GB2487910A

GB2487910A - Corner connector and frame assembly

Info

Publication number: GB2487910A
Application number: GB1101984.1A
Authority: GB
Inventors: Robert Friedrich Hoellrigl
Original assignee: Bowater Building Products Ltd
Current assignee: Bowater Building Products Ltd
Priority date: 2011-02-04
Filing date: 2011-02-04
Publication date: 2012-08-15
Anticipated expiration: 2031-02-04
Also published as: GB2487910B; GB201101984D0

Abstract

An L-shaped corner 39 connector having a first arm perpendicular to second arm for coupling first and second frame assemblies 13, 15 of a window or door together; first and second frame assemblies each comprising a frame core 17, 19 to which fascia panels 25, 27 are coupled, preferably clipped on; each core has a cavity, an arm of the L-shaped corner connector is slid into each cavity to join the frame assemblies. Preferably the connector is screwed in place. The frame assemblies may have a plurality of cavities (channels) including a cavity in the fascia and a plurality of corner connectors. The core is preferably of a lower thermal conductive material, such as plastic or wood, than the fascia (cladding) which is of higher thermal conductivity such as metal (e.g. aluminium).

Description

I

APPARATUS FOR COUPLING HYBRID FRAME COMPONENTS

Field

This invention relates to apparatus for coupling hybrid frame components, for example hybrid frame components of a window or door. Hybrid frame components, in the context of the present application, comprise window or door frame components that comprise a core having a poor thermal conductivity (for example of u-PVC or WPC (wood/plastic composite)) to which one or more fascia panels having a higher thermal conductivity (for example of aluminium or aluminium alloy) have been coupled.

Background

A typical window or door comprises a frame that is mounted to the fabric of the building, and a sash that is then mounted in the frame. Modern windows are typically of u-PVC, aluminium or WPC (wood plastic composite), and it is conventional to fabricate the frames (both the frame of the sash and the frame that is coupled to the fabric of the building) from a number of extruded frame components that are then joined together to form the frame. Typically, where such frame components are of aluminium, they are joined together by crimping, and where such frame components are of u-PVC or WPC, they are typically joined together by means of a welding process.

Modern windows and doors are typically given a u-value that signifies how efficient they are at preventing heat transfer from one side of the window/door to the other. With the drive to use our natural resources more efficiently, aluminium windows have become less popular as the u-value achievable with such a window is typically much less than that achievable with a comparable u-PVC or WPC frame. It is also the case that aluminium windows are typically more expensive than their u-PVC or WPC equivalents. However, aluminium windows are still generally perceived to be more attractive than u-PVC or WPC equivalents, and hence are often installed for aesthetic reasons.

In an effort to address both the environmental and cost issues associated with aluminium windows we have proposed in our co-pending UK patent application no. 1101949.4 (the entire contents of which are incorporated herein by reference) to provide a frame component that comprises a u-PVC or WPC core to which aluminium fascia panels are clipped. As shown in Figs. 1(a) to 1(c), in this co-pending application we disclose a hybrid window or door frame component where metallic (typically aluminium) fascia panels I are clipped to a u-PCV or WPC core 3 by locating an upstand 5 on the core 3 in a groove 7 on the fascia 1, and then rotating the fascia I relative to the core 3 until a catch 9 on the fascia engages with a groove 11 in the core.

Once the fascia panels have been attached to the core, respective ends of the frame component are mitred (typically by cutting the assembled core and fascia) ready for joining to like frame components to form a frame for a hybrid window or door.

However, a problem exists that with such an arrangement it is no longer possible to crimp or weld adjacent frame components together to form a finished frame for installation. For example, if one were to contemplate welding the cores together, the fascia panels would interfere (to a varying extent from join to join) as parts of the cores meld together during the welding process. Similar problems arise if one were to attempt to crimp the outer metallic fascia panels together.

The present invention has been devised with the foregoing problems in mind.

S ummarv In accordance with a presently preferred embodiment of the present invention, there is provided apparatus for coupling a first and a second hybrid frame component of a window or door together, wherein said first and second frame components each comprise a core to which a fascia panel has been coupled, each of said cores including an internal void, the apparatus comprising: a first coupling component having first and second arms that each have a distal end and a proximal end, said first and second arm distal ends being coupled together so that said second arm extends generally perpendicularly from said first arm, said proximal end of said first arm being receivable within the void of said first component core and said proximal end of said second arm being receivable within the void of said second component core, and means for coupling said proximal end of said first arm to said first component core, and for coupling said proximal end of said second arm to said second component core to thereby couple said first frame component to said second frame component.

In a preferred implementation, each said fascia panel comprises an internal void, and said apparatus further comprises: a second coupling component having first and second arms that each have a distal end and a proximal end, said first and second arm distal ends being coupled together so that said second arm extends generally perpendicularly from said first arm, said proximal end of said first arm being receivable within the void of a first of said fascia panels and said proximal end of said second arm being receivable within the void of a second of said fascia panels, and means for coupling said proximal end of said first arm to the first of said fascia panels, and for coupling said proximal end of said second arm to the second of said fascia panels to thereby couple said first fascia panel to said second fascia panel.

In another implementation, said first and second frame components may each comprise a second internal void, and the apparatus may comprise: a third coupling component having first and second arms that each have a distal end and a proximal end, said first and second arm distal ends being coupled together so that said second arm extends generally perpendicularly from said first arm, said proximal end of said first arm being receivable within the second void of a first of said frame components and said proximal end of said second arm being receivable within the second void of a second of said frame components, and means for coupling said proximal end of said first arm to the first of said frame components, and for coupling said proximal end of said second arm to the second of said frame components.

In another implementation, said first and second frame components may each comprise a third internal void, and the apparatus may comprise: a fourth coupling component having first and second arms that each have a distal end and a proximal end, said first and second arm distal ends being coupled together so that said second arm extends generally perpendicularly from said first arm, said proximal end of said first arm being receivable within the third void of a first of said frame components and said proximal end of said second arm being receivable within the third void of a second of said frame components, and means for coupling said proximal end of said first arm to the first of said frame components, and for coupling said proximal end of said second arm to the second of said frame components.

In preferred embodiments, the coupling means comprises a plurality of fixings.

The coupling means may comprise a plurality of screws.

The component cores may be of a material having a lower thermal conductivity than the material of said fascia panels. The component cores may be of u-PVC or WPC.

The fascia panels may be of metal, such as aluminium or an alloy thereof.

The teachings of the present invention also provide a method of coupling a first and a second hybrid frame component of a window or door together, wherein said first and second frame components each comprise a core to which a fascia panel has been coupled, each of said cores including an internal void, the method comprising: providing a first coupling component having first and second arms that each have a distal end and a proximal end, said first and second arm distal ends being coupled together so that said second arm extends generally perpendicularly from said first arm; inserting said proximal end of said first arm into the void of said first component core; inserting said proximal end of said second arm into the void of said second component core; coupling said proximal end of said first arm to said first component core, and coupling said proximal end of said second arm to said second component core.

Other features, advantages and embodiments of the present invention are set

out in the following detailed description.

Brief Description of the Drawings

Various aspects of the teachings of the present invention, and arrangements embodying those teachings, will hereafter be described by way of illustrative example with reference to the accompanying drawings, in which: Figs 1(a) to 1(c) are schematic cross-sectional views of arrangements disclosed in co-pending UK Patent Application no. 1101949.4; Fig. 2 is an exploded schematic representation of apparatus for coupling hybrid frame components; Fig. 3 is a cross-sectional view of the apparatus depicted in Fig. 2 installed in a said frame component; Figs. 4(a) to (c) are cross-sectional views of illustrative frame configurations.

Detailed Description of Preferred Embodiments

In the following detailed description, the teachings of the invention will be disclosed with reference to a window, but it should be remembered that the teachings of the invention are equally applicable to doors and hence the following detailed description should not be interpreted as being limited only to windows.

With the above proviso in mind, reference will now be made to Fig. 2 of the accompanying drawings in which there is depicted a first frame component 13 that is to be coupled to a second frame component 15. Each frame component 13, 15 is a hybrid frame component, by which we mean that each frame component comprises a core 17, 19 to which fascia panels 21, 23, 25 and 27 have been coupled (for example, in the manner described in UK patent application no. 1101949.4). The component cores 17, 19 are of a material, such as u-PVC or WPC (wood/plastic composite), that has a lower thermal conductivity than the material, typically aluminium or an aluminium alloy, from which the fascia panels 21, 23, 25, 27 are formed.

As shown in Fig 2, the frame component cores 17, 19 each define first 29, second 31, and third 33 internal voids. In addition, the fascia panels 25, 27 each comprise an internal void 35, 37.

The apparatus for coupling the frame components together comprises a first coupling component 39 that comprises a first arm 39(i) and a second arm 39(u) that are joined together at respective distal ends. In a preferred arrangement, the first and second arms are integrally formed (for example by a moulding process), but it will be appreciated that they may equally be manufactured separately and then joined one to the other. In one envisaged arrangement the first and second arms are relatively stiff and are set at roughly 90 degrees to one another, but in other envisaged arrangements the first and second arms may be more pliable and in such an arrangement they need not be set exactly at a right angle to one another.

The proximal ends of the first and second arms 39(i), 39(u) are configured to fit within the first internal voids 29 of the first and second frame components 13, 15, respectively. Once inserted, the arms are then coupled to the frame components, for example by means of couplings 40 (Fig. 3) (such as screws) extending through the underside of the core. The first coupling component may be of a metal, but in a preferred arrangement the first coupling component is of a plastics material, such as u-PVC.

ln a preferred embodiment, the apparatus further comprises a second coupling component 41 that comprises a first arm 41(i) and a second arm 41(u) that are joined together at respective distal ends. In a preferred arrangement, the first and second arms are integrally formed, but it will be appreciated that they may equally be manufactured separately and then joined one to the other. In one envisaged arrangement the first and second arms are set at roughly 90 degrees to one another, and the coupling component itself is formed of a metal (such as aluminium), for example, by a die casting process.

The proximal ends of the first and second arms 41(i), 41(u) are configured to fit within the internal voids 35, 37 of the fascia panels 25, 27. Once inserted, the arms are then coupled to the fascia panels, for example by means of couplings (such as screws 43) extending through a face of the fascia that is normally not visible in use.

In another embodiment, the apparatus further comprises a third coupling component 45 that comprises a first arm 45(i) and a second arm 45(u) that are joined together at respective distal ends. In a preferred arrangement, the first and second arms of the third coupling component are integrally formed, but it will be appreciated that they may equally be manufactured separately and then joined one to the other. In one envisaged arrangement the first and second arms are set at roughly 90 degrees to one another, and the coupling component 45 is formed of a metal (such as aluminium), for example, by a die casting process.

The proximal ends of the first and second arms 45(i), 45(u) are configured to fit within the third internal voids 33 of the cores 17, 19. Once inserted, the arms are then coupled to the core, for example by means of couplings (such as screws 47) extending through the underside of the fascia panels 25, 27 and into the cores 17, 19.

In yet another embodiment, the apparatus further comprises a fourth coupling component 49 that comprises a first arm 49(i) and a second arm 49(u) that are joined together at respective distal ends. ln a preferred arrangement, the first and second arms of the fourth coupling component are integrally formed, but it will be appreciated that they may equally be manufactured separately and then joined one to the other. In one envisaged arrangement the first and second arms are set at roughly 90 degrees to one another, and the coupling component 49 is formed of a metal (such as aluminium), for example, by a die casting process.

The proximal ends of the first and second arms 49(i), 49(u) are configured to fit within the second internal voids 31 of the cores 17, 19. Once inserted, the arms are then coupled to the core, for example by means of couplings (such as screws 51) extending through the underside of the fascia panels 21, 23 and into the cores 17, 19.

It is particularly preferred for the apparatus to comprise each of the four coupling components mentioned above, but it will be appreciated that some of these components may not in fact be required and hence may be omitted without departing from the scope of the invention.

Referring now to Fig. 3 of the drawings, there is depicted a schematic perspective view of the second frame component core 19 into which the second arms of the four aforementioned coupling components 39, 41, 45, 49 have been inserted, but the first core component 13 has yet to be fitted over the coupling components.

An advantage of the arrangement shown is that the couplings 51, 47, 43 function not only to connect the coupling components 49, 45, 41 to the core 19, but also to couple the fascia panels 21, 27 to the core 19.

In the arrangement depicted, in Figs. 2 and 3 of the drawings, the first void 29 within the first and second core components 13, 15 is unfilled. In further embodiments, the first void 29 of the first and second core components 13, 15 can be filled to reduce the u-value of the frame or to increase its structural rigidity.

In Fig. 4a, a reinforcing bar 53 (typically of metal) has been inserted into the first void 29 to increase the structural integrity of the core component 19. In Fig. 4b, a thermal barrier 55 has been inserted into the void 29, the barrier (typically of a material having a low thermal conductivity) including a number of internal compartments (some or all of which may be filled with material, such as a foam, that further limits heat transfer) that function to reduce heat transfer from one side of the frame component to the other.

In Fig. 4(c) an enhanced thermal barrier 57 has been inserted into the void 29, the barrier being substantially completely filled with a foam material to further reduce heat transfer from one side of the frame component to the other.

To yet further reduce the u-value of the frame, one or more of the second and third voids may also be wholly or partly filled with foam to reduce heat transfer from one side of the frame to the other.

It will be appreciated that whilst various aspects and embodiments of the present invention have heretofore been described, the scope of the present invention is not limited to the particular arrangements set out herein and instead extends to encompass all arrangements, and modifications and alterations thereto, which fall within the scope of the appended claims. In particular, it should be noted that references herein to aluminium should be construed to include aluminium alloys, and vice versa.

It should also be noted that whilst the accompanying claims set out particular combinations of features described herein, the scope of the present invention is not limited to the particular combinations hereafter claimed, but instead extends to encompass any combination of features herein disclosed.

Claims

CLAIMS1. Apparatus for coupling a first and a second hybrid frame component of a window or door together, wherein said first and second frame components each comprise a core to which a fascia panel has been coupled, each of said cores including an internal void, the apparatus comprising: a first coupling component having first and second arms that each have a distal end and a proximal end, said first and second arm distal ends being coupled together so that said second arm extends generally perpendicularly from said first arm, said proximal end of said first arm being receivable within the void of said first component core and said proximal end of said second arm being receivable within the void of said second component core, and means for coupling said proximal end of said first arm to said first component core, and for coupling said proximal end of said second arm to said second component core to thereby couple said first frame component to said second frame component.
2. Apparatus according to Claim 1, wherein each said fascia panel comprises an internal void, and said apparatus further comprises: a second coupling component having first and second arms that each have a distal end and a proximal end, said first and second arm distal ends being coupled together so that said second arm extends generally perpendicularly from said first arm, said proximal end of said first arm being receivable within the void of a first of said fascia panels and said proximal end of said second arm being receivable within the void of a second of said fascia panels, and means for coupling said proximal end of said first arm to the first of said fascia panels, and for coupling said proximal end of said second arm to the second of said fascia panels to thereby couple said first fascia panel to said second fascia panel.
3. Apparatus according to Claim I or 2, wherein said first and second frame components each comprise a second internal void, the apparatus comprising: a third coupling component having first and second arms that each have a distal end and a proximal end, said first and second arm distal ends being coupled together so that said second arm extends generally perpendicularly from said first arm, said proximal end of said first arm being receivable within the second void of a first of said frame components and said proximal end of said second arm being receivable within the second void of a second of said frame components, and means for coupling said proximal end of said first arm to the first of said frame components, and for coupling said proximal end of said second arm to the second of said frame components.
4. Apparatus according to any of Claims I to 3, wherein said first and second frame components each comprise a third internal void, the apparatus comprising: a fourth coupling component having first and second arms that each have a distal end and a proximal end, said first and second arm distal ends being coupled together so that said second arm extends generally perpendicularly from said first arm, said proximal end of said first arm being receivable within the third void of a first of said frame components and said proximal end of said second arm being receivable within the third void of a second of said frame components, and means for coupling said proximal end of said first arm to the first of said frame components, and for coupling said proximal end of said second arm to the second of said frame components.
5. Apparatus according to any preceding claim, wherein said coupling means comprises a plurality of fixings.
6. Apparatus according to any preceding claim, wherein said coupling means comprises a plurality of screws.
7. Apparatus according to any preceding claim, wherein said component cores are of a material having a lower thermal conductivity than the material of said fascia panels.
8. Apparatus according to any preceding claim, wherein said component cores are of u-PVC or WPC.
9. Apparatus according to any preceding claim, wherein said fascia panels are of metal, such as aluminium or an alloy thereof.
10. A window or door frame comprising a plurality of hybrid frame components, wherein adjacent frame components are coupled together by apparatus according to any preceding claim.
11. A window or door frame according to Claim 10, comprising a plurality of structural reinforcing inserts, one inserted into the first voids of each said frame component.
12. A window or door frame according to Claim 10, comprising a plurality of thermal inserts, one inserted into the first voids of each said frame component.
13. A method of coupling a first and a second hybrid frame component of a window or door together, wherein said first and second frame components each comprise a core to which a fascia panel has been coupled, each of said cores including an internal void, the method comprising: providing a first coupling component having first and second arms that each have a distal end and a proximal end, said first and second arm distal ends being coupled together so that said second arm extends generally perpendicularly from said first arm; inserting said proximal end of said first arm into the void of said first component core; inserting said proximal end of said second arm into the void of said second component core; coupling said proximal end of said first arm to said first component core, and coupling said proximal end of said second arm to said second component core.
14. Apparatus for coupling a first and a second hybrid frame component of a window or door together, the apparatus being substantially as hereinbefore described with reference to the accompanying drawings.