GB2511163A

GB2511163A - Corner fixing system and method

Info

Publication number: GB2511163A
Application number: GB201321444A
Authority: GB
Inventors: David Leonard Johnson
Original assignee: Grouphomesafe Ltd
Current assignee: Era Home Security Ltd
Priority date: 2012-12-06
Filing date: 2013-12-05
Publication date: 2014-08-27
Anticipated expiration: 2033-12-05
Also published as: CN103850597B; GB2511163B; GB201321444D0; CN103850597A

Abstract

A corner fixing system 10 for use with sash frame members of type having an outer recessed channel comprises an L-shaped fixing bracket 11 for fitting to a recessed corner created by abutting mitred edges 52 of respective frame members 50. An L-shaped corner block 20 is provided to fit into the recessed corner over the fixing bracket. The bracket and the block are each provided with at least one aperture (18, 21, figs 2, 3) through their respective corners, the apertures being aligned with respect to each other at the same inclination. The apertures receive a screw 60 that engages with the abutting frame members and clamps the corner block around the frame edges at the mitred frame corner as the screw is tightened. The screw may be provided to engage along the mitred ends of the frame members. A method of corner fixing sash frames is also provided.

Description

CORNER FIXING SYSTEM AND METHOD

The invention relates to a corner fixing system and a method for corner jointing of frames using the system. In particular, the invention relates to a corner fixing system for frames of door and window sashes, including but not limited to, aluminium frames.

Glazed doors and windows, often collectively referred to as sash closures, may typically be constructed from single, double or even triple glazed panels mounted in a sash frame. The sash frames may, for example, be made of aluminium, uPVC or wood-plastic composite profiles which are typically fabricated as extrusions and then cut to the desired length and joined together to form the sash frame.

Generally, the corner joints are mitred, and are required to be strong, especially in view of the weight of the glazed panels that are retained in the sash frame.

It is an object of the present invention to provide a system for door and sash frame corner jointing that results in a robust construction and is suitable for both inward and outward sash movement, such as may be encountered in so called bi-fold or multi fold doors.

Accordingly, from a first aspect, the invention resides in a corner fixing system for use with sash frame members of type having a recessed channel along the outer edge thereof in use, the system comprising a substantially L-shaped fixing bracket for fitting to a recessed corner created by abutting mitred edges of respective frame members to maintain the frame members in alignment and a substantially L-shaped corner block for fitting into the recessed corner over the fixing bracket, wherein the fixing bracket and the corner block are each provided with at least one aperture through their respective corners, the apertures being aligned with respect to each other and inclined at the same angle for receiving a screw that engages with the abutting frame members and clamps the corner block around the frame edges at the mitred frame corner as the screw is tightened.

By means of the invention, the system allows all locking and bearing points to be mounted both centrally and within the outer faces of the profile to be fixed, that is within the recessed channels of the frame members. The resulting sash construction and hardware location makes the product suitable for both inward and outward door sash movement.

For example, the corner fixing system and method of the invention may be used in joining the mitred corners of door and window profiles, especially aluminium profiles, or uPVC profiles, and more especially profiles for bi-folding door frames and the like. The profiles for such use typically comprise an elongate frame length, often of extruded aluminium, having a recessed channel along its outer edge face in use that allows the fixing system to be accommodated within the recess, i.e. within the outer faces of the profile. The recessed channel may also be used to accommodate sash hardware such as hinges, rollers, shoot bolts and the like.

The corner fixing system may further comprise a clamping screw for insertion through the aligned apertures of the fixing bracket and corner block and engagement with the frame members. Preferably, the clamping screw is a self-tapping screw. The screw may be threaded across its entire body length, or may be threaded across only a portion thereof remote from the screw head. Thus the threaded portion engages with the frame members, but not necessarily with the corner block and fixing bracket.

Accordingly, after positioning of the fixing bracket(s) and fitting of the corner block over the fixing bracket(s) in the recesses of the abutting frame members, the bracket(s) and corner block and secured to the frame members through their respective corners by means of the clamping screw.

In a preferred arrangement, the system comprises a pair of fixing brackets for fitting in the recess at the corner of the sash frame and the corner block is provided with a pair of screw apertures which align with the respective screw apertures on each of the fixing brackets. As will be understood, four sets of fixing brackets and corner blocks are required for securing each of the four corners of the sash frame.

The fixing brackets may be attached to the base of each recessed channel of the abutting frame members, such as by means of screws or the like, prior to fitting of the corner block. For example, the fixing brackets may be attached using self-tapping screws. Alternatively, the fixing brackets may be secured to the frame members together with the corner block, such as by means of screws or the like passing through both components, after the corner block has been fitted and the clamping screw engaged with the frame members.

Generally, the fixing bracket is for achieving and maintaining the correct alignment of the frame members whilst the clamping screw is secured and preferably is of relatively thin construction compared to the corner block which provides strength to the corner joint. Accordingly, in order that the aperture through the corner of the fixing bracket does not unduly weaken the bracket, it is preferable that the bracket is reinforced at the corner. For example, instead of the arms of the L-shaped bracket meeting at a g° angle, the corner may comprise an inclined section, typically at 450 to the respective axes of the arms, and from which the arms extend. The aperture is then provided through the inclined section. More preferably, the fixing bracket is further strengthened around the aperture, such as by enlargement or thickening of the bracket in the corner region. For example, the outside corner may include an enlarged section having an outer inclined face parallel with the inner inclined face, with the aperture extending substantially normally through the corner from the outer to inner inclined faces. Thus the fixing bracket is effectively reinforced in the corner region around the aperture.

As with the corner block, the fixing brackets are accommodated in the recessed channels along the outer edge of the frame member. Typically, the recessed channels are substantially U-shaped. However, the frame channels may be adapted to provide positive location of the fixing brackets. For example, the base of the channel may be formed with a pair of elongate grooves so that when the mitred ends of two profiles are held together to form a corner joint of a frame, each groove runs continuously into the corresponding groove of the adjoining profile, in an L-shaped formation. The substantially L-shaped fixing brackets may then be inserted, at least partially, into the resulting pair of L-shaped grooves at the corners.

The grooves and fixing brackets may include complementary interconnecting features, such as projections and slots, ensuring that the brackets are secured in position ready to receive the corner block.

Whether or not the fixing brackets are located and/or secured in grooves in the recessed channels, the fixing brackets serve to maintain the adjoining frame profiles in correct alignment with respect to each other. Ideally, a temporary clamping force or the like is applied to the frame profiles throughout the jointing process, for example, by means of a vice or the like. The vice or similar is able to support the weight of the frame members during cornerjointing.

As hereinbefore described, the corner block is a substantially L-shaped element provided with one, or preferably a pair, of screw holes through the corner of the L-shape. The corner block is sufficiently substantial that the boring of one or more apertures therethrough does not substantially affect the strength of the block. The outside corner edge of the corner block is preferably chamfered, making the surface around the aperture less sharp and reducing the risk of minor injury to personnel fitting the fixing system. Other edges of the corner block may be similarly chamfered.

The aperture(s) through the corner block may be screw threaded for complementary engagement with the clamping screw, but this is not essential. The aperture must however have a diameter that allows the screw body of the clamping screw to pass through, but not the screw head. It will be understood that the screw holes typically extend at an angle of 45° with respect to the side faces of the block so that the screws engage with both abutting frame members at the corner.

Clamping screws inserted through the aperture of the corner block emerge through the aligned apertures of the fixing brackets and are then driven into the frame members which preferably comprise aluminium profiles. As the clamping screws are tightened the profiles are pulled against the corner block.

At least one of the arms of the L-shaped corner block may include a recess, preferably a pair of recesses, along an internal face thereof in use and in which an arm of the fixing bracket, or the arms of a pair of fixing brackets, can be at least partly accommodated. In this way, the corner block may be easily aligned with the fixing bracket(s) and a person fitting the fixing system can readily determine when the corner block is in the correct position prior to insertion of the clamping screw.

Preferably the recesses on the corner block are provided on the corner block arm that lies along a vertical side edge of the sash frame in use.

Furthermore, when the fixing bracket includes a reinforced corner region as hereinbefore described, the inside corner of the corner block preferably includes a complementary recessed portion for accommodating the enlarged outer bracket formation. Again, such a recessed portion is helpful for correctly aligning the block over the bracket.

To finally secure the corner joint, further fixing screws may be used for screwing through respective "legs" of the L-shaped corner block. The legs of the substantially L-shaped corner block are preferably long enough that the final fixing screws are screwed directly into the frame members (e.g. the aluminium profiles), as opposed to via the fixing brackets. Accordingly, the corner block preferably further comprises ports through the legs at the distal ends thereof through which the final fixing screws are located. These fixing screws may also be self-tapping screws.

In one preferred embodiment, the corner block may be provided with a bore passing through the upright arm in use, for example in the mid-section of the arm between the outer sections which have the clamping screw apertures and fixing holes. Such a bore may be used to accommodate an end portion of a shoot bolt such that the corner block acts also as a shoot bolt guide. The corner block may equally be provided with other features for cooperation with sash hardware fitted in the corner regions of the sash frame.

The fixing system may further comprise an end cap for the corner block, preferably for covering all or at least a substantial part of the corner block. As with the fixing bracket(s) and corner block, the end cap when fitted is accommodated within the recessed channels of the aluminium profiles, ensuring that the resulting sash frame remains suitable for both outward and inward door sash movement.

Such an end cap may be designed to fit over the corner block after the clamping screw(s) have been fitted, for example, obscuring the clamping screws and providing an aesthetically pleasing appearance around the corners. The end cap may, for example, clip over the corner block such as by snap-fitting or by use of adhesive. The end cap is preferably substantially L-shaped for fitting over and around the corner block.

Alternatively, the end cap may be put in position over the corner block prior to the clamping screws and fixing screws being secured. In the latter case, the corner block may be provided with apertures and screw holes for alignment with the aperture(s) and screw holes of the corner block.

The end cap may simply comprise a blanking plate, or it may comprise a location element for sash hardware, either on its own, or in combination with the corner block.

In a preferred arrangement, the corner block and end cap together define a cavity for positioning of sash hardware components. For example, the outer surface of a corner block arm, may include a hardware channel extending along the full length of the arm and the opposing inner surface of the end cap also includes a hardware channel, such that when the end cap is fitted over the corner block, the hardware channels combine to form a bore in which a hardware component bolt can be located. The hardware may, for example, be fitted along a side edge of the sash frame member, in the recessed channel, prior to fitting the end cap.

A range of different end caps may be provided as part of the corner fixing system, with a particular end cap being selected according to the requirements at the particular corner of the sash frame. For example, one end cap may simply comprise a blanking plate for use when no hardware is fitted at the relevant sash frame corner; and another end cap may together with the corner block comprise an end guide for use with a shoot bolt, or a mounting location for a roller. When the corner block and end cap combine to form a shoot bolt guide, for example, the hardware channels are located along the vertical side edges in use of the sash frame; and when they combine to provide a location piece or mounting for a roller the locating features are provided along the horizontal side edges in use of the sash frame. Of course, it is particularly preferred for an end cap to be provided with a sash bolt guide along one arm of the end cap and for the other arm to be provided with a roller location mounting.

Most preferably, the corner block for use in the system comprises a universal block provided with the range of features for cooperating with different end caps, according to the hardware requirements at the relevant corner of the sash frame.

Thus, for example, the corner block may be provided with both a hardware channel and roller location mounting, yet also be compatible with a blanking end cap which obscures the hardware related features when fitted.

From a further aspect, the invention resides in a method of corner fixing sash frame members of the type having mitred ends and a recessed channel along the outer edge thereof in use, said method comprising holding first and second frame members so that one of their respective mitred ends are in abutment to form a sash frame corner, aligning the recessed channels of the abutted frame members with one or more fixing brackets extending around the sash frame corner in the recessed channel, fitting a corner block in the recessed channel over the or each fixing bracket, inserting a clamping screw in an aperture extending through the corner block and fixing brackets and tightening the screw to engage with each of first and second frame members along their respective abutting mitred edges.

The method preferably further comprises fitting of an end cap into the recessed channel over all or a substantial part of the corner block. This step may be performed before or after insertion and tightening of the clamping screw.

Advantageously, the method may further comprise mounting of a hardware component or part thereof between the corner block and end cap.

From yet another aspect, the invention resides in a sash frame, such as for use in a bi-fold door system, wherein the corners of the frame are fixed by means of the corner fixing system as hereinbefore described, or by the aforementioned method.

The method and system according to the invention will now be illustrated in the following drawings by way of example only, and in which: Figure 1 is an exploded view of a corner fixing system in accordance with the invention with frame members; Figure 2 is a view from the front and left side of the frame members of Figure 1 with fixing brackets; Figure 3 is a view of the frame members of Figure 2 with corner block; Figure 4 is a view of the frame members of Figure 3 with end cap; Figure 5 is a view of the frame members of Figure 4 with clamping screws; Figure 6 is a view of the frame members of Figure 5 with fixing screws; and Figure 7 is a cross-section through an alternative fixing system of the invention assembled on frame members.

Turning first to Figure 1, there is shown in exploded view the various components of a corner fixing system 10 in accordance with one embodiment of the invention along with the sash frame members SOa, SOb to which the system 10 is to be fitted.

The sash frame members 50a, Sob are fabricated from aluminium and are of substantially hollow section with recessed channels 51a, Sib along their outer side edges in use. The frame members 50a, SOb are mitred at the respective ends 52a, 52b so that when the ends are brought into abutment they form a corner of a sash frame.

The fixing system 10 includes a pair of fixing brackets 11 being L-shaped in cross-section and provided with fixing holes 12 on each of their arms proximal to the bracket corner 14. The corner 14 of each bracket 11 is angled to provide an inner inclined surface 15 and the corner 14 is strengthened at the outside by means of a thickened region terminating in outer inclined surface 16. Inner and outer inclined surfaces 15, 16 are substantially parallel with each other and have an aperture 18 passing therethrough between the surfaces 15, 16 at an angle of about 45°.

The fixing system also includes corner block 20 substantially L-shaped in cross-section having a pair of apertures 21, 21' each extending through the corner region at 45° for aligning with the corresponding aperture 18 in each of the fixing brackets 11. The corner block is provided with fixing holes 22, 23 for securing the block to the fixing brackets 11 and to the base 53a, 53b of the recessed channels Sla, Sib respectively of frame members SOa, Sob.

The inner face of upright arm 24 of corner block 20 includes a pair of recesses 25, 25' for locating over the upright arm 18 of each fixing bracket 11 when installed over the bracket. The upper and lower outside edges 26, 27 respectively of the corner block 20 are chamfered, and the outer face of upright arm 24 includes a hardware channel 28 extending across its full length for accommodating at least partially the end portion of a shoot bolt (not shown).

Also shown in Figure 1 is end cap 30 for fitting over the corner block 20. The end cap 30 is again substantially [-shaped in cross-section for corner mounting and has a pair of inclined apertures 31, 31' at the corners that align with apertures 18, 21, 21' of the corner block and fixing brackets respectively. Fixing holes 32 are also provided which align with the fixing holes 22 of the corner block.

The inner face of upright arm 34 of the end cap 30 includes a hardware channel 38 which combines with the hardware channel 28 of the corner block 20 when the end cap is fitted over the corner block to create a bore through the recessed channel 51a for guiding a shoot bolt. The outer face of the upright arm 34 of the end cap 30 is itself recessed having two slots 36, 36' which accommodate the heads of fixing screws 70. The horizontal arm 36 of the end cap 30 is profiled to fit snugly against the profiled section 29 on the underside of the horizontal arm of the corner block 20.

The combined depth of the fixing bracket 11, corner block 20 and end cap 30 when installed on the frame members SOa, 5Db is such that the end cap 30 lies substantially within the recessed channels 51a, Sib.

The remaining components of the fixing system 10 are the pair of clamping screws which are partially threaded along the screw body.

Figure 2 shows the pair of fixing brackets ii inserted into the recessed channels 51a, Sib prior to fixing to the bases 53a, 53b of the channels to hold the frame members 50a, SOb in alignment.

Once the pair of fixing brackets ii are in position with the frame members 50a, 5Db correctly aligned, the corner block 20 is introduced into the recessed channels Sia, Sib at the corner and mounted over the brackets ii as shown in Figure 3. The recesses 25, 25' on in the inside face of the upright arm 24 fit over the upright arms of the brackets 11 confirming that the corner block 20 is successfully aligned with the brackets H. With the fixing brackets 11 and corner block 20 mounted in the recessed channels 5Th, Sib, the end cap 30 is fitted over the corner block as shown in Figure 4. When in the correct position, the horizontal arm 36 of the end cap 30 abuts against the profiled section 29 on the underside of the horizontal arm of the corner block 20, and the hardware channel 38 is aligned with hardware channel 28 of the corner block to form a continuous bore 80 which can be used as a shoot bolt guide.

After the fixing brackets 11, corner block 20 and end cap 30 have been mounted around the corner of the abutting frame members SQa, SOb clamping screws 60 are inserted through the aligned corner apertures 18, 21, 21', 31, 31' of the respective components as shown in Figure 5. As the screws 60 are turned (by screwing) the threaded portion starts to engage with the frame members 50a, SOb along their mitred ends 52a, 52b. As the screws 60 are further tightened the corner block 20 becomes firmly clamped around the corner thereby securing the frame members 50a, 50b together around corner joint of the sash frame.

As shown in Figure 6, following tightening of the clamping screws 60, fixing screws are screwed in to the various fixing holes 32 in the upright and horizontal arms of the end cap 30 which are aligned with fixing holes 22 in the corner block 20.

The above sequence is repeated at each of the four corners that make up the sash frame and any temporary support used to hold the frame members during the fixing process can then be safely removed.

Figure 7 shows a cross-section through a corner section of a sash frame that has been fixed using a variant of the system of Figures ito 6. In this system, the frame members SODa, SOOb have been formed with a pair of grooves 521k, 52Db in the base of the recessed channel SlOa, Slob. The fixing brackets 110 (only one visible) :ii are slotted on the upright and horizontal arms and have projections 560 at their distal ends that form a snap fit with complementary projections within the grooves 520a, 520b. Each fixing bracket 110 has an inclined aperture 180 for receiving the body of clamping screw 600.

The corner block 200 is also provided with inclined apertures 280 which align with fixing bracket apertures 180 when mounted on the frame members 500a, 50Db over the brackets 110. In this arrangement, a pair of clamping screws 600 is inserted through the corner block 200 and fixing brackets 110 and tightened to engage with the frame members SODa, 50Db along their mitred ends 520a, 52Db.

Fixing screws 700 are inserted through the fixing holes 220, 230 in the upright and horizontal arms of the corner block 200 to engage with the frame members SODa, 50Db at the base of the recessed channels SlOa, SlOb.

The end cap 300 is fitted over the corner block 200 to cover the head of the clamping screw 600 and is retained in position by fixing screw 710 through fixing hole 320.

Various adaptations and modifications may be made and it is to be appreciated that the present invention is not limited to the specific ways described herein and the scope of the invention is determined by the claims.

Claims

CLAIMS1. A corner fixing system for use with sash frame members of type having a recessed channel along the outer edge thereof in use, the system comprising a substantially [-shaped fixing bracket for fitting to a recessed corner created by abutting mitred edges of respective frame members to maintain the frame members in alignment, and a substantially L-shaped corner block for fitting into the recessed corner over the fixing bracket, wherein the fixing bracket and the corner block are each provided with at least one aperture through their respective corners, the apertures being aligned with respect to each other and inclined at the same angle for receiving a screw that engages with the abutting frame members and clamps the corner block around the frame edges at the mitred frame corner as the screw is tightened.
2. The system of claim 1, further comprising a clamping screw for insertion through the aligned apertures of the fixing bracket and corner block and engagement with the abutting mitred ends of the frame members.
3. The system of claim 1 or claim 2, wherein the arms of the [-shaped fixing bracket meet at an inclined corner section and the fixing bracket aperture extends through the inclined section.
4. The system of claim 3, wherein the inclined corner section of the fixing bracket is reinforced with an enlarged section around the outside corner, the enlarged section having an outer inclined face parallel with the inner inclined section and between which the aperture extends at 450 to the respective axes of the bracket arms.
5. The system according to any one of the preceding claims, comprising a pair of fixing brackets for fitting at each sash frame corner.
6. The system according to any one of the preceding claims, wherein the corner block is provided with a recess or a pair of recesses along an inner face of an arm thereof for positive location over a corresponding arm of the or each fixing bracket.
7. The system according to any one of the preceding claims, wherein the corner block is provided with one or more fixing holes through each arm thereof for receiving fixing screws to secure the corner block to the frame members.
8. The system according to any one of the preceding claims, wherein the corner block is adapted to co-operate with sash hardware for fitting adjacent to the corner of the sash frame.
9. The system according to any one of the preceding claims, further comprising an end cap for mounting over the corner block to cover all or a substantial part of the corner block.
10. The system of claim 9, wherein the end cap is provided with an aperture which aligns with the apertures of the fixing bracket and corner block to receive the clamping screw.
11. The system of claim 7 or claim 8, wherein the end cap is substantially L-shaped.
12. The system according to any one of claims 9 to 11, wherein the corner bracket and end cap cooperate to define a cavity therebetween for positioning of sash hardware components, such as rollers, shoot bolts and hinges.
13. The system of claim 12, wherein the outer face of an arm of the corner block and an inner face of the end cap are each provided with a groove which cooperate when the corner block and end cap are fitted to the recess of the frame members to define a bore for accommodating an and portion of a shoot bolt.
14. The system according to any one of claims 9 to 14, further comprising an end cap in the form of a blanking plate for use when no hardware is to be fitted at the sash frame corner.
15. The system according to any one of the preceding claims wherein the corner block comprises a universal block provided with a range of features for cooperating with different end caps accordingly to the functionality required at the relevant sash frame corner.
16. A method of corner fixing sash frame members of the type having mitred ends and a recessed channel along the outer edge thereof in use, said method comprising holding first and second frame members so that one of their respective mitred ends are in abutment to form a sash frame corner, aligning the recessed channels of the abutted frame members with one or more fixing brackets extending around the sash frame corner in the recessed channel, fitting a corner block in the recessed channel over the or each fixing bracket, inserting a clamping screw in an aperture extending through the corner block and fixing brackets and tightening the screw to engage with each of first and second frame members along their respective abutting mitred edges.
17. The method of claim 16, wherein the sash frame members are corner fixed using a corner fixing system according to any of claims ito 15.
18. A sash frame, such as for use in a bi-fold door system, wherein the corners of the frame are fixed by means of the corner fixing system as claimed in any one of claims ito 15, or by the method of claim 16.
19. A corner fixing system substantially as hereinbefore described with reference to Figures ito 6, or Figure 7 of the accompanying drawings.