GB2605599A

GB2605599A - A bar assembly

Info

Publication number: GB2605599A
Application number: GB2104875.6A
Authority: GB
Inventors: Redshaw Adrian
Original assignee: Garner Aluminium Extrusions Ltd
Current assignee: Garner Aluminium Extrusions Ltd
Priority date: 2021-04-06
Filing date: 2021-04-06
Publication date: 2022-10-12
Also published as: GB202104875D0

Abstract

A bar assembly 24a for securing to a fastening member (16, fig 1) of a fenestration unit (10, fig 1) and overlying an external face of a panel 22 of the fenestration unit, the bar assembly comprising: a support member 40 having a cross section extending along a longitudinal axis; and an elongate exterior trim 38 fastened to an exterior surface of the support member; wherein the support member has an interior formation 34 configured to engage with the fastening member; and wherein the bar assembly is configured to overlie the glazing unit such that longitudinal axis of the support member and the longitudinal axis of the exterior trim are offset from a perimeter of the fenestration unit. The trim may be push-fit onto the support member, and the support member preferably comprises a second formation to fasten to the trim.

Description

A Bar Assembly

FIELD

The present teachings relate to a bar assembly for a fenestration unit, and a fenestration unit comprising said bar assembly.

BACKGROUND

Modern fenestration units typically include a frame assembly, into which a panel, such as a glass pane, or a sealed double glazing unit, is inserted in a direction generally normal to the plane of the panel. Typically, such frame assemblies are pre-assembled prior to the panel being inserted. A glazing bead is then secured to the frame assembly after the panel has been inserted into the frame assembly, along with a gasket, for securing and sealing said panel within the frame assembly.

In alternative beadless designs of fenestration units, the frame assembly and the glazing unit are assembled without the use of a glazing bead. Instead, the frame members have a U-shaped cross-section and connectors are used to join adjacent frame members around the glazing unit.

For a variety of types of fenestration unit, it is desirable in certain circumstances to have an effect on the exposed faces of the panel such as the appearance of a Georgian bar thereon. A Georgian bar is a cross or trellis effect on the glazing assembly giving the appearance that the glazing is made up of multiple smaller glazing panels in a plane. Traditionally these Georgian bars are manufactured from timber with single panes of glass held in place by putty on the bars. For reasons of manufacturing complexity, it is generally undesirable to manufacture traditional Georgian windows (i.e. with multiple discrete panels), but the appearance is often sought.

Frames for a fenestration unit can be manufactured from a variety of materials, for example aluminium and uPVC. Typically, the bar member is formed from a uPVC profile which matches the colour and finish of the surround frame. However aluminium windows are becoming increasingly prevalent for domestic windows.

Obtaining a matching finish and colour between uPVC bar and aluminium frame is problematic.

The present teachings seek to overcome or at least mitigate one or more problems associated with the prior art.

SUMMARY

A first aspect of the teachings provides a bar assembly for securing to a fastening member of a fenestration unit or closure and overlying an external face of a panel for the fenestration unit or closure, the bar assembly comprising: a support member having a cross section extending along a longitudinal axis; and an elongate exterior trim fastened to an exterior surface of the support member; wherein the support member has an interior formation configured to engage with the fastening member; and wherein the bar assembly is configured to overlie the glazing unit such that longitudinal axis of the support member and the longitudinal axis of the exterior trim are offset from a perimeter of the fenestration unit.

Advantageously, the support member is designed to secure the bar assembly in the correct position and alignment, and the exterior trim provides the aesthetic requirements of the bar assembly. In particular, a standard support member can be used in conjunction with a variety of trim members having the correct finish, colour and shape to match the remainder of the frame members of the fenestration unit.

The support member and the exterior trim may be manufactured from different materials. By different materials we mean that the primary constituent of one part if different from the primary constituent of the other part.

The exterior trim may be manufactured from aluminium or an aluminium alloy.

This is beneficial if the frame members of the fenestration unit or closure have an aluminium/aluminium alloy surface on the corresponding face (e.g. because the frames are principally made from aluminium), this enables a better match of colour and finish to the frame members.

The support member may be manufactured from a plastics material, for example uPVC.

This has aesthetic benefits because the non-aluminium interior is hidden, which gives the appearance the whole bar assembly is also aluminium when assembled to a frame. Manufacturing the support member from plastics material such as uPVC is advantageous to the function as it is more compliant than aluminium, meaning it will flex more easily and is more easily attached to/removed from the fastening member and the exterior trim. This is because it has the ability to absorb energy when deformed elastically without creating permanent deformation.

At least one seal may be mounted to the bar assembly, and wherein the seal may be configured to sealingly engage with the glazing unit.

Advantageously, this inhibits the ingress of moisture underneath the bar assembly which may otherwise lead to a build-up of mould etc, which is unsightly. It can also enable the Georgian bar to have a consistent aesthetic with gaskets/seals on the frame members.

The at least one seal may be coextruded with the support member.

This removes the need for a seal to be fitted in a further assembly process, thereby reducing the manufacturing time and possibly lowering cost. Advantageously, this means fewer parts have to be assembled when the glazing unit is installed and removed.

The seal may be manufactured from a thermoplastic elastomer (TPE).

Using a thermoplastic elastomer (TPE) gasket enables the gasket to be coextruded with the support member due to its ability to chemically bond to plastics, which simplifies the manufacturing process. TPE also has the advantage of being lower cost than silicone, which is commonly used to manufacture gaskets.

The interior formation of the support member may be mechanically fastened to the fastening member.

This enables the bar assembly to be replaced relatively easily and with minimal damage to either the bar assembly or the fastening member.

The interior formation may be configured to mechanically fasten the support member to the fastening member using a push fit.

This provides a fast and convenient assembly method.

The interior formation may be a female formation extending along the longitudinal axis of the support member.

The support member and the exterior trim may be mechanically fastened together.

This may enable the trim to be assembled and/or replaced relatively easily and with minimal damage to either the trim or the support member.

The support member may comprise a second formation or a second set of formations, and the exterior trim has at least one corresponding formation to mechanically fasten the support member to the exterior trim using a snap fit.

The snap-fit arrangement enables easy fastening and separating of parts upon installation and removal. Advantageously, this requires a fewer number of parts than alternative fastening mechanisms, making it simpler and more convenient for fitter.

The support member and the exterior trim may be substantially the same length.

This means that the support member is hidden by the exterior trim, giving the appearance of an entirely aluminium bar assembly.

An exterior surface of the exterior trim is any one of planar, stepped, curved or triangular.

This makes the exterior trim customisable and more versatile by having a choice of both material and shape, e.g. for aesthetic or performance benefits.

The support member may comprise at least one hollow profile extending along the longitudinal axis of the support member.

This allows for greater flexibility of the support member, less material used in manufacture.

A further aspect of the teachings provides a fenestration unit assembly for installing within an opening, the fenestration unit assembly comprising: a frame member comprising a groove; a glazing unit positioned within a portion thereof the groove of the frame; a fastening member; and a bar assembly according to any preceding claim overlying an external face of the glazing unit and attached to the fastening member.

The frame member and the exterior trim may be manufactured from the same material.

This may aid the visual matching of the frame members and the exterior trim.

The fastening member may comprise a male formation to mechanically fasten the fastening member to the support member using a push fit, optionally wherein the male formation includes a bulbous cross-sectional profile.

The push fit arrangement enables easy fastening and separating of parts upon installation and removal. Advantageously, this requires a fewer number of parts than alternative fastening mechanisms, making it simpler and more convenient for fitter.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described with reference to the accompanying drawings, in which: Figure 1 is a front view of a beadless fenestration unit having a bar assembly according to the present teachings; Figure 2 is a cross sectional view of a fenestration unit on the plane z-z of Figure 1; and IS Figure 3 is an isometric view of the clip of figures 1 and 2.

DETAILED DESCRIPTION OF EMBODIMENT(S)

Referring firstly to Figure 1, a fenestration unit of an embodiment of the present teachings is generally indicated at 10, including a mounting assembly 16. The fenestration unit 10 has frame assembly 12 comprising frame members 12a-d and glazing beads 14a-d mounted thereto. The glazing beads 14a-d are fitted to the frame members 12a-d with ends finished at right angles. In alternative embodiments, the ends of the glazing beads 14a-d may be mitred, or any suitable shape. The fenestration unit 10 of this embodiment is suitable for a window, door or other type of fenestration, such as a vent or a cladding panel.

The fenestration unit 10 includes a frame assembly 12 made up of a plurality of frame members 12a-d. The fenestration unit 10 is suitable for a window, door or other type of fenestration, such as a vent or cladding panel. The frame assembly 12 receives and supports a pane or panel 18 such as a pane of glass, a double or triple glazed sealed unit, or a panel of wood, aluminium or other suitable material.

It shall be appreciated that in the embodiments of Figure 1, the panel 18 is a glazing unit.

Fenestration units 10, of this type are typically used in exterior walls of domestic and commercial buildings. It is therefore necessary that the fenestration unit 10 meets requirements for thermal insulation, sealing against water ingress, draughts etc. Referring to Figure 1, typically, the frame assembly 12 is a metallic frame assembly.

A metallic frame assembly as described here may include features or components of some non-metallic or composite material, such as plastics material or wood. In particular, the frame members 12a-d may comprise exterior and interior aluminium profiles, which provide structural strength to the frame assembly 12, with a thermal break 19 of plastics or foam material sandwiched therebetween to meet insulation requirements.

The frame assembly 12 of this embodiment is manufactured from a 6063T6 aluminium alloy. However, it shall be appreciated that any other suitable material may be used. In one alternative, the frame assembly is of some other suitable material, such as some other 6063 series aluminium alloy, or a 6060 series aluminium alloy.

The frame members 12a-d of this embodiment are typically manufactured by extrusion. However, it shall be appreciated that other suitable manufacturing methods may be used.

Each frame member 12a-d includes a pair of angled or mitred edges. The mitred edges of each frame member 12a-d interface with a corresponding mitred edge of a neighbouring frame member 12a-d so as to form a mitre joint 13. In the embodiment illustrated in Figure 1, the frame assembly 2 is made up of four modular frame members 12a-d, with each frame member 12a-d comprising a respective pair of mitred edges. The mitred edges each interface with a respective mitred edge of a neighbouring frame member 12a-d to form four mitre joints 13a-d, one at each corner of the frame assembly 2.

In other embodiments comprising more than four frame members, it shall be appreciated that the frame assembly may include more than four mitre joints. In alternative embodiments, the frame members may be joined at right angled edges as opposed to mitre joints, or any suitable shaped joint may be used.

It shall be appreciated that the bar assembly of the present teachings is suitable for used on an alternative frame assembly, for example a beadless frame assembly.

In a beadless frame assembly, the frame members have U-shaped cross-sections and connectors are used to join adjacent frame members around the glazing unit.

It shall be appreciated that the term 'exterior' refers to the area outside of the fenestration unit 10, and the term 'interior' refers to the area enclosed between the frame member 12d and the glazing unit 18. Therefore, for example, 'exterior side' refers to the side closest to the outside of the fenestration unit 10, and 'interior side' refers to the side closest to the area enclosed between the frame member 12d and the glazing unit 18.

In order to provide a desirable aesthetic on the glazing unit 18, bar assemblies 24 are secured over the first and second exposed faces 20, 22 of the glazing unit 18.

In the embodiment of Figure 1, there is a first set of three bar assemblies secured to a first exposed face (not shown) of the glazing unit 18, and a second set 24 of three bar assemblies 24a, 24b, 24c secured to a second exposed face 22 of the glazing unit 18 in alignment with the first set.

The first and second sets of bar assemblies 24 each include a bar assembly 24a dimensioned to extend between the first frame member 12d and the fourth frame member 12b. The bar assembly 24a is secured to a first fastening member 16 located in the first frame member 12d at a first end, and to a second fastening member 16 located in the fourth frame member 12b. The bar assemblies 24b, 24c are dimensioned to extend between the mounting assemblies 16 located in the second and third frame members 12a, 12c and a longitudinal midpoint of the bar assembly 24a. A clip 17 is provided to secure the bar assemblies 24b, 24c to each other behind the first bar member and optionally to the glazing unit 18 and/or the bar assembly 24a via adhesive tape (not shown).

However, in alternative embodiments any number of bar assemblies may be provided depending on the aesthetic requirements of the fenestration unit. It shall be appreciated that although only one exposed face 22 of the glazing unit is illustrated in Figure 1, the pattern of the assemblies is mirrored on the opposing exposed face 20 of the glazing unit 18.

A fastening member 16 is mounted to each of the frame members 12a-d. In this embodiment, a fastening member 16 secures a first bar assembly 24a in relation to the first exposed face 22 of the glazing unit 18, and a second bar assembly in relation to the second exposed face 22 of the glazing unit 18. However, it shall be appreciated that in alternative embodiments a first fastening member may be used to secure the first bar assembly 24a in relation to the second exposed faced 22, and a separate fastening member 16 may be used to secure the bar assembly to the first exposed face 20. Alternatively, any suitable fastening member may be used to secure the bar assemblies 24 to the exposed faces 20, 22.

In this embodiment, as the bar assemblies 24 extend along central axes of the glazing unit, the fastening member 16 is fastened at the longitudinal midpoint of the frame member 12d. However, the fastening assembly 16 may be positioned at any location along the frame member, depending on the desired visual effect. The fastening member 16 may be fastening into the frame member using any suitable means, for example screwed in or push-fitted in.

Figure 2 shows a cross sectional view of a portion of the fenestration unit 10 on the plane z-z, including the bar assembly 24b illustrated in Figure 1. Whilst only one bar assembly 24b is illustrated in Figure 2, it shall be appreciated that each of the bar assemblies depicted in Figure 1 is of substantially the same configuration.

Therefore, for reasons of conciseness and brevity, one bar assembly 24b shall be described herein.

The fastening member 16 is manufactured from a thermoplastic material, such as uPVC, however any suitable material may be used, for example an aluminium or stainless steel pressing. The fastening member is manufactured using injection moulding, however any alternative manufacturing method may be used, for

example die-casting.

With reference to figures 2 and 3, the clip 17 in this embodiment has a flat central region 27 separating first and second end regions 31 which each incorporate a central male formation 28 for engaging with the bar assemblies 24b and 24c respectively. The male formation 28 is linear, and includes an increase in cross-sectional profile, for example a bulbous cross-sectional profile 29a on a narrower neck 29b.

The bar assembly 24b includes an interior formation 30 for engaging with the formation 28 of the fastening member 16. The interior formation 30 extends along a longitudinal axis of the bar assembly 24b, and is located on an interior surface 32 of the bar assembly 24b. It shall be appreciated that in alternative embodiments, any number of formations may be used, or a set of formations. In this embodiment, the interior formation 30 of the bar assembly 24b is a female formation 30.

The female formation 30 includes a channel 34 and an opening 36 defined between first and second protrusions 36a, 36b. A width of the opening 36 less than a width of the bulbous cross-sectional profile 29. The bulbous cross-sectional profile 29a passes through the opening 36 and forces the first and second protrusions 36a, 36b to flex away from each other. Once the bulbous cross-sectional profile 29a has passed through the opening 36, the first and second protrusions 36a, 36b return to a relaxed state and engage with the narrower neck 29b.

The channel 34 provides space for the bulbous cross-sectional profile 29a to sit when the bar assembly 24a is secured to the exposed face 22 of the glazing unit 18. To enable this, a width of the channel 34 is greater than the width of the opening 36. The features of the female formation 30 mean it can receive the male formation 28, and therefore retain the bar assembly 24a using a push-fit mechanism.

The fastening members 16 include a similar male formation to the clip 17. This means that the same profile of female formation 30 can be secured to both the clip 17 and the fastening member 16.

The bar assembly 24a includes an exterior trim 38 and a support member 40. The cross sections of the exterior trim 38 and the support member 40 extend along their respective cross-sectional axes. The bar assembly 24a also includes at least one seal to inhibit the ingress of moisture underneath the bar assembly 24a. In this embodiment, the seal is in the form of a first gasket 42 and a second gasket 44.

The first gasket 42 and the second gasket 44 are coextruded with the support member 40.

In this embodiment, the exterior trim 38, the support member 40 and the first and second gaskets 42, 44 are of constant cross-section, i.e. a prism formed in a suitable extrusion process. However, in alternative embodiments the exterior trim 38, support member 40 and the first and second gasket 42, 44 may have an alternative geometry, e.g. a non-constant cross-section, for example from post processing. The structural support member 40, the exterior trim 38 and the first and second gaskets 42, 44 are substantially the same length.

The support member 40 is manufactured from uPVC. As uPVC is resilient, this eases the installation and removal of the support member to the fastening member 16 and the exterior trim 38 and permits the gaskets 42 and 44 to be co-extruded therewith.

The support member 40 includes the female formation 30 for receiving the male formation 28 of the fastening members 16 and clip 17. However, in alternative embodiments, there could be more than one female formation located at any suitable location. For example, there could be two female formations located at distal ends of the interior surface of the support member. Alternatively, the male formation could be located on the fastening member, and the female formation could be located on the support member.

The support member 40 includes the channel 34, the opening 36 and a first and a second hollow profile 39a, 39b extending along the longitudinal axis of the support member 40. This configuration is simple to manufacture using an extrusion process.

The channel 34 and the first and second hollow profiles 39a, 39b minimise the total mass and material required to manufacture the support member 40, whilst meeting the necessary strength requirements for the application.

In this embodiment, the support member 40 includes a set of formations, specifically a first formation and a second formation 50, 52 located on a first side 37a and an opposing second side 37b of the support member respectively. The first and second sides 37a, 37b of the support member extend between the interior surface 32 and exterior surface 48 of the support member. The first formation 50 is a first notch 50, and the second formation 52 is a second notch 52. In alternative embodiments, any number of formations may be used, and the formation or set of formations may take any suitable form, for example protrusions. The formation or set or formations may be located on the exterior surface of the support member, as opposed to on the sides.

The support member 40 and the first and second gaskets 42, 44 are coextruded to form one part during the manufacturing process, and therefore extend along parallel longitudinal axes. However, it shall be appreciated that in alternative embodiments the first and second gaskets and the support member may be manufactured separately, and may be mounted on the support member using any suitable method, such as adhesive or heat bonding.

The first and second gaskets 42, 44 extend from the first and second sides 37a, 37b of the support member 40, however in alternative embodiments, the first and second gasket may be positioned on the interior surface of the support member. The first and second gaskets 42, 44 extend at an angle between the first and second sides 37a, 37b of the structural support member 40 and the exposed face 22 of the glazing unit 18. This creates a seal and prevent the ingress of moisture underneath the bar assembly 24b.

The first and second gaskets 42, 44 are typically manufactured from a resilient material configured to provide a sealing effect against the glazing unit 18. The first and second gaskets may be manufactured from a rubber-like material, in particular Thermoplastic Elastomer (TPE) or EDPM, although it shall be appreciated that any other suitable material may be used.

In this embodiment, the exterior trim 38 includes a first formation 54 and a second formation 56 located at a first end and a distal second end of the exterior trim 38.

The exterior trim 38 is manufactured from metal, in this embodiment an aluminium alloy. This is to match the material of the exterior trim 38 to the material of the frame member 12d in order to provide a uniform appearance.

In this embodiment, the exterior trim is substantially planar apart from the first and second formations 54, 56. However, in alternative embodiments, any suitable shape may be used depending on the aesthetic requirements. For example, the exterior trim may be stepped, triangular or curved.

The first and second formations 54, 56 are in the form of a first protrusion 54 and a second protrusion 56 extending from an interior surface 58 of the exterior trim 38. The first and second protrusions 54, 56 are substantially L-shaped. The first protrusion 54 of the exterior trim 38 at the first end engages with the first notch of the support member 40, and the second protrusion 56 of the exterior trim 38 at the second end engages with the second notch 52 of the support member 40. This arrangement mechanically fastens the interior surface 48 of the exterior trim 38 and the exterior surface of the support member using a snap-fit mechanism. In an assembled state, a first and second section 54a, 56a of each of the first and second protrusions 54, 56 sits within the corresponding notches 50, 52 located on the sides of the support member 40.

The sections 54a, 56a of the protrusions abut against the first and second gaskets 42, 44. This defines a cover over an entirety of the support member 40 to give the appearance of a uniform material throughout. The interior and exterior surfaces 32, 48 of the support member 40 are substantially parallel to each other and to the exterior trim 38. However, it shall be appreciated that in alternative embodiments, the interior and exterior surfaces of the support member and the exterior trim may be arranged in any suitable shape.

To fasten the bar assembly 24b to the second exposed face 22 of the glazing unit 18, the fastening members 16 are first fitted within the respective grooves of each of the frame members 12a-d so as to overlie the exposed faces 20, 22 of the glazing unit 18. As discussed above, the number of fastening members 16 depends on the design of the bar assemblies. In this embodiment, four fastening members 16 each with two arms are attached at the centre of each of the frame members 12a-d.

The bar assemblies 24 are then mounted to the formations of the fastening members 16. Firstly, the clip 17 is positioned on the second exposed face 22. The support member 40 of the first bar assembly 24a is push-fitted at a first end to the formation associated with the first frame member 12d, and at a second end to the formation associated with the fourth frame member 12b. The bar assemblies 24b, 24c are then push-fitted at first ends to the formations associated with the second and third frame members 12a, 12c, and to the formations 28 of the clip 17 at the second ends. This process is repeated for the first exposed face 20.

Additionally, double-sided adhesive tape (not shown) may be used to secure the support member 40 directly to the glazing unit 18 intermediate or instead of the fastening members 16 and/or the clip 17. In this embodiment, the support member comprises ridges 65 on the side facing the glazing unit that act as guides for the application of the tape to the support member.

The exterior trim 38 is then fastened to each of the support members 40 to form the assembled bars 24a, 24b, 24c. The first and second protrusions 54, 56 are snap-fitted to the notches 50, 52 of the support member 40 to complete the assembly.

Although the teachings have been described above with reference to one or more preferred embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope as defined in the appended claims. For example the clip 17 may have an additional formation 28 at right angles to the other formations and located in the central region 27 in order to engage the bar assembly 24a.

Claims

Claims 1. A bar assembly for securing to a fastening member of a fenestration unit or closure and overlying an external face of a panel for the fenestration unit or closure, the bar assembly comprising: a support member having a cross section extending along a longitudinal axis; and an elongate exterior trim fastened to an exterior surface of the support member; wherein the support member has an interior formation configured to engage with the fastening member; and wherein the bar assembly is configured to overlie the glazing unit such that longitudinal axis of the support member and the longitudinal axis of the exterior trim are offset from a perimeter of the fenestration unit.
2. The bar assembly of claim 1, wherein the support member and the exterior trim are manufactured from different materials.
3. The bar assembly of claim 2, wherein the exterior trim is manufactured from aluminium.
4. The bar assembly of claim 2 or claim 3, wherein the support member is manufactured from a plastics material, for example uPVC.
5. The bar assembly of any preceding claim, wherein at least one seal is mounted to the bar assembly, and wherein the seal is configured to sealingly engage with the glazing unit.
6. The bar assembly of claim 5, wherein the at least one seal is coextruded with the support member.
7. The bar assembly of claim 6, wherein the seal is manufactured from a thermoplastic elastomer (TPE).
8. The bar assembly of any preceding claim, wherein the interior formation of the support member is mechanically fastened to the fastening member.
9. The bar assembly of claim 8, wherein the interior formation is configured to mechanically fasten the support member to the fastening member using a push fit.
10. The bar assembly of claim 9, wherein the interior formation is a female formation extending along the longitudinal axis of the support member.
11.The bar assembly of any preceding claim, wherein the support member and the exterior trim are mechanically fastened together.
12.The bar assembly of claim 11, wherein the support member comprises a second formation or a second set of formations, and the exterior trim has at least one corresponding formation to mechanically fasten the support member to the exterior trim using a snap fit.
13.The bar assembly of any preceding claim, wherein the support member and the exterior trim are substantially the same length.
14. The bar assembly of any preceding claim, wherein an exterior surface of the exterior trim is any one of planar, stepped, curved or triangular.
15.The bar assembly of any preceding claim, wherein the support member comprises at least one hollow profile extending along the longitudinal axis of the support member.
16.A fenestration unit assembly for installing within an opening, the fenestration unit assembly comprising: a frame member comprising a groove; a glazing unit positioned within a portion thereof the groove of the frame; a fastening member; and a bar assembly according to any preceding claim overlying an external face of the glazing unit and attached to the fastening member.
17.The fenestration unit assembly of claim 16, wherein the frame member and the exterior trim are manufactured from the same material.
18.The fenestration unit of claim 16 or claim 17, wherein the fastening member comprises a male formation to mechanically fasten the fastening member to the support member using a push fit, optionally wherein the male formation includes a bulbous cross-sectional profile.