a groove 221 in a top surface 223. The hollow portions extend along a length of the extruded plastics section 201. The length of reinforcement 1 is arranged such that it may be inserted into the hollow portion 205 and when inserted, the curved edge 21 of the displaced portion 19 jammingly abuts the lower surface 209 and external surface 5 of the base 3 abuts the upper surface 207. Sides 7 and 9 of the length of reinforcement 1 may be arranged to abut sides 213 and 211 respectively, or may have clearance as shown. Preferably such clearance is less than that which would allow the length of reinforcement to be displaced laterally by distance 2M in the direction of arrow 21- such that the groove 221 would no longer be over the base 3.

Preferably such clearance is greater than any lateral bow or out of straightness that may exist resulting from the manufacturing tolerances in the length of reinforcement 1. A benefit of this is that manufacturing costs may be reduced by permitting a lateral out of straightness tolerance on a length of reinforcement, while the groove 221 may be used to enable screws to be inserted through the extrusion into the length of reinforcement preventing relative lateral movement of the extruded plastics section 201 and the length of reinforcement 1 once the screws are fitted. These screws may also fulfil other functions of retaining window or door hardware.

Figure 3 to shows a plan view of a long length of reinforcement 300. The long length of reinforcement 300 is in a new condition. It may be seen from Figure 3 1 - 5 - that the long length of reinforcement may have a lateral out of straightness up to a maximum tolerance of dimension 3T, which in this Figure is shown exaggerated out of proportion for clarity. However, it may be seen that this dimension is less than the maximum allowable lateral mis-placement 2M shown in Figure 2.

Likewise from Figure 3A a side view of the long length of reinforcement 300 is shown which illustrates longitudinal vertical out of straightness tolerance 3V is much less than 3T. In manufacture of the long length of reinforcement 300 it is easier to achieve a smaller tolerance 3T than the lateral tolerance 3T.

In use it although it is possible to achieve benefit from a length of reinforcement that has one retention shape on the length or preferably two diagonally opposed retention shapes on the two opposite sides, more preferably a length of reinforcement will have at least 4 retention shapes formed in two places on opposing sides. 15 Figure 4 shows a tool 400 for producing the retention shapes on two opposing sides in an operation combined with cropping the reinforcement to length. The tool 400 comprises a top tool 402 and an anvil 440. The top tool 402 has pair of opposed punches 406 and 408. Each of the opposed punches comprises a shear punch 412 and 414, and a planishing extension 416 and 417. In an 20 embodiment of the invention, the planishing extensions are omitted from the opposed punches. The anvil 440 comprises a mounting plate 442 to which is mounted a bottom punch 444 which has a profile 448 which may be seen from the end face 446 to match an inner profile 29 of the length of reinforcement 1. The tool 400 may also comprise an edge 450 on the anvil, and a cut-off blade 25 410 attached to the top tool 402. A benefit of the tool 400 including edge 450 and cut-off blade 410 is that a long length of reinforcement may be cut to a required length in the same operation that produces the retention shapes 15 and 16. A further benefit of this arrangement of the tool 400 is that the retention shapes are formed adjacent to each end of the cut length of reinforcement, and 30 insertion of the length of reinforcement into a hollow portion 205 is facilitated.

In operation a new length of reinforcement (not shown in new condition in Figure 4, but see long length of reinforcement 300 in Figures 3 and 3M is placed on the anvil, so that the length of reinforcement is aligned with edge 450 so that when cut a required length 41---of the reinforcement will be obtained. (A length of reinforcement in the new condition has side walls 7 and 9 continuing along the length of the reinforcement so that the edges 23 are straight and un- deformed.) When the length of reinforcement is positioned as required, the top tool is lowered vertically in the direction of arrow 4D onto the anvil, so that the opposed punches 406 and 408 and the cut-off blade 410 come into contact with the length of reinforcement. As the top tool is moved further in the direction of arrow 4D, the opposed punches 406 and 408 then start to shear the side walls 7 and 9 and the cutoff blade 410 crops the end of the length of reinforcement to give length 4L. The movement in the direction of arrow 4D is controlled such that the curved edge 21 of the displaced portion 19 produces a dimension 4S such that an overall height 4H is obtained that produces a required interference fit when the length of reinforcement is inserted into the hollow portion 205 of the extruded plastics section 201.

Preferably the said required interference fit is such that the external surface 5 of the length of reinforcement closely abuts the upper surface 207, and preferably the interference fit is such that the force required to insert the length of reinforcement into the hollow portion 205 is such that the length of reinforcement may be easily inserted by hand, and more preferably does not fall out of the hollow portion in subsequent handling of the extruded plastics section in a manufacturing process for a door or window frame.

A benefit of the curved edge 21 is that resistance from friction (on insertion) between the length of reinforcement and the lower surface 209 is minimised, and a further benefit is that due to the small contact area and the resilience of the extruded plastics section a wide manufacturing tolerance of height 4H and internal height 2H may be accommodated.

From Figure 5, an alternative embodiment of the invention may be seen, which comprises a second length of reinforcement 500, generally similar to the other lengths of reinforcement described above with a base 603 having an external surface 605, but having planished areas 502 and 504. Each planished area 502 and 504 have been reduced in thickness so that the side walls 506 and 508 respectively have each been displaced in the direction of arrow 6A away from the base 603 in a plane co-incident with each of the side walls. The planished areas 502 and 504 each have a curved edge 521 and 522 which are preferably continuous with cut edges 523 and 524. In use, the second length of reinforcement 500 is inserted into a hollow portion, such as hollow portion 205 in a similar manner to the length of reinforcement 1, and provides similar benefits of ensuring an external surface 505 abuts the upper surface 207. The planished areas 502 and 504 are preferably such that a similar said preferred interference fit is obtained, and the second length of reinforcement may be easily inserted by hand, and more preferably does not fall out of the hollow portion in subsequent handling of the extruded plastics section in a manufacturing process for a door or window frame.

From Figure 6, an alternative embodiment of the invention may be seen, which comprises a third length of reinforcement 600, generally similar to the other lengths of reinforcement described above with a base 603 having an external surface 605, but having slit portion 602 in side wall 606 and a second corresponding slit portion 604 in side wall 608. Each slit portion 602 and 604 has a strip portion 663 and 665 respectively. The strip portions have been displaced in the direction of arrow 6A away from the base 603 so that the side walls 606 and 608 respectively have each been displaced in a plane co- incident with each of the side walls. The planished areas 602 and 604 each have a curved edge 621 and 622 which are preferably continuous with cut edges 623 and 624. In use, the third length of reinforcement 600 is inserted into a hollow portion, such as hollow portion 205 in a similar manner to the length of reinforcement 1, and provides similar benefits of ensuring an external surface 605 abuts the upper surface 207. The strip portions 663 and 665 are preferably displaced a distance 6S such that a similar said preferred interference fit is obtained, and the third length of reinforcement may be easily inserted by hand, and more preferably does not fall out of the hollow portion in subsequent handling of the extruded plastics section in a manufacturing process for a door or window frame.

8 Although in Figure 6, the slit portion is shown with a top edge 670 positioned within the side wall 606, in an alternative embodiment the top edge 670 is formed at a join 672 between the base 603 and the side wall 606 From Figure 7, an end view of a length of reinforcement 700 with a first alternative profile may be seen, with a base 703. Projecting from the base is a central web 701. The central web 701 has a further projecting part 708 at at least one position along the length of the reinforcement 700. From Figure 7A, an end view of a length of reinforcement 710 with a second alternative profile may be seen, with side walls 711 and 712, and a base 713. Base 713 is formed with a depression 714 along the length of the reinforcement 710. The side walls 711 and 712 respectively have a displaced portion 718 and 719 projecting further in a direction of arrow 7D away from the base. Figure 7B shows a length of reinforcement 720 with a third alternative profile, having side walls 721 and 722, and a base 723. The base 723 having a rib 724, comprising inner walls 725 and 726 and a inner base 727. The side walls 721 and 722 respectively have a displaced portion 728 and 729 projecting further away from the base. The portions 708, 718, 719, 728 and 729 formed in the central web or side wall are similar to that already described with reference to the earlier Figures, and ensure that the respective base of each of the lengths of reinforcement will jammingly abut a surface of an extrusion to which it is arranged to be fitted. A benefit of the alternative profiles is that reinforcement according to the present invention may be used with plastics extrusions, where an internal hollow portion may not have a rectangular section or may have intrusions such as weld flash running along a longitudinal axis of the internal hollow portion. Similarly if the internal hollow portion were trapezoidal or other non rectangular shape, a further alternative profile may be required to enable the benefits of the invention to be obtained. By way of example, where an internal hollow portion has a triangular cross section, a L shaped profile may be most suitable for a reinforcement.

The reinforcement may be made from any suitable material, which will add desired strength and rigidity to a plastics extrusion. Such a suitable material would be a metal such as steel or aluminium, or a material such as wood or a fibre reinforced material.

9

Claims

1. A hollow extruded plastics frame section having a reinforcement, the reinforcement comprising a base and a portion projecting from the base in a direction away from the base, the portion having a part projecting further from the base in the said direction, the part formed so as to cause the reinforcement to jam within the plastics section.

2. A hollow extruded plastics frame section having a reinforcement as claimed in claim 1 wherein the part comprises an aperture, the aperture being formed by displacing a displaced portion.

3. A hollow extruded plastics frame section having a reinforcement as claimed in claim 2 wherein the aperture is rectangular.

4. A hollow extruded plastics frame section having a reinforcement as claimed in claim 3 wherein the aperture has three sides formed in the respective upstanding side wall, and the fourth side formed at a join between the side wall and the base.

5. A hollow extruded plastics frame section having a reinforcement as claimed in any one of claims 2 to 4 wherein the displaced portion forms a displaced edge of an edge of the portion projecting such that the displaced edge is displaced in the said direction.

6. A hollow extruded plastics frame section having a reinforcement as claimed in claim 5 wherein the displaced edge has a surface continuous with the edge of the portion projecting.

7. A hollow extruded plastics frame section having a reinforcement as claimed in any one of the preceding claims wherein the part projecting further is 25 in a plane coincident with the portion projecting from the base.

8. A hollow extruded plastics frame section having a reinforcement as claimed in any one of the above claims wherein the reinforcement has a second portion projecting from the base in the said direction.

9. A hollow extruded plastics frame section having a reinforcement as claimed in any one of the above claims wherein the reinforcement has more than one said part projecting further.

10. A hollow extruded plastics frame section having a reinforcement as claimed in claim 9 wherein at least one said part projecting is in each of the portion and the second portion.

11. A hollow extruded plastics frame section having a reinforcement as claimed in any of the preceding claims, the hollow extruded plastics frame section being a part of a frame for a window or a door.

12. A hollow extruded plastics frame section having a reinforcement as described with reference to Figures 1 to 7.

13. A tool for producing a sheared metal reinforcement for a hollow extruded plastics frame section as described with reference to Figure 4.

is

11 Amendments to the claims have been filed as follows CLAIMS 1. A hollow extruded plastics frame section having a reinforcement, the reinforcement comprising a base and a portion projecting from the base in a direction away from the base, the portion having a part projecting further from the base in the said direction, the part formed so as to cause the reinforcement to jam within the plastics section.

2. A hollow extruded plastics frame section having a reinforcement as claimed in claim 1 wherein the portion includes an aperture, the aperture corresponding by displacement to a displaced portion, the displaced portion forming the projecting part.

5. A hollow extruded plastics frame section having a reinforcement as claimed in any one of claims 2 to 4 wherein the displaced portion forms a displaced edge of an edge of the portion projecting such that the displaced edge 2.0 is displaced in the said direction.

7. A hollow extruded plastics frame section having a reinforcement as claimed in any one of the preceding claims wherein the part projecting further is in a plane co-incident with the portion projecting from the base.

1 k r 9. A hollow extruded plastics frame section having a reinforcement as claimed in any one of the above claims wherein the reinforcement has more than one said part projecting further.