GB2510845A - Improved Composite Profile for a Door or Window Frame - Google Patents

Abstract

A composite profile for a frame of a door or window comprising an outer frame member 14 and an inner frame member 12, and at least one thermally insulating member 16 which connects the outer and inner frame members together at a predetermined distance from each other. The outer frame member further comprises a protruding element 20 extending towards the inner member to a distance of more than 30% of the predetermined distance and not contacting the inner frame member, the protruding element stiffening the outer frame member and malting the outer frame member less susceptible to bending. The insulating members may be secured in place via grooves 15 and may be secured in place at one end via knurling 17 or adhesive. The protruding element 20 may hollow and have a volume 70% of the space between the insulating members. Also claimed in a method of manufacture and the outer frame member on its own.

Description

IMPROVED COMPOSITE PROFILE FOR A DOOR OR WINDOW FRAME

FIELD OF THE INVENTION

The present invention relates to the field of composite profiles for door or window frames, doors and windows formed from frames with such profiles, and a method of manufacturing the profiles.

BACKGROUNI) OF THE INVENTION Window or door frames that are formed from thermally conductive materials such as metals or metal alloys suffer from the potential problem of cooling of the interior of the frame due to heat conduction through the frame, resulting in heat loss from the room and also condensation if the interior is warm and humid.

This problem has previously been addressed by the use of inner and outer members hereby referred to as profiles being joined together by a thermally insulating material to form a composite profile. This results in a so-called thermally broken design where the inner and outer profiles are insulated from each other which substantially reduces the thermal conduction between them, A problem arising from such designs is that in certain circumstances the temperature of one of the profiles may become substantially higher than the temperature of the other. This can result in warping of bowing of thc composite profile.

For example, it may be that the outer profile is for some periods in direct sunlight.

This may result iii it heating up considerably and expanding while the inner profile remains at a lower temperature and therefore does not expand. This results in forces on the composite profile which may lead to deformation or warping of the frame. This may result in an inability to close a door or window with a frame formed from such a composite profile.

It would be desirable to be able to reduce the deformation or warping of such composite profiles.

SUMMARY OF THE INVENTION

Viewed from a first aspect, the present invention provides a composite profile for a frame of a door or window comprising: an outer frame member and an inner frame member, and at least one thermally insulating member; said outer frame member and said inner frame member being connected together by said at least one thermally insulating member, said at least one thermally insulating member holding said inner and said outer frame members at a predetermined distance from each other; wherein said outer frame member comprises a protruding element that extends from said outer member towards said inner frame member to a distance of more than 30% of said predetermined distance and does not contact said inner frame member, said protruding element stiffening said outer frame member and making said outer frame member less susceptible to deformation.

As noted above frames for doors and windows, particularly those that are formed of conductive materials which may be selected for their strength and rigidity, have the potential disadvantage of heat transfer occurring between the inner and outer surfaces. This has been addressed by forming the frame from composite profiles, which are formed of inner and outer members that are connected together by at least one thermally insulating member that thcrmally isolates the inner and outer surfaces from each other.

A potential problem with such a system is that the inner surface and the outer surface may be at significantly different temperatures. For example, the outer member may be in an environment where temperatures change significantly while the inner member is held at a comparatively steady temperature. This results in the outer member either expanding or contracting with respect to the inner member which can lead to deformation such as warping or bowing of the composite profile forming the frame.

The present invention recognises the problem of deformation of composite frames that arises from differences in temperature between thermally isolated inner and outer frame members. lt addresses this problem by providing a protruding element that reinforces the outer member which is the member that is subject to the greatest temperature variations. [his element has been placed in the interior of the composite profile between the inner and outer profile, where it is not generally visible to the user. This allows this protruding or strengthening element to have a size and shape can be dictated by function and by the constraints of the size of the space between the elements. The protruding element has a significant size and extends to at least 30% of the distance bctwcen the inner and outer members. In sonic cases it may be advantageous for it to extend to at least 50% of the predetermined distance and in other cases to over 70%, in most cases it extends to lcss than 90% of the predetermined distance.

There is a technical prejudice in this field against placing any element that is not an insulating element within the space between the inner and outer members as there is a desire to insulate the inner member from the outer member to avoid heat transfer between them. However, the inventors of the present invention realised that the heat transfer effect of such a reintbrcing protruding element is surprisingly small.

This is due in some part to the heat sink effect of the protruding element which in the case that the outer member is heated, can conduct some of the heat away from the surface and by providing additional radiating surfaces, can dissipate at least some of this received heat.

Furthermore, by locating this protruding element in a hidden position between the inner and outcr members, this protruding element can have a size and shape that is dictated by function and by the constraints of the size of the space between the elements and thus, an element that provides effective strengthening and is a good heat sink can be selected.

In this way, the increase in heat transfer between the two members was found to be surprisingly small, while the increase in stiffness of the outer member was considerable. It is also aesthetically more acceptable to locate the protruding member in this position than it would be to locate it on the visible surfaces.

It should be noted that the terms inner and outer refer to the location of the member when mounted on a structure such as a building, wherein the inner member generally faces the interior of the building and the outer member the exterior. In general the inner frame member should be viewed as forming the side of the frame that is thermally protected when mounted and generally sees a lower temperamre change than the outer frame member that is mounted in a location that sees a greater temperature variation. In this regard these terms should not be viewed overly restrictively, and cases where the frames are mounted internally within a building could be envisaged, in such a ease the outer frame member should be mounted on the S side that sees the greatest temperature changes as it has been designed to be robust under such conditions.

In sonic embodiments, said protruding element is a hollow element.

Although the protruding element can have a number of forms, it can be advantageous for it to be a hollow clement. A hollow element has the advantage of requiring a reduced amount of additional material compared to a corresponding solid element, while still having a considerable strength. Furthermore, for a relatively small amount of additional material a large area of radiating surfaces can be formed.

Additionally, convection currents can flow both within and outside of the element.

In this regard the protruding element may be formed with two leg like structures attaching to the outer frame member with a bridging element running between them. Such a structure will increase the strength and robustness of the composite profile.

In some embodiments, the profile comprises two thermally insulating members wherein said outer and said inner frame members are connected together by said two thermally insulating members, said protruding element extending into the space between said two thermally insulating members.

Although in some embodiments the two fames may he held by a single thermally insulating member, in some embodiments it is held by two, the space between the two being the place where the protruding element is formed. This position is not visible to the outside and as such the protruding element can l1ave a form that is suitable for its ftnetion without the need to make it visually attractive.

In some embodiments, a volume of said protruding element is at least 70% of a volume of said space between said two thennally insulating members and said inner and outer frame members.

It may be advantageous if the protruding element is quite large as this will increase the radiating surfaces and also increase its stiffening ability. Where it is located between the thermally insulating elements the volume of the space within which it must fit is a constraint on its size. Furthermore, it is advantageous for there to be some gap between the protruding element and the inner frame. A protruding clement of at least 70% of the volume of the space is one which is advantageously large having large radiating surfaces and good strength.

S It should be noted that the shape of the protruding profile can be selected dependent on assembly techniques and required function. Its position within the composite frame means that visual appearance may not be a constraint.

In some embodiments, said outer and inner frame members each comprise two grooves for receiving said two thennally insulating members, and said protruding element has a width which is a dimension in a same plane as and perpendicular to said two grooves that is at least 30% oF a distance between said two grooves and a depth that is a distance that said protruding element extends out from said outer frame member that is greater than said width.

The strength of the protruding element increases with its depth and similarly the radiating areas increase. An increase in width may also be advantageous, however the width may be limited as the space between the grooves may be required for mounting other hardware elements. l'hus, a protruding element that is deeper than it is wide may be preferable and one that is fairly wide but perhaps allows some space for mounting additional elements may be advantageous.

Although the outer member and the protruding element may he formed of two parts that are joined together perhaps by riveting, in some embodiments, said outer frame member and said protruding element arc formed as a single piece by extrusion.

A simple way of forming the protruding element is to form it with the outer frame as a single piece by extrusion. Forming the two pieces separately will result in them needing to be joined, with the join inevitably being a weakness in the resulting structure, The join will also increase the complexity and therefore the cost of the manufacturing process.

In oilier embodiments, said outer member comprises two grooves for receiving said protruding element, said protruding element being formed as a separate element and being mounted on said outer member in said two grooves.

In some eases, it may be advantageous if the protruding element is formed of a different material from the outer member, perhaps a material with a particular stiffness, heat conductivity or heat capacity and in such a case it may be advantageous to form the two elements as separate pieces and join them in some way. In this regard the material may be a metal or a polymer. A metal has the advantage of robustness, high conductivity, but a polymer may be easier to mount in the grooves.

The use of grooves allows an outer member that is adapted to mount a protruding element to be manufactured. The outer member could then be used in composite profiles that had protruding elements mounted and those that did not. In this way a general purpose outer member could be made and a composite profile that is strengthened or not could be produced using such an outer member depending on circumstances.

In some embodiments, said inner and outer framc members and said protruding clement are formed of an extruded aluminium alloy.

Embodiments of the present technique are particularly applicable to frame members that are fonned of an extruded aluminium alloy. The use of an aluminium alloy to form the frames may be advantageous in generating frames that are robust and secure, but has the disadvantage of providing francs that are good heat conductors and that expand and contract with changes in temperature. Such window frames are usually fonned in a thermally broken manner such that there are two members connected by a thernrnlly insulating member such that the problem of conduction is alleviated but the problem of waiping occurs. ilius, a protruding element which strengthens the outer member and provides a thcnnal sink is particularly advantagcous in such frames.

Furthermorc, an extrusion technique can be used to fonn the outer member and protruding element in a single process.

In some embodiments, said inner and outer members each comprise at least one groove for receiving said at least one thennally insulating member, said at least one groove on said inner member comprising gripping means for impeding longitudinal movement of said thennally insulating member within said at least one groove, said at least one groove on said outer member not comprising said gripping means for impeding longitudinal movement of said thermally insulating member within said at least one groove.

A further way of reducing the warping effect that arises due to a temperature gradient between the inner and outer members is to allow some longitudinal movement in the join between the inner and outer profiles. It should be noted that for the sake of construction and transport the composite members do need to be robust and stable, however the problem of warping of the frame is exacerbated by rigid joints between the inter and outer members. Providing gripping means on the groove of the inner member which impedes longitudinal movement of the thermally insulating member while not providing them on the outer member allows some movement of the outer member longitudinally along the thermally insulating member which can reduce the effect of bowing while retaining the rigidity of the structure as a whole. In particular, the grooves are such that vertical movement between the two members is prevented or at least impcdcd, whilc longitudinal movcmcnt along the groove in the outer member is allowed, which can help reduce deformation of the frame when the outer member either expands or contracts with respect to the inner member due to changes in outside temperature.

In particular, it has been found that by providing the outer frame with the protruding element to increase stiffness, along with a means of allowing sonic movement of the joint along the groove in the outer member, provides two effects that act together in a synergetic manner to provide a robust composite profile with increased resistance to deformation.

In some embodiments. said gripping means comprises knurling on at least one inner surface of said at least one groove.

Although the means for improving longitudinal movement may take a number of forms, lcnurling or some sort of roughening of the inner surface of one of the grooves is an effective way of increasing the friction between the member and the groove and thereby providing improved gripping.

Alternatively and!or additionally, the gripping means may comprise adhesive on at least one of the inner surfaces of the groove. This is a further way of causing the insulating member to he held tightly within that groove while being allowed to slide within the other.

Although the composite profile can be frnished in a number of ways such as mill finishing or anodising, in some cases, said inner and outer frame member and said protmding element are powder coated.

Powder coating of the frame members is one way of finishing them and if it is performed after the inner and outer frame members arc joined to form the composite profile then it has the additional advantageous effect of driving the moisture out of the thermally insulating member which, where the thermally insulating member is formed of a plastic such as polyamide, relaxes the strength of the joint allowing some movement thereby reducing warping effects.

A second aspect of the present invention provides a door comprising a plurality of frame members, at least one of said frame members being formed of a composite profile according to a first aspect of the present invention.

A third aspect of the present invention provides a window comprising a plurality of frame members, at least one of said frame members being formed of a composite profile according to a first aspect of the present invention.

A fourth aspect of the present invention provides a method of manufacturing a composite profile according to any preceding claim, comprising the steps of: forming an inner frame member by extrusion; forming an outer frame member comprising a protruding element by extrusion; joining said inner and outer frame members together by at least one thermally insulating strip to form said composite profile, said at least one thermally insulating strip being held within grooves on said inner and outer frame members, such that said inner and outer frame members are held at a predetermined distance from each other by said at least one thermally insulating strip; wherein said protruding element extends from said outer member towards said inner member to a distance of more than 30% of said predetermined distance.

In some embodiments, the method comprises the further step of powder coating said composite profile after said step ofjoining said inner and outer said frame members.

As noted previously by performing powder coating after the inner and outer frame members have been joined by the thermally insulating strip relaxation of the strip occurs and the joint is not as rigid.

In some embodiments a ffirther step of knurling at least one of inner surfaces said groove on said inner frame prior to joining said inner/outer frame is performed.

It may be advantageous if the inner surface of the groove on the inner frame is treated in some way such as by knurling to improve the gripping of the thermally insulating member while the groove on the outer member is not treated such that the thermally insulating member can slide within it allowing some movement and reducing the bowing of the door in high temperature differences.

A fifth aspect of the invention provides a reinforced outer member for a composite frame for a window or door, comprising an outer surface and an inner surface, said inner surface comprising: two grooves for receiving thermally insulating members for connecting to an inner member of said composite frame; and a protruding element between said two grooves and cxtcnding out from said inner surface for increasing the strength of said outer member.

A sixth aspect of the present invention provides a use for a reinforced outer member according to a fifth aspect of the present invention in the manufacture of a door or a window.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be described further, by way of example only, with reference to embodiments thereof as illustrated in the accompanying drawings, in which: Figures 1A to 1C show a cross section of different composite profiles according to embodiments of the present invention; Figure 2 shows a window according to an embodiment of the present invention; Figure 3 shows a door according to an embodiment of the present invention; Figure 4A shows a cross section of a lock stile according to an embodiment of the present invention and the corresponding lock jamb; Figure 4B shows a cross section of an alternative embodiment where the protruding element is mounted in grooves; mid Figure 5 shows a flow diagram illustrating steps in a method according to an embodiment of the present invention.

DESCRIPTION OF EMBODIMENTS

Figure 1A shows a composite profile 10 according to an embodiment of the present invention. The composite profile 10 comprises an inner frame member 12 which is the portion of the frame facing the interior and an outer frame member 14 which is the portion of the frame facing the exterior when rnoimted on a structure.

These are joined together by two insulating members 16 which are held within grooves 11 on the inner member and 15 on the outer member. The insulating members may be made of any suitable material, which is robust relatively rigid and which is a good thermal insulator. Various plastic materials such as polyamide are preferred. The inner and outer frame members are formed from a metal alloy, in this case an aluminium alloy.

The outer member has a protruding element 20 which is integral to the outer member 14 and substantially fills the gap between the insulating members 16 and the inner 12 and outer frame members 14.

In this embodiment it has a sloped portion 22 which is provided such that there is an increased gap at this point between the protruding clement 20 and the inner frame member 12 which allows tools used during manufacturing to handle the different members.

The side of the cross section of the composite profile shown as 19 is the side where the glass panes for a window or the leaf of a door are held. The other side mates with a locking assembly (see figures 4A and 4B). Although the outer shell is shown in this embodiment as a flat plate with a protruding element it may have an additional outer box like shell similar to that on the inner member to increase strength and rigidity this may be required for particularly long frames.

Figure lB shows an alternative embodiment where the protruding element 20 has a simple rectangular cross section. In this embodiment, there is knurling 17 on the inner surfaces of the grooves 11 on the inner member. This holds the insulating strips 16 tightly and provides a resistance to longitudinal movement along the length of the grooves. No such knurling is present on the grooves 15 of the outer shell 14 and this allows the outer shell some movement with respect to the inner shell and can reduce warping. Although, in this example knurling is shown as the means to hold the insulating strip tightly other ways of doing this are envisaged such as adhesives or some other surface roughening.

It should be noted that it is advantageous if the outer shell is held more loosely as it is this shell that experiences the large differences in temperature and thus the expansion and contraction which causes the warping. Allowing some movement while providing a stiffened outer frame member leads to a robust frame that can be handled easily during manufacture and yet is resistant to warping.

Figure 1 C shows an alternative embodiment where the protruding element 20 has a curved shape. The shape of the element selected will depend on different factors.

However, a body that has sipiificant radiating surfaces and has a shape with a relatively large distance from the neutral access may be advantageous. The shape of the element must be such that it fits within the space between the inner and outer frame mcmbcrs 12, 14 and between the two thermal strips 16, and one that fills much of that space may be desirable. The amount of material that such a shape takes is a cost and therefore hollow bodies ate advantageous. Furthermore, hollow bodies provide additional convection and radiating surfaces. The location of the protruding body within this hidden space means that the shape does not have to be visually attractive and that different surface treatments that are used are hidden.

Surface treatments that are used on such profiles include mill treating, anodising and powder coating. It has been found that where powder coating is used it may be advantageous to apply this treatment after assembly of the composite profile.

Powder coating the thermal insulating strips, relaxes the plastic material making for a more flexible joint which can reduce warping.

Although, in the example shown here the outer member and protruding element are formed as a single extruded piece, in other embodiments they may be formed as separate pieces, with the protruding body connected to the outer member by sonic means such as rivets. This would allow different materials to those of the outer and inner members to be selected for the protruding element, which materials may be selected for their increased strength, good radiating properties and/or high specific heat capacity. However, a disadvantage of such an arrangement is that the riveted joints arc a weakness in the structure such that it is weaker than a frame formed as a single piece, furthermore, such a frame requires is more complex to manufacture.

Figure 2 shows a window 30 according to an embodiment of the present invention, l'he window opens about hinges on the right hand side of the frame and has a handle 32 for closing the window. At least one side of the frame of thc window frame that holds the glass 33 is formed from a composite profile such as shown in figures 1A -IC. It may be that just the side of the window having the handle is formed of the strengthened composite profile as it is particularly important that this section of the frame does not warp as this may impede closure of the window. In other embodiments all of the frame may be formed of such composite profiles.

S Figure 3 shows a sliding glass door 40 according to an embodiment of the present invention. Again the frame is formed of composite profiles, at least some of which are strengthened by the protruding element 20 of Figures IA to C. It is particularly important that the section of the frame 42 that has the locking mechanism within it should not warp and thus, this section may be formed of one of the strengthened composite profiles of Figure I even where the other sections of the frame are not. In other embodiments all of the sections of the frame are strengthened.

Tests performed on a standard height sliding glass patio door as shown in Figure 3, which is strengthened by the protruding element 20 and has no knurling or rolling on the grooves that hold the insulating connecting strip on the outer side of the door, showed a deflection of the door between the lock location in the middle and the top and bottom edges of the door to he less than 1mm, which is well within the tolerances for acceptable operation. A standard door that was not strengthened in this way showed a deflection in the region of 5mm.

Figure 4A shows the composite profile 10 of Figure 1A that mates with a lock jamb 50 in the closed position. This example is a sliding window or door such as is shown in Figure 3. As can he appreciated from this figure any deformation of the composite profile 10 forming the mating frame member, that is the lock stile, is particularly undesirable as it can lead to an inability for the window or door to fit within the corresponding recesses of the lock jam preventing it from being closed.

Thus, strengthening of this portion of the frame with the composite profile of an embodiment of the present invention is particularly advantageous.

One point to note is that although the provision of the protruding body makes for a more robust and improved composite profile, in certain cases this may not be necessary. For example where the window or door is to be used in an environment where no large temperature gradient is expected, perhaps due to the outer frame member having a heat reflective outer surface then the provision of the protruding body may not be required and can be omitted. This will provide a reduced cost frame as the protruding element has a cost due to the additional material required. As the protruding element is a simple change to a composite profile then it is a simple matter to supply a composite profile with the protruding element and a composite profile without the protruding element, the two profiles having the same visual characteristics and being able to be used together in the same frame.

In this regard, Figure 4B shows an alternative embodiment where the protruding element 20 is formed of a different material to the outer and inner frame members and is held in grooves 52 on the outer frame member by feet 53 which have a shape corresponding to the grooves 52. This is a convenient way of mounting the profile which provides a good thermal link and is easy to mount. Furthermore, an outer frame member with such grooves 52 can be manufactured allowing it to have the protruding element 20 mounted if the frame requires strengthening or not mounted for frames that do not require strengthening. In this way a single manufacturing process can be used to generate the outer frame members which can be used with a protruding element inserted for strengthened frames and without a protruding element for more standard frames.

In addition to supplying some complete frames without the protruding element, it may bc desirable to simply strengthen a portion of the composite profile that forms a frame. Thus, the frame edge that mates with the locking member as shown in Figure 4A or 4B may be strengthened while the rest of the frame may be formed of conventional composite profiles.

The composite profiles may be sold as a kit to form window and door frames either with or without the other materials required to form the windows and doors.

Each composite profile may form one of the frame members, with in sonic cases one or more of the frame members being strengthened according to an embodiment of the present invention while the other frame members not having the protruding element.

Figure 5 shows a flow diagram illustrating steps in a method of manufacturing a composite profile according to an embodiment of the present invention, Initially the inner and outer frame members are each generated by extrusion. This is formed as two independent extrusion processes and can be performed in any order. The inner and outer frame members are each formed with two grooves for receiving thermal strips that hold them together, the outer frame member has a protruding element located between the two grooves for strengthening the outer frame member. In this embodiment the outer frame member is extruded with the protruding member present.

In oilier embodiments the protruding element may be mounted to the outer frame member after the formation of the frame members and before they are joined. ln sonic cases this may be by screwing or riveting, while in others it may be by The use of grooves with protruding elements having feet adapted to fit and be held within the groove.

The next step involves roughening the inner surface of the grooves on the inner frame members using knurling such that the thermal break strips in thcsc grooves have more resistance to longitudinal movement than the thermal break strips held in the grooves on the outer member. This allows some slippage to occur in the outer member grooves when the outer member experiences expansion or contraction due to temperature changes. Such slippage can reduce warping of the composite profile.

The inner and outer frame members are then joined together by locating the two thermally insulating strips in respective ones of the two grooves on the inner and outer frame members to form the composite profile. This composite profile is then finished by powder coating. This provides the desired appearance of the frame. Powder coating at the end of the process also causes relaxation of the thermally insulating strips making them less rigid and allowing a more flexible join thcrcby decreasing warping effects due to temperature differences. In some embodiments the outer surface is anodised rather than being power coated. This provides the desired finish Various further aspects and (eatures of the present invention are defined hi the appended claims. Various modifications can be made to the embodiments herein before described without departing from the scope of the present invention.

Claims (12)

1. CLAiMS 1. A composite profile for a frame of a door or window comprising: an outer frame member and an inner frame member, and at least one thermally insulating member; said outer frame member and said inner frame member being eonnceted together by said at least one thermally insulating member, said at least one thermally insulating member holding said inner and said outer frame members at a predetermined distance 1 0 from each other; wherein said outer frame member comprises a protruding element that extends from said outer member towards said inner frame member to a distance of more than 30% of said predetermined distance and does not contact said inner frame member, said protruding element stiffening said outer frame member and making said outer frame member less susceptible to deformation.
2. 2. A composite profile according to claim 1, wherein said protruding element is a hollow element.
3. 3, A composite profile according to any preceding claim, comprising two thermally insulating members wherein said outer and said inner frame members are connected together by said two thermally insulating members, said protruding element extending into the space between said two thermally insulating members.
4. 4. A composite profile according to claims 2 and 3, wherein a volume of said protruding element is at least 70% of a volume of said space between said two thermally insulating members and said inner and outer frame members.
5. 5. A composite profile according to claim 3 or 4, wherein said outer and inner frame members each comprise two grooves for receiving said two thermally insulating members, and said protruding element has a width which is a dimension in a same plane as and perpendicular to said two grooves that is at least 30% of a distance between said two grooves and a depth that is a distance that said protruding element extends out from said outer frame member that is greater than said width.
6. 6. A composite profile according to any preceding claim, wherein said outer frame member and said protruding element are fomied as a single piece by extrusion.
7. 7. A composite profile according to claim 6, wherein said inner and outer frame members and said protruding element are formed of an extruded aluminium alloy.

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8. 8. A composite profile according to ally one of claims 1 to 5, wherein said outer member comprises two grooves for receiving said protruding element, said protruding element being formed as a separate element and being mounted on said outer member in said two grooves.
9. 9. A composite profile according to any one of claims I to 5 or 8, wherein said protruding element is formed of a metal or a polymer, 10. A composite profile according to any preceding claim, wherein said inner and outer members each compr se at least one groove for receiving said at least one thermally insulating member, said at least one groove on said inner member comprising gripping means for impeding longitudinal movement of said thermally insulating member within said at least one groove, said at least one groove on said outer member not comprising said gripping means for impeding longitudinal movement of said thermally insulating member within said at least one groove.11. A composite profile according to any preceding claim, wherein said gripping means comprises knurling on at least one inner surface of said at least one groove.12. A composite profile according to any preceding claim, wherein said gripping means comprises adhesive on at least one inner surface of said at least one groove.13. A composite profile according to any preceding claim, wherein said inner and outer frame member and said protruding element are powder coated or anodised.14. A door comprising a plurality of frame members, at least one of said frame members being formed of a composite profile according to any preceding claim.15, A window comprising a plurality of frame members, at least one of said frame members being formed of a composite profile according to any one of claims Ito 12.16. A method of manufacturing a composite profile according to any one of claims ltol3, comprising the steps of: forming an inner frame member; forming an outer frame member; joining said inner and outer frame members together by at least one thermally insulating strip to form said composite profile, said at least one thermally insulating strip being held within grooves on said inner and outer frame members, such that said inner and outer frame members are held at a predetermined distance from each other by said at least one thermally insulating strip; wherein prior to perfonning said joining step providing a protruding element on a surface of the outer frame member that faces said inner frame membcr when joined, said protruding element being of a size such that it extends from said outer member towards said inner frame member to a distance of more than 30% of said predetermined distance and does not contact said inner frame member, said protruding element stitTening said outer frame member and making said outer frame member less susceptible to deformation.1 7. A method according to claim 16, wherein said step of forming said inner frame member compnses fonning said inner frame member by extrusion; and said step of forming said outer frame member and providing said protruding element on a surface of said outer frame member comprises a single extruding step, said outer frame member and protruding element being formed by extrusion.18. A method according to claim 16, wherein said outer frame member comprises further grooves for receiving said protruding body, said step of step providing a protruding element on a surface of the outer frame member comprising attaching said protruding body in said further grooves.19. A method according to any one of claims 16 to 18, comprising a Luther step of powder coating or anodising said composite profile after said step of joining said inner and outer frame members.20. A method according to any one of claims 16 to 19, comprising a further step of knurling at least one inner surface of said groove oii said inner frame prior to joining said inner and outer frame.21. A reinforced outer member for a composite frame for a window or door, comprising an outer surface and an inner surface, said inner surface comprising: two grooves for receiving thermally insulating members for connecting to an inter mcmber of said compositc frame; and a protruding element situated between said two grooves and extending out from said inner surface for increasing the strength of said outer frame member.22. A reinforced outer member according to claim 21, wherein said protruding element is a hollow element with a depth that extends away from said reinforced outer membcr to a distance that is greater than a distance that it extends between and perpendicular to said two grooves.23. A rcinforccd outer mcnihcr according to any one of claims 21 or 22, wherein said protruding element has a width which is a dimension in a same plane as and perpendicular to said two grooves that is at least 30% of a distance between said two grooves.24. Use of a reinforced outer member according to any one of claims 21 to 23, in the manufacture of a window or a door.25. A composite profile substantially as hereinhefore described with reference to the appended Figures.26. A window substantially as hereinbefore described with reference to the appended Figures.27. A door substantially as hereinbefore described with reference to the appended Figures.28. A reinforced outer member for a composite profile substanlially as hereinbefore described with reference to the appended Figures.29. A method of manufacturing a composite profile substantially as hereinbcfore described ith reference to the appended Figures.30. A use of a reinforced outer member substantially as hereinbefore described with reference to the appended Figures in the manufacture of a door or a window.Amendment to the claims have been filed as foflowsCLAIMS1. A composite profile for a frame of a door or window comprising: an outer frame member and an inner frame member, and at least one thermally insulating member; said outer frame member and said inner frame member being connected together by said at least one thermally insulating member, said at least one thermally insulating member holding said inner and said outer frame members at a predetermined distance from each other; wherein i 0 said outer frame member comprises a protruding element that extends from said outer member towards said inner frame member to a distance of more than 30% of said predetermined distance and does not contact said inner frame member, said protruding element being a hollow element stiffening said outer frame member and making said C") outer frame member less susceptible to deformation; said outer frame member and said protruding element being formed as a single piece by extrusion. N.r 2. A composite profile according to any preceding claim, compnsmg two thennally insulating members wherein said outer and said inner frame members are connected together by said two thermally insulating members, said protruding element extending into the space between said two thermally insulating members.3. A composite profile according to claim 2, wherein a volume of said protruding element is at least 70% of a volume of said space between said two thermally insulating members and said inner and outer frame members.4. A composite profile according to claim 2 or 3, wherein said outer and inner frame members each comprise two grooves for receiving said two thermally insulating members, and said protruding element has a width which is a dimension in a same plane as and perpendicular to said two grooves that is at least 30% of a distancc between said two grooves and a depth that is a distance that said protruding element extends out from said outer frame member that is greater than said width.A composite profile according to any preceding claim, wherein said inner and outer frame members and said protruding element are formed of an extruded aluminium alloy.6. A composite profile according to any preceding claim, wherein said inner and outer members each comprise at least one groove (hr receiving said at least one thermally insulating member, said at least one groove on said inner member comprising gripping means for impeding longitudinal movement of said thermally insulating member withm said at least one groove, said at least one groove on said outer member not comprising said gripping means for impeding longitudinal movement of said thermally insulating member within said at least one groove.C') 7. A composite profile according to claim 6, wherein said gripping means comprises knurling on at least one inner surface of said at least one groove. (08. A composite profile according to claim 6 or 7, wherein said gripping means r comprises adhesive on at least one inner surface of said at least one groove.9. A composite profile according to any preceding claim, wherein said inner and outer frame member and said protruding element arc powder coated or anodised.
10. 10. A door comprising a plurality of frame members, at least one of said frame members being formed of a composite profile according to any preceding claim.
11. 11. A window comprising a plurality of frame menibers, at least one of said frame members being formed of a composite profile according to any one of claims 1 to 9.
12. 12. A method of manufacturing a composite profile according to any one of claims ltol 1, comprising the steps of': forming an ilmer frame member; forming an outer frame member; joining said inner and outer frame members together by at least one thermally insulating strip to form said composite profile, said at least one thermally insulating strip being held within grooves on said inner and outer frame members, such that said inner and outer frame members are held at a predetermined distance from each other by said at least one thermally insulating strip; wherein prior to performing said joining step providing a hollow protruding element on a surface of the outer frame member that faces said inner frame member when joined, such that said protruding clement and said outer frame member are formed as a single piece by extrusion, said protruding element being of a size such that it extends from said outer member towards said inner frame member to a distance of more than 30% of said predetermined distance and does not contact said inner frame member, said protruding element stiffening said outer frame member and making said outer frame member tess suseeptibe to deformation. Co13. A method according to claim 12, wherein said step of forming said inner frame 0 member comprises forming said inner frame member by extrusion.14. A method according to claim 13, comprising a further step of powder coating or anodising said composite profile after said step of joining said inner and outer frame members.15. A method according to any one of claims 13 to 14, comprising a further step of knurling at least one inner surface of said groove on said inner frame prior to joining said inner and outer frame.16. A composite profile substantially as hereinbefore described with reference to the appended Figures 1-4a and 5.17. A window substantially as hereinbefore described with reference to the appended Figures 1-4a and 5.18. A door substantially as hereinbefore described with reference to the appended Figures 1-4a and 5.19. A method of manufacturing a composite profile substantially as hereinbefore described with reference to the appended Figures 1-4a and 5.20. A use of a reinforced outer member substantially as hereinbefore described with reference to thc appended Figures 1-4a and 5 in the manufacture of a door or a window. C') r r