GB2494641A

GB2494641A - Reinforcement insert for extruded frame

Info

Publication number: GB2494641A
Application number: GB201115792A
Authority: GB
Inventors: Adrian Redshaw
Original assignee: HL Plastics Ltd
Current assignee: Liniar Ltd
Priority date: 2011-09-13
Filing date: 2011-09-13
Publication date: 2013-03-20
Anticipated expiration: 2031-09-13
Also published as: GB201115792D0; GB2494641B

Abstract

A sash member 110 for a door or a window comprising an elongate plastics sash body 36 which has a unitary cross-sectional profile 38 which includes a first cross-sectional formation 40 to receive and selectively retain a corresponding door panel or window panel 42 and a second cross-sectional formation 46 within which lies an elongate reinforcing member 48. The second cross-sectional formation 46 includes a break 50 in the perimeter 52 thereof which defines an elongate aperture 54 via which a portion of the reinforcing member 48 is exposed relative to the sash body 36. The reinforcing member 48 is selectively insertable laterally into and removable laterally from the second cross-sectional formation 46 via the elongate aperture 54. The insert may be U shaped and manufactured from metal. It may include at least one hardware assembly, for example a bogie (Fig 5) or a lock assembly (Fig 4). It may be located in two orientations, and thus appear to be a u shape or an n shape reinforcement member (c.f. Fig 5/6).

Description

IMPROVEMENTS IN OR RELATING TO

SASH MEMBERS

This invention relates to a sash member for a door or a window, a door or window including such a sash member, and a method of forming such a sash member.

Conventional plastic door and window sash members, while having desirable appearance characteristics, are typically too weak to act alone to retain and support a corresponding door or window panel, e.g. a glazed panel.

Such sash members therefore require a degree of reinforcing to increase their strength.

In a conventional sash member 10 the required reinforcing is provided by inserting an elongate reinforcing member 14 into a closed cavity 20 with a sash body 12, as illustrated for example in Figures 1 and 2.

In particular, at the left of Figure 1 is shown a sash member 10 in a threshold section of a conventional patio door, and at the right of Figure 1 is shown a conventional sash member 10 in a jamb section of the patio door 16. Figure 2 shows a conventional sash member lOin a bottom rail section of a casement window 18.

In each case the reinforcing member 14 is received and wholly contained within the closed cavity 20 formed in the sash body 12. One or more secondary fasteners (not shown), such as one or more screws, are used to secure the reinforcing member 14 within the cavity 20.

Such an arrangement provides a desired increase in strength of the sash member 10 and a suitable fixing site with which further secondary fasteners can engage during manufacture of an associated door or window from a plurality of interconnected sash members 10.

However, once the individual sash members 10 are assembled into a door or window it is very difficult to separate the reinforcing member 14 from the sash body 12 and so such conventional sash members 10 are very difficult to recycle.

There is, therefore, a need for an improved sash member which provides environmental benefits in terms of the ease with which it may be recycled but is also easy to manufacture and assemble.

According to a first aspect of the invention there is provided a sash member, for a door or a window, comprising an elongate plastics sash body having a unitary cross-sectional profile, the cross-sectional profile including a first cross-sectional formation to receive and selectively retain a corresponding door panel or window panel and a second cross- sectional formation within which lies an elongate reinforcing member, the second cross-sectional formation including a break in the perimeter thereof, the perimeter break defining an elongate aperture via which a portion of the reinforcing member is exposed relative to the sash body and through which the reinforcing member is selectively insertable laterally into and removable laterally from the second cross-sectional formation.

The inclusion of an elongate aperture in the sash body, e.g. an aperture which extends completely along the length of the sash body, allows the reinforcing member to be inserted into the sash body to perform its reinforcing function either before the sash member is assembled into a door or window, e.g. shortly after extrusion of the sash body, or after the sash member is assembled into a door or window.. As a result the invention provides an increase in manufacturing flexibility in terms of when an operative is able to add a desired degree of reinforcing to a particular length of sash body during the fabrication of a door or window.

In addition, such an elongate aperture allows for ready removal and subsequent separation of the reinforcing member from the sash body following assembly of the sash body into a door or window, and so permits recycling of each of the reinforcing member and the sash body.

Preferably the reinforcing member resists bending in at least two planes lying substantially perpendicular to one another. Such a reinforcing member reinforces the sash body in a desired manner corresponding to the two main modes in which loading is applied to, e.g. a door or window formed from such a sash member.

Optionally the sash body and the reinforcing member are formed from different materials.

Forming lhe reinforcing member from a different material to the sash body allows the reinforcing member to provide a substantial increase in strength and stiffness to the sash body within the limited dimensional constraints defined by the overall size envelope of the sash body and resulting sash member.

The reinforcing member may be formed from a metal. A metal reinforcing member has high strength to weight and size ratios and so is well-suited to use in the size-limited confines of the sash body.

In a preferred embodiment of the invention the reinforcing member has a U-shaped cross-sectional profile. Providing the reinforcing member with a U-shaped cross-sectional profile helps the reinforcing member resist bending in two perpendicular planes while being relatively easy to manufacture.

Optionally the U-shaped cross-sectional profile includes arm portions which have a greater thickness than the remainder of the profile. Including arm portions which have a greater thickness than the remainder of the U-shaped profile increases the bending resistance of the reinforcing member without unduly increasing its overall dimensions.

In another preferred embodiment of the invention the reinforcing member includes at least one hardware assembly coupled therewith. Including one or more hardware assemblies coupled with the reinforcing member simplifies greatly the assembly of, e.g. a door or window, from the sash member of the invention. This is because insertion of the reinforcing member into the second cross-sectional formation simultaneously positions and secures the or each hardware assembly relative to the resulting door/window without the need for a further fastening operation to fix and secure the hardware into the sash member, as is required with conventional sash member assemblies.

Preferably one or more of the hardware assemblies is or includes one of a lock assembly, a bogie assembly, and a hinge assembly. Such hardware assemblies provide desirable further functionality to a door or window formed from the sash member of the invention.

Optionally the reinforcing member and the second cross-sectional formation are configured to permit the reinforcing member to lie in the second cross-sectional formation in at least two different orientations. Such a feature allows the reinforcing member to, e.g., accommodate differently configured hardware assemblies while lying as desired within the second cross-sectional formation.

The second cross-sectional formation may lie on an opposite side of the sash body to the first cross-sectional formation. Having the second cross-sectional formation lie opposite the first cross-sectional formation allows any hardware assembly coupled with the reinforcing member to act in substantially the same plane as any door or window panel received and retained by the first cross-sectional formation.

In a further preferred embodiment of the invention the second cross-sectional formation includes at least one detent formation. The inclusion of at least one such detent formation helps to selectively retain the reinforcing member within the second cross-sectional formation.

The reinforcing member may include at least one region that cooperates with the detent formation, Such a feature helps to further ensure the reinforcing member is selectively retained within the second cross-sectional formation, as desired.

According to a second aspect of the invention there is provided a door including a plurality of sash members accordingly to any preceding claim coupled to one another to define an outer perimeter of the door.

According to a third aspect of the invention there is provided a window including a plurality of sash members accordingly to any preceding claim coupled to one another to define an outer perimeter of the window.

The door and window of the invention share the benefits of the associated feature of the sash member of the invention.

According to a fourth aspect of the invention there is provided a method of forming a sash member for a door or a window comprising the steps of: (a) providing an elongate plastics sash body having a unitary cross-sectional profile, the cross-sectional profile including a first cross-sectional formation to receive and selectively retain a corresponding door panel or window panel and a second cross-sectional formation including a break in the perimeter thereof, the perimeter break defining an elongate aperture; and (b) inserting an elongate reinforcing member through the elongate aperture into the second cross-sectional formation with a portion of the reinforcing member remaining exposed relative to the sash body.

The provision of a break in the perimeter of the second cross-sectional formation to define an elongate aperture again allows for ready insertion and subsequent removal of the reinforcing member from the sash body.

There now follows a brief description of preferred embodiments of the invention, by way of non-limiting examples, with reference to the accompanying drawings in which: Figure 1 shows cross-sectional views through a sash member in respective jamb and threshold sections of a conventional patio door; Figure 2 shows a cross-sectional view through a sash member in a bottom rail section of a conventional casement window; Figure 3 shows a schematic view of a patio door according to an embodiment of the invention; Figure 4 shows a cross-sectional view through a sash member according to an embodiment of the invention in a jamb section of the patio door shown in Figure 3; Figure 5 shows a cross-sectional view through a sash member according to another embodiment of the invention in a threshold section of the patio door shown in Figure 3; and Figure 6 shows a cross-sectional view through a sash member according to a further embodiment of the invention in a bottom rail section of a casement window according to an embodiment of the invention.

A sash member according to a first embodiment of the invention is designated generally by the reference numeral 30, as illustrated in Figure 4.

The first sash member 30 forms a jamb section 32 in a patio door 34 according to an embodiment of the invention, as illustrated in Figure 3.

The sash member 30 includes an elongate plastics sash body 36 which has a unitary cross-sectional profile 38. In the embodiments shown the sash body 36 is formed from unplasticised polyvinyl chloride (FVCu), although in other embodiments of the invention it may be formed from a different plastics material.

The cross-sectional profile 38 includes a first cross-sectional formation 40 which in use receives a corresponding window panel 42. In the embodiment shown the first cross-sectional formation 40 cooperates with a bead member 44 to selectively retain the window panel 42. In other embodiments (not shown) the first cross-sectional formation may receive and selectively retain a door panel rather than a window panel.

The cross-sectional profile 38 also includes a second cross-sectional formation 46 within which lies an elongate reinforcing member 48. The second cross-sectional formation 46 lies on an opposite side of the sash body 36 to the first cross-sectional formation 40, although in other embodiments of the invention this need not be the case.

The second cross-sectional formation 46 includes a break 50 in the perimeter 52 thereof.

The perimeter break 50 defines an elongate aperture 54, i.e. an aperture which extends along the whole length of the sash body 36, via which a portion of the reinforcing member 48 is exposed relative to the sash body 36.

In other embodiments of the invention, for example those in which only a discrete length of a sash member requires reinforcement, the elongate aperture need only extend along a portion of the length of the sash body, i.e. only a portion of the length of the sash body is need have a second cross-sectional formation which includes a break in the perimeter thereof.

The reinforcing member 48 resists bending in first and second planes P1. P2 which lie perpendicular to one another.

The reinforcing member 48 is formed from a different material to the sash body 36 and1 in the embodiment shown, is formed from a metal. Suitable metals are steel and aluminium which may, additionally, be coated or otherwise treated to inhibit rusting or other deterioration caused by adverse environmental conditions.

As shown in Figure 4, the reinforcing member 48 has a generally U-shaped cross-sectional profile 56 which includes arm portions 58 that have a greater thickness than the remainder of the profile 56. In particular each arm portion 58 is formed from a double-thickness U-section 60. Such an arrangement increases the stiffness of the reinforcing member 48, and hence its resistance to bending in each of the first and second planes P11 P2. In other embodiments of the invention (not shown) the overall thickness of each arm portion may be less than or more than double the thickness of the remaining profile 56.

The reinforcing member 48 includes a hardware assembly 62, in the form of a lock assembly 64, coupled therewith. In the embodiment shown the lock assembly 64 is bolted to the reinforcing member 48, although other means of fastening such as screws, rivets, welding, and/or adhesive, could be used to secure the lock assembly 64 to the reinforcing member 48.

In order to accommodate the configuration of the lock assembly 64 and the manner in which it is received within the sash body 36 the arm portions 58 of the reinforcing member 48 are arranged to extend towards the second cross-sectional formation 46, i.e. the reinforcing member 48 ies in the second cross-sectional formation 46 in a first orientation.

The second cross-sectional formation 46 includes first and second opposed detent formations 66, 68 which extend lengthwise along the elongate aperture 54 adjacent to a mouth 70 of the aperture 54.

The reinforcing member 48 includes corresponding first and second regions 72, 74 which are shaped, i.e. curved, to cooperate with a respective detent formation 66, 68.

In use, after fabrication, e.g. extrusion, of the sash body 36, the reinforcing member 38 is inserted laterally into the second cross-sectional formation 46 via the elongate aperture 54. At this stage the first sash member 30 may or may not be interconnected with one or more similar such sash members 30 to form a door or window.

The reinforcing member 48 carries with it the lock assembly 64 and so the insertion step positions the lock assembly 64 as desired relative to the jamb section 32 such as, for example, for use with a corresponding lock keep 76 located in an outer frame member 78 secured to a support wall (not shown).

The detent formations 66, 68 cooperate with the corresponding first and second regions 72, 74 of the reinforcing member 48 to selectively retain the reinforcing member 48 relative to the sash body 36. In addition the reinforcing member 48 may be further secured within the second cross-sectional formation 46 by a plurality of secondary fasteners, e.g. one or more screws (not shown), or by virtue of friction-fitting engagement with the second cross-sectional formation 46.

As desired, e.g. when decommissioning the patio door 34, an operative is able readily to remove the reinforcing member 48 laterally from the second cross-sectional formation 46, via the elongate aperture 54, by deforming the second cross-sectional formation 46 to allow the reinforcing member 48 to move relative to the detent formations 66, 68.

In other embodiments of the invention (not shown) the operative may alternatively, or additionally, need to remove one or more secondary fasteners that provide further securing of the reinforcing member 48 within the second cross-sectional formation 46.

A second sash member 90 according to a second embodiment of the invention is illustrated schematically in Figure 5.

The second sash member 90 forms a threshold section 92 in the patio door 34 but is otherwise similar to the first sash member 30. Like features share the same reference n u mera Is.

One way in which the second sash member 90 differs from the first sash member 30 is that the reinforcing member 48 has a hardware assembly 62 in the form of a bogie assembly 94 coupled therewith.

To accommodate the configuration of the bogie assembly 94 the arm portions 58 of the reinforcing member 48 are arranged to extend outwards from the second cross-sectional formation 46, i.e. the reinforcing member 48 lies within the second cross-sectional formation 46 in a second orientation.

The reinforcing member 48 includes third and fourth regions 96, 98 which are shaped, i.e. curved, to cooperate with the corresponding detent formations 66, 68 of the second cross-sectional formation 46 to selectively retain the reinforcing member 48 and associated bogie assembly 94 relative to the sash body 36.

In use the reinforcing member 38 is, as with the first sash member 30, inserted laterally into the second cross-sectional formation 46 via the elongate aperture 54.

The reinforcing member 48 carries the bogie assembly 94 with it and so insertion of the reinforcing member 48 into the second cross-sectional formation 46 positions the bogie assembly 94 as desired relative to the threshold section 92 for use, eg. with a corresponding track member 100 located in an outer frame member 78 secured to a support wall (not shown).

The detent formations 66, 68 cooperate with the corresponding third and fourth regions 96, 98 of the reinforcing member 48 to selectively retain the reinforcing member 48 relative to the sash body 36.

S It is noted that the reinforcing member 48 in each of the first and second sash members 30; 90 includes first, second, third and fourth regions 72, 74, 96 98 which permit a single such reinforcing member 48 to cooperate with the detent formations 66, 68 of the second cross-sectional formation 46 when the reinforcing member 48 lies in each of the first and second orientations relative to the sash body 36. In this manner a single profile of reinforcing member 48 is suitable for inclusion in each of the said first and second sash members 30; 90.

When decommissioning the patio door 34, for example, an operative is again able readily to remove the reinforcing member 48 laterally from the second cross-sectional formation is 46, via the elongate aperture 54, by deforming the second cross-sectional formation 46 to allow the reinforcing member 48 to move relative to the detent formations 66, 68.

A third sash member 110 according to a third embodiment of the invention is illustrated schematically in Figure 6.

The third sash member 110 forms a bottom rail section 112 in a casement window (not shown) but is otherwise similar to the first sash member 30. Like features share the same reference numerals.

One way in which the third sash member 110 differs from the first sash member 30 is that the second cross-sectional formation 46 omits first and second detent formations 66, 68 and instead the reinforcing member 46 is secured within the second cross-sectional formation 46 by a plurality of secondary fasteners (not shown), e.g. screws, to retain it relative to the second cross-sectional formation 46 until later separation is required.

Claims

<claim-text>CLAIMS: 1. A sash member, for a door or a window, comprising an elongate plastics sash body having a unitary cross-sectional profile, the cross-sectional profile including a first cross-sectional formation to receive and selectively retain a corresponding door panel or window panel and a second cross-sectional formation within which lies an elongate reinforcing member, the second cross-sectional formation including a break in the perimeter thereof, the perimeter break defining an elongate aperture via which a portion of the reinforcing member is exposed relative to the sash body and through which the io reinforcing member is selectively insertable laterally into and removable laterally from the second cross-sectional formation.</claim-text> <claim-text>2. A sash member according to Claim 1 wherein the reinforcing member resists bending in at least two planes lying substantially perpendicular to one another.</claim-text> <claim-text>3. A sash member according to Claim 1 or Claim 2 wherein the sash body and the reinforcing member are formed from different materials.</claim-text> <claim-text>4. A sash member according to Claim 3 wherein the reinforcing member is formed from a metal.</claim-text> <claim-text>5. A sash member according to any preceding claim wherein the reinforcing member has a U-shaped cross-sectional profile.</claim-text> <claim-text>6. A sash member according to Claim 5 wherein the U-shaped cross-sectional profile includes arm portions which have a greater thickness than the remainder of the profile.</claim-text> <claim-text>7. A sash member according to any preceding claim wherein the reinforcing member includes at least one hardware assembly coupled therewith.</claim-text> <claim-text>8. A sash member according to Claim 7 wherein one or more of the hardware assemblies is or includes one of a lock assembly, a bogie assembly, and a hinge assembly.</claim-text> <claim-text>9. A sash member according to any preceding claim wherein the reinforcing member and the second cross-sectional formation are configured to permit the reinforcing member to lie in the second cross-sectional formation in at least two different orientations.</claim-text> <claim-text>10. A sash member according to any preceding claim wherein the second cross-sectional formation lies on an opposite side of the sash body to the first cross-sectional formation.</claim-text> <claim-text>11. A sash member according to any preceding claim wherein the second cross-sectional formation includes at least one detent formation.</claim-text> <claim-text>12. A sash member according to Claim 11 wherein the reinforcing member includes at least one region that cooperates with the detent formation.</claim-text> <claim-text>13. A door including a plurality of sash members accordingly to any preceding claim is coupled to one another to define an outer perimeter of the door.</claim-text> <claim-text>14. A window including a plurality of sash members accordingly to any preceding claim coupled to one another to define an outer perimeter of the window.</claim-text> <claim-text>15. A method of forming a sash member for a door or a window comprising the steps of: (a) providing an elongate plastics sash body having a unitary cross-sectional profile, the cross-sectional profile including a first cross-sectional formation to receive and selectively retain a corresponding door panel or window panel and a second cross-sectional formation including a break in the perimeter thereof, the perimeter break defining an elongate aperture; and (b) inserting an elongate reinforcing member through the elongate aperture into the second cross-sectional formation with a portion of the reinforcing member remaining exposed relative to the sash body.</claim-text> <claim-text>16. A sash member generally as herein described with reference to and/or as illustrated in Figures 3 to 6 of the accompanying drawings.</claim-text> <claim-text>17. A door or window generally as herein described with reference to and/or as illustrated in Figures 3 to 6 of the accompanying drawings.</claim-text> <claim-text>18. A method of forming a sash member for a door or a window generally as herein described with reference to and/or as illustrated in Figures 3 to 6 of the accompanying drawings.</claim-text>