GB2467518A

GB2467518A - Reinforcement element with friction promoting member which opposes lengthwise movement

Info

Publication number: GB2467518A
Application number: GB0901425A
Authority: GB
Inventors: Ian Kernaghan
Original assignee: Eurocell Profiles Ltd
Current assignee: Eurocell Profiles Ltd
Priority date: 2009-01-29
Filing date: 2009-01-29
Publication date: 2010-08-04
Also published as: GB0901425D0

Abstract

A reinforced frame part 1 comprising an elongate body 2 defining a hollow interior 12; an elongate reinforcement element 14 adapted to be slideably received in the hollow interior; and at least one friction promoting member 24 provided between the body 2 and the element 14 to oppose movement in a lengthwise direction of the reinforcement element 14 in the hollow interior 12. The reinforcement element is adapted such that, when the reinforced frame part is cut laterally into two sub-parts, irrespective of their length, movement in a lengthwise direction of a sub-part reinforcement element in a corresponding sub-part hollow interior is opposed by the friction promoting member. Also disclosed is method for manufacturing a reinforced frame part with the above friction promoting member and a method of manufacturing a reinforced window using the above mentioned reinforced frame part. Preferably the friction promoting member is elongate and continuous, and attached to the surface of the body or element by adhesive. Preferably the friction promoting member is resilient, flexible and rubber and integrally formed by extrusion with the body or the element. Preferably the friction promoting member comprises a wide base portion relative to a narrow free end.

Description

A Reinforced Frame Part The present invention relates generally to a reinforced elongate part of a window, door or conservatory frame structure and more specifically to window frame parts having a hollow interior in which a reinforcement element is inserted to provide the frame part with additional strength and rigidity.

Window fabricators make window frame from stock lengths of window frame profile. Typically, window profiles include a body having a hollow interior extending longitudinally therein. The body may define a polygonal cross section or may define a more complex custom cross section for a particular application. The body may be extruded from a suitable material, such as steel, aluminium or thermoplastic. An exemplary thermoplastic is polyvinyl chloride (PVC). PVC or PVC-u window profiles are typically extruded in lengths of six metres.

It is known to strengthen window frame parts, particularly when made from a plastics material, by inserting a longitudinal reinforcement element inside the hollow interior of the body. The reinforcement element provides the frame structure with additional strength and rigidity so a window or door frame, for example, is able to withstand the loads subjected to it during service. A reinforcement element also provides the profile with additional thickness to allow hardware, such as suitable fasteners, to penetrate and securely attach to.

Generally, the reinforcement element is a metal material, such as steel or aluminium. However, it is recognised that corrosion is undesirable and it is known to use a plastics material, such as a thermoplastic material, e.g. PVC-u. Recycled PVC, or regrind' as otherwise known in the industry, may be used to form the body of the frame part and/or the reinforcement element.

A known method of manufacturing a PVC window frame is to mitre cut to length a body of PVC material to form a series of frame sub-parts, insert and fix corresponding lengths of reinforcement element therein, and machine the sub-parts for attachment of hardware, such as locks and hinges. The frame sub-parts are then joined together, by fusion welding for example, to form a window frame. The reinforcement elements are commonly fixed to a body of a corresponding sub-part by suitable fasteners, such as self tapping screws.

GB2437786 describes a reinforcement part for a window or door frame comprising a body of extruded thermoplastic material having a hollow interior into which a reinforcement insert is inserted and fixed. The reinforcement insert is fixed to the body by mechanical means, such as fasteners, at regular intervals along the length of the body. The body and reinforcement insert fixed therein can then be cut together reducing manufacturing time and resultant waste material.

However, the reinforcement insert is fixed to the body and is prevented from moving in any direction relative to the body. This is undesirable where the reinforcement insert requires a degree of lateral movement to compensate for temperature effects, such as expansion or contraction.

Also, once fixed to the body, the reinforcement insert cannot easily be manually removed therefrom or repositioned therein, if required.

In addition, where metal mechanical fasteners are used to join the reinforcement insert to the body, the fixings will corrode over time and, in particular, will cause undesirable staining of the outer surface of the body in the vicinity of the fixing.

Also, the individually spaced fasteners fixing the reinforcement insert to the body present a hazard to cutting or machining tools. They also present an obstacle to hardware, such as hinges or locks, being provided at the same location.

The body and reinforcement insert forming a reinforced frame part are cut together. However, if the body and insert are laterally cut at two spaced locations between two neighbouring fasteners, the resulting frame sub-part will have no means to secure the insert to the body. The reinforcement insert in the frame sub-part is allowed to move within the sub-part body and slide out of the sub-part body. This is particularly undesirable when further cutting or machining the frame sub-part, handling/transporting the frame sub-part and/or joining a plurality of frame sub-parts together to form a frame.

A first aspect of the present invention provides a reinforced frame part comprising: -an elongate body defining a hollow interior; -an elongate reinforcement element adapted to be slideably received in the hollow interior; and -at least one friction promoting member provided between the body and the element to oppose movement in a lengthwise direction of the reinforcement element in the hollow interior, wherein the friction promoting member is adapted such that, when the reinforced frame part is cut generally laterally into two or more sub-parts, irrespective of the length of the sub-parts, movement in a lengthwise direction of a sub-part reinforcement element in a hollow interior of a corresponding sub-part body is opposed by the friction promoting member.

The friction promoting member prevents the reinforcement element moving in a lengthwise direction in the hollow interior of the body and prevents the element sliding therefrom during cutting, machining, and handling etc. The reinforced frame part may be divided into shorter frame sub-parts during manufacturing of a window, door or conservatory frame which may include known cutting techniques such as sawing, laser or water jet cutting, for example. A stock length of reinforced frame part comprising the reinforcement element and elongate body can be mitre-cut as one into shorter frame sub-parts for joining together into a window frame, for example. A single cutting operation saves on manufacturing time and cost and ensures the reinforcement element is cut to the same length as its corresponding body in which it is disposed. If a reinforcement element is cut independently to the body a further cutting operation is required. Also, if a reinforcement element is cut too long and its ends extend from the ends of the body it is disposed in, further machining will be required to ensure the ends of the reinforcement element are flush with the ends of the body. If the reinforcement element is cut shorter than the body in which it is disposed, the frame would be allowed to flex and the strength of the frame would be below optimal. Cutting the reinforcement element and body of the frame part in a single operation therefore increases the quality and accuracy of the operation which in turn improves the join between adjacent frame sub-parts and the strength of an assembled frame.

Advantageously, the frame part may be cut generally laterally at any point along its length without the risk of a cutting tool engaging a mechanical fastening. The corresponding sub-part reinforcement elements inside the bodies of the resulting shorter frame sub-parts are held therein after the original length of frame part has been cut. This is desirable when further cutting or machining of the shorter sub-parts, assembling the frame sub-parts to make a frame, dressing the frame sub-parts with hardware and/or handling/transporting the frame sub-parts.

The friction promoting member also eliminates the need for mechanical fasteners to fix the reinforcement element inside the body. Such fasteners require a drilling operation to provide holes in the body and element thereby compromising the integrity of the frame part. This can have an adverse affect on the strength of the frame part and a frame structure.

Mechanical fasteners increase the overall weight of the frame part, increase manufacturing costs and also present a hazard for tools when cutting or machining the frame part, for example.

The friction promoting member is suitably provided to engage with an internal surface of the hollow interior of the body and an external surface of the reinforcement element.

Suitably the at least one friction promoting member is provided on a surface of one of the body or the element.

Preferably the friction promoting member is provided on at least one surface of the element. The friction promoting member may be provided on more than one surface of the element to provide increased opposition to movement of the element in the hollow in a lengthwise direction. A suitable surface of the element may be an outer wall of the element.

Suitably the friction promoting member is attached to the body or element by attachment means. Preferably the attachment means comprises adhesive. Alternatively, the friction promoting member may be integrally formed with the element or body.

Suitably the friction promoting member may be a plurality of individual members provided substantially along an outer surface of the element.

The friction promoting members may be raised projections adapted to engage with an inner surface of the body when the element is inserted into the hollow interior thereof. The friction promoting members may be dome-shaped, for example, comprising a wide base for attachment to the element and a friction promoting surface for engagement with the outer section.

Alternatively and preferably, the friction promoting member may be continuous. Preferably the friction promoting member is at least one continuous elongate friction promoting member. A continuous elongate friction promoting member can be extruded which reduces manufacturing costs and can advantageously be extruded with the reinforcement element. In accordance with the advantages of the invention, a continuous elongate friction promoting member allows an elongate reinforced frame part to be divided into smaller frame sub-parts whilst preventing a sub-part reinforcement element in a corresponding sub-part body from moving therein or sliding therefrom.

Suitably the friction promoting member may be integrally formed with the body or the element. The friction promoting member may be conveniently extruded with the body or the element.

Suitably the friction promoting member is adapted to urge the element towards an inner surface of the body. The effect of this increases the friction between the element and the body by laterally clamping the element against the body and ensures the element is securely retained therein.

Suitably the friction promoting member is resilient. The friction promoting member may be flexible. An exemplary material for the friction promoting member is rubber.

Suitably the friction promoting member may comprise a wide base portion relative to a narrow free end. Such a profile may provide adequate resilience and flexibility.

Suitably the reinforcement element comprises first and second side walls and at least one transverse wall extending therebetween.

Suitably one or both of the body and element comprise one or more projections to space the element from the body. One or more projections may ensure the element is centrally disposed within the hollow interior of the body or in a similar desired position. To allow for extrusion of the body or the element, the one or more projections may be one or more ridges extending lengthwise along the body and outwardly into the hollow interior.

The body may comprise at least one outwardly extending projection. Such an outwardly extending projection may be provided for retaining window glass or for connecting window components to the reinforced frame part.

Suitably one or both of the body and element are formed from a polymer material. The body and/or element may be formed from a recycled polymer material. Exemplary polymer materials include polyvinyl chloride (PVC) or regrind PVC or PVC-u.

A further aspect of the present invention provides a window, door or conservatory frame comprising a reinforced frame part as described above.

A further aspect of the present invention provides a method of manufacturing a reinforced frame part for a window, door or conservatory frame, the method comprising the steps of: -extruding an elongate body defining a hollow interior; -extruding an elongate reinforcement element; -attaching at least one friction promoting member on the reinforcement element in a lengthwise direction; -slideably inserting the reinforcement element and friction promoting member into the hollow interior of the body; and -cutting the frame part generally laterally into two or more frame sub-parts, irrespective of the length of the sub-parts; whereby the at least one friction promoting member being provided between the body and the element to oppose movement of the element in the hollow interior in a lengthwise direction, and is adapted such that, when the frame part is cut generally laterally into two or more frame sub-parts, irrespective of the length of the sub-parts, movement in a lengthwise direction of a sub-part reinforcement element in a corresponding sub-part body is opposed by the friction promoting member.

Where the frame part is for a window frame or closure part of a window, the reinforced frame part may be a perimeter section, a sash section, a transom section or a mullion section of the window frame or closure part.

In a similar manner, the reinforced frame part may be for a door or conservatory frame or door or conservatory closure part.

Suitably the cutting step may comprise mitre-cutting the body and reinforcement element to provide shorter frame sub-parts before the sub-parts are mitre-joined together to form a rectangular frame, for example.

A further aspect of the present invention provides a method of manufacturing a reinforced window, door or conservatory frame 1 0 comprising the steps of: -manufacturing a plurality of shorter frame parts according to a method as describe above; and -joining the plurality of frame parts together to provide the frame.

The joining step may comprise fusing the frame parts together.

An embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: -Figure 1 shows a cross section through a window profile in accordance with the present invention.

As shown in Figure 1, a reinforced frame part 1 of a perimeter section of a window frame comprises a T-shaped body 2 having a cellular upper portion 4 which provides a pair of arms 6 for retaining window glass. A seal 8 is mounted to each arm 6 to seal an interface between window glass (not shown) and the frame part 1.

The body 2 is elongate and defines a hollow interior 12. The body 2 is extruded from a thermoplastic material such as PVC-u and the hollow interior 12 extends therethrough. The hollow interior 12 is adapted to slideably receive a reinforcement element 14 which adds strength and rigidity to the frame part 1 and a frame when a plurality of frame sub-parts 1 are joined together.

The element 14 has first and second side walls 16, 18 and first and second transverse walls 20, 22 defining a box section. The element 14 is cellular to increase the strength of the element 14. The element 14 is also elongate and extruded from a thermoplastic material, such as PVC-u.

An elongate friction promoting member 24 is adhered to a wall 16 of the element 14. The friction promoting member 24 is resilient and flexible. An exemplary material for the friction promoting member 24 is rubber. The member 24 has a wide base portion which is attached to the element 14 and has a narrow free end which engages with an inner surface 26 of the hollow interior 12. The material characteristics of the member 24 provide a frictional force between the element 14 and the body 2 which opposes movement in a lengthwise direction of the element 14 in the hollow interior 12. The friction promoting member 24 ensures the element 14 does not moving longitudinally relative to the body 2, and particularly sliding completely therefrom, when the frame part 1 is being worked on, handled or transported.

A set of inwardly extending longitudinal ridges 28 space the element 14 from the inner surfaces of the body 2. The ridges 28 act as guide rails when the element 14 is being slideably inserted into the hollow interior 12 of the body 2 and also locate the element 14 towards a central position.

The ridges 28 can of course be sized and located as desired to position the element 14 in a preferred location or orientation within the body 2.

The resilience of the friction promoting member 24 tends to urge the element 14 towards a surface of the hollow interior 1 2 which is opposite to the surface with which the member 24 engages. This has the desirable effect of laterally clamping the element 14 against ridges 28 and providing additional retainment of the element 14 in the body 2.

The body 2 and element 14 are extruded from polyvinyl chloride or PVC.

One or both of the body 2 and element 14 may be extruded from recycled PVC or regrind' as commonly known. Conveniently, the body 2 and element 14 may be extruded together. The friction promoting member 24 may be extruded with the element 14 which desirably reduces manufacturing time and cost.

Advantageously, the friction promoting member 24 prevents the reinforcement element 14 moving in the hollow interior 12 of the body 2 and prevents the element 14 sliding completely from the body 2 during handling, for example.

A six metre stock length of frame part 1 may be divided into shorter frame sub-parts 1 which are later joined to form a window, door or conservatory frame which may include known cutting techniques such as sawing, laser or water jet cutting, for example. The element 14 is inserted into a stock length of body 2 before being mitre-cut as a single assembly 1 to form two or more shorter frame sub-parts. This single operation saves on manufacturing time and cost and increases the quality and accuracy of the join when a plurality of frame sub-parts 1 are joined together to form a frame.

The friction promoting member 24 engages substantially along the element 14 to retain the same in the hollow interior 12 of the body 2. This is particularly advantageous when a stock length of frame part 1 is being divided into shorter frame sub-parts before being joined to form a window, door or conservatory frame. This is because the element 14 inside each shorter frame sub-part will remain therein and movement in a lengthwise direction of a sub-part reinforcement element 14 in a hollow interior 1 2 of a corresponding sub-part body 2 will be opposed by the corresponding sub-part friction promoting member 24.

The friction promoting member 24 also eliminates the need for mechanical 1 0 fasteners to fix the reinforcement element 14 inside the body 2. Such fasteners require a drilling operation to provide holes in the body 2 and element 14 thereby compromising the integrity of the frame part 1.

Mechanical fasteners increase the overall weight of the frame part 1, increase manufacturing costs and also present a hazard for tools when cutting or machining the frame part 1, for example.

Claims

Claims 1. A reinforced frame part comprising: -an elongate body defining a hollow interior; -an elongate reinforcement element adapted to be slideably received in the hollow interior; and -at least one friction promoting member provided between the body and the element to oppose movement in a lengthwise direction of the reinforcement element in the hollow interior, wherein the friction promoting member is adapted such that, when the reinforced frame part is cut generally laterally into two or more sub-parts, irrespective of the length of the sub-parts, movement in a lengthwise direction of a sub-part reinforcement element in a hollow interior of a corresponding sub-part body is opposed by the friction promoting member.
2. A window profile according to claim 1, wherein the friction promoting member is provided on a surface of one of the body or the element.
3. A window profile according to claim 2, wherein the friction promoting member is attached to the body or element by attachment means.
4. A window profile according to claim 3, wherein the attachment means comprises adhesive.
5. A window profile according to any preceding claim, wherein the friction promoting member comprises an elongate friction promoting member.
6. A window profile according to claim 5, wherein the friction promoting member is continuous.
7. A window profile according to claim 6, wherein the friction promoting member is integrally formed with the body or the element.
8. A window profile according to claim 7, wherein the friction promoting member is extruded with the body or the element.
9. A window profile according to any preceding claim, wherein the friction promoting member is adapted to urge the element towards an internal surface of the body defining the hollow interior.
10. A window profile according to claim 9, wherein the friction promoting member is resilient.
11. A window profile according to any preceding claim, wherein the friction promoting member is flexible.
12. A window profile according to any preceding claim, wherein the friction promoting member is rubber.
13. A window profile according to any preceding claim, wherein the friction promoting member comprises a wide base portion relative to a narrow free end.
14. A window profile according to any preceding claim, wherein the element comprises first and second side walls and at least one transverse wall extending therebetween.
15. A window profile according to claim 14, wherein one or both of the body and element comprise one or more projections to space an element surface from the body.
16. A window profile according to claim 15, wherein the one or more projections are one or more longitudinal ridges.
17. A window profile according to any preceding claim, wherein the body comprises at least one outwardly extending portion.
18. A window profile according to any preceding claim, wherein one or both of the body and element are formed from a polymer material.
19. A window profile according to claim 18, wherein one or both of the body and element are formed from a recycled polymer material.
20. A window profile according to claim 18 or 19, wherein one or both of the outer section and element are formed from polyvinyl chloride (PVC).
21. A window, door or conservatory comprising a reinforced frame part according to any one claims 1 to 20.
22. A method of manufacturing a reinforced frame part for a window, door or conservatory frame, the method comprising the steps of: -extruding an elongate body defining a hollow interior; -extruding an elongate reinforcement element; -attaching at least one friction promoting member on the reinforcement element in a lengthwise direction; -slideably inserting the reinforcement element and friction promoting member into the hollow interior of the body; and -cutting the frame part generally laterally into two or more frame sub-parts, irrespective of the length of the sub-parts; whereby the at least one friction promoting member being provided between the body and the element to oppose movement of the element in the hollow interior in a lengthwise direction, and is adapted such that, when the frame part is cut generally laterally into two or more frame sub-parts, irrespective 1 0 of the length of the sub-parts, movement in a lengthwise direction of a sub-part reinforcement element in a corresponding sub-part body is opposed by the friction promoting member.
23. A method of manufacturing a reinforced window, door or conservatory frame comprising the steps of: -manufacturing a plurality of shorter frame parts according to a method as describe above; and -joining the plurality of frame parts together to provide the frame.