GB2464156A

GB2464156A - Manufacturing a laminated window frame

Info

Publication number: GB2464156A
Application number: GB0818564A
Authority: GB
Inventors: Dawn Davies; Anthony Davies
Original assignee: ANTHONY A DAVIES Ltd; COED DERWEN JOINERY
Current assignee: ANTHONY A. DAVIES LIMITED
Priority date: 2008-10-09
Filing date: 2008-10-09
Publication date: 2010-04-14
Also published as: GB0818564D0

Abstract

A method of manufacturing a wooden window frame, the method comprising selecting a length of wood with finished cross section, cutting the wood to predetermined length to form components 11 12 13 26 27 28 and repeating previous two steps to produce a number of components. These frame components and then laminated together to form a frame member 10 20 and then the frame members are joined together to form the frame. The components can be joined together using adhesive or glue. The finished cross section can be formed via planing of the wood prior to cutting. The laminating process can be performed by placing the frame component in a jig, coating it with adhesive, placing another component in contact with the first and clamping the components in the jig until the adhesive is cured.

Description

FRAME ASSEMBLIES

Field of the Invention

The present invention relates to frame assemblies, particularly frame assemblies for glazing units.

Background of the Invention

Glazing units, such as windows and doors, are available in many different styles and materials. A desirable material from which to manufacture the frame assembly of a glazing unit is wood.

Increasingly, wooden glazing units are required that have similar insulation properties to mass produced double glazing units. In addition, it is becoming more important to make effective use of scarce natural resources, for example by using small section forest thinnings, and to maximise the use of raw materials in order to reduce waste.

In order to meet these requirements, it is desirable to provide a technique that enables high quality manufacture of wooden frame assemblies, where waste is reduced.

Summary of the Present Invention

According to one aspect of the present invention, there is provided a method of manufacturing a wooden frame assembly for a glazing unit, the method comprising the steps of: a) selecting a length of wood having a finished cross section; b) cutting the length of wood to a predetermined length to produce a frame component; c) repeating steps a) and b) to produce a predetermined number of frame components; d) laminating a predetermined number of frame components together to form a frame member; e) joining a predetermined number of frame members to produce a frame assembly.

Such a method may also comprise, before step a) the steps of: selecting a length of wood having an desired approximate cross section; and planing the selected length of wood to produce a finished cross section.

Such a method may also comprise, before the step of selecting a length of wood having a desired approximate cross section, the steps of: obtaining a length of wood; and planing a selected side of the length of wood, and cutting other sides of the length of wood to produce a desired approximate cross section.

The predetermined number of frame components may be three. Cutting the length of wood to a predetermined length may comprise cutting the length of wood to a predetermined tolerance. The predetermined tolerance may be +/-0.1mm.

Laminating a predetermined number of frame components may comprise the steps of: i) placing a frame component in a jig; ii) coating a surface of the frame component with an adhesive material; iii) placing another frame component into contact with the adhesive material; iv) repeating steps i) to iii) for the predetermined number of frame components; v) clamping the frame components into the jig until the adhesive is cured.

According to another aspect o the present invention, there is provided a frame assembly for a glazing unit manufactured in accordance with a method according to the first aspect of the present invention.

According to another aspect of the present invention, there is provide a frame assembly for a glazing unit, the assembly comprising a predetermined number of frame members, at least one of which comprises a predetermined number of frame components that are laminated together to form the frame member.

The predetermined number of frame components may be twelve. The frame assembly may be a casement for window assembly.

Brief Description of the Drawings

Figure 1 illustrates a cross Section of a part of a sash window unit manufactured according to a method according to one aspect of the present invention; Figure2 is a flow chart illustrating steps in a method embodying the present invention.

Detailed Description of the Preferred Embodiment

The present invention will be described with reference to a casement window assembly, but it will be appreciated that the techniques may be applied to any type of frame assembly.

Figure 1 illustrates a cross section of a part of a casement window unit which includes an outer frame portion 10, and a casement portion 20. As is well known, in use, the outer frame portion 10 is fixed in position around a window aperture of a building. The sash portion 20 includes an inner frame portion inside which a glazed unit 22 is carried. The glazed unit 22 is preferably a double glazed unit, but could be provided by any suitable glazed unit. The casement portion 20 is arranged to hinge within the outer frame portion 10 from a closed position to an open position, in conventional fashion.

Embodiments of the preset invention are concerned with the method by which the Outer frame portion 10 and the inner frame portion are manufactured. The outer frame portion consists of a number of Sections 11, 12, 13 which are laminated together to form the overall outer frame portion 10. The number of sections shown in Figure 1 is three, but it will be readily appreciated that the outer frame portion may be made up of as many sections as appropriate. Similarly, Figure illustrates the sash portion 20 having an inner frame portion made up of three sections 26, 27 and 28, which sections are laminated together to form the inner frame portion. Once again, it will be readily appreciated that the inner frame portion may be made up of any appropriate number of sections.

A method of manufacturing the inner and outer frame portions described above will now be described with reference to Figure 2, which is a flow diagram illustrating steps in the method. Initially, wood lengths are received (100) and are rip sawed (104) to an approximate size, with one face being planed square (102).

Preferably, the wood cross sections are cut to within 4-6mm of the end required size. The rip sawed lengths are then processed (106) using a 4 head planer, in order to produce the required cross section. A tolerance of �/-0.1mm is desirable.

The planed lengths of wood are then stored in a storage area and are organised by length, cross section, and material for ease of selection later.

When a frame assembly is to be a manufactured, a wood length of the correct material and cross section is selected (108), and is Cut (110) to length. Preferably, each length of wood is inspected and any defects marked with fluorescent marker.

A cutting machine can then be used which detects the presence of the defects, and selects cutting points to avoid the defects. Preferably, the material is cut to length to a tolerance better than +1-0.1mm. The required number of lengths are cut for a given frame assembly, and these parts are identified (112) with a label and stored together as a kit for assembly.

When the cutting operations are complete, then the parts are glued together and are located in a jig to enable accurate alignment of the parts (114). Each section of the frame assembly is constructed from a number of wood lengths (laminates), which are laminated together in order to form a single glued section. The lengths may be offset from one another in order to provide required rebates and mortice and tennon joints for the assembly.

Overall positioning accuracy is preferably to a tolerance of better than 0.1mm.

Each laminate is located into the jig before having adhesive spread onto the uppermost surface. The second laminate is positioned and similarly glued. The third laminate is then positioned. When small length frame or casement elements are being manufactured the jigs can be divided using a dividing end plate to double capacity.

The parts are then clamped in the jig (116) using clamping blocks, and excess adhesive is removed (118). When the glue has cured for the laminated sections, the outer and inner frame portions are assembled, and glued together (120). Following curing of the adhesive, any additional machining (122) is carried out (for example, for cills, weathering grooves, or other profiles).

The frame assembly is then sanded (124), either by hand or using a machine sander, following which a number, preferably three, coats of finish are applied (126). Required hinges, vents, glazing, cills and locks can then be assembled (128) and the completed assembly wrapped ready for shipping (13).

Although the process has been described with reference to a casement window frame assembly, for the sake of clarity, it will be readily appreciated that the process is applicable to any type of frame assembly, such and a top hinged window, or a door.

Such a process enables frame assemblies to be manufactured from wood, in such a way as to produce high quality products from small section wood lengths, whilst minimising waste.

Claims

CLAIMS: 1. A method of manufacturing a wooden frame assembly for a glazing unit, the method comprising the steps of: a) selecting a length of wood having a finished cross section; b) cutting the length of wood to a predetermined length to produce a frame component; c) repeating steps a) and b) to produce a predetermined number of frame components; d) laminating a predetermined number of frame components together to form a frame member; e) joining a predetermined number of frame members to produce a frame assembly.
2. A method as claimed in claim 1, comprising, before step a) the steps of: selecting a length of wood having an desired approximate cross section; and planing the selected length of wood to produce a finished cross section.
3. A method as claimed in claim 2, comprising, before the step of selecting a length of wood having a desired approximate cross section, the steps of: obtaining a length of wood; and planing a selected side of the length of wood, and cutting other sides of the length of wood to produce a desired approximate cross section.
4. A method as claimed in any one of the preceding claims, wherein the predetermined number of frame components is three.
5. A method as claimed in any one of the preceding claims, wherein cutting the length of wood to a predetermined length comprises cutting the length of wood to a predetermined tolerance. 4.
6. A method as claimed in claim 5, wherein the predetermined tolerance is +1-0.1mm.
7. A method as claimed in any one of the preceding claims, wherein laminating a predetermined number of frame components comprises the steps of: i) placing a frame component in a jig; ii) coating a surface of the frame component with an adhesive material; iii) placing another frame component into contact with the adhesive material; iv) repeating steps i) to iii) for the predetermined number of frame components; v) clamping the frame components into the jig until the adhesive is cured.
8. A frame assembly for a glazing unit manufactured in accordance with a method as claimed in any one of the preceding claims.
9. A frame assembly for a glazing unit, the assembly comprising a predetermined number of frame members, at least one of which comprises a predetermined number of frame components that are laminated together to form the frame member.
10. A frame assembly as claimed in claim 9, wherein the predetermined number of frame components is three.
11. A frame assembly as claimed in any one of claims 8 to 10, being a casement window assembly.