GB2620576A

GB2620576A - A connector

Info

Publication number: GB2620576A
Application number: GB2210158.8A
Authority: GB
Inventors: Hartshorn Ben
Original assignee: Garner Aluminium Extrusions Ltd
Current assignee: Garner Aluminium Extrusions Ltd
Priority date: 2022-07-11
Filing date: 2022-07-11
Publication date: 2024-01-17
Also published as: GB202210158D0

Abstract

A connector 18 for a joint of a frame for a fenestration/window unit. The connector couples two frame members 12b together and has first and second 32b fasteners which secure the frame members to the connector. The connector has first and second 24b arms, which are located in hollow sections of the fame members, and where the longitudinal axis of the arms is parallel or in-line with one another, and the longitudinal axis of the first and second fasteners is parallel to a longitudinal axis of the respective connector arm. The connector further comprises an access feature 19, such as a hole or bore, which provides access to the first and second fasteners, and which allows the engagement of a tool T to adjust at least one of the fasteners at a non-zero angle to the longitudinal axis. The access feature may be positioned between the two fasteners and may be a slot which may be located on a surface of the connector, parallel with the longitudinal axis. There may be a third connector arm and/or an access feature to allow access to a third fastener. A joint for a window or fenestration unit, and a fenestration unit which comprises the joint, are also disclosed.

Description

Intellectual Property Office Application No G132210158.8 RTM Date:22 December 2022 The following terms are registered trade marks and should be read as such wherever they occur in this document: Ton( Intellectual Property Office is an operating name of the Patent Office www.gov.uk/ipo

A CONNECTOR

FIELD

The present teachings relate to a connector configured to locate first and second frame members of a joint for a frame of a fenestration unit, a joint comprising a connector, and a fenestration unit comprising a joint.

BACKGROUND

Modern fenestration units typically comprise a frame assembly, into which a panel, such as a glass pane, or a sealed double glazing unit, is fitted. The frame assembly is commonly a moveable sash, which can pivot and translate within an outer frame of the fenestration unit. It is also common to provide a fixed glazing light or a second sash with its own frame adjacent to the moveable sash and separated vertically by a mullion or horizontally by a transom. A fixed glazing light is typically held directly in the outer frame by an upstand or rebate on one face and clip-in or shuffle glazing bead on the other face. If the sash is fixed it is often referred to as a dummy sash. The fixed glazing light is the simpler, lower cost, solution but, the use of a dummy sash creates more uniform sightlines within the overall window.

Windows are typically mounted to their opening in a structure via fixings that extend transversely through the outer frame. Windows are usually supplied to a site with moveable or dummy sashes assembled to the frame, but without the glazing in place. These need to be opened or temporarily be removed for the fixings to be fitted. Whilst fixed glazing lights are not normally supplied to a site as part of the frame, in the event they are, these would also need to be removed to fit the fixings.

For conventional aluminium windows, the outer frame assembly is made up of two horizontal and two vertical frame members with upstands for providing a sealing surface for the moveable sash to abut against in a closed position. The upstand for the moveable sash, and therefore for the whole outer frame, must be located on an interior side of the frame assembly or it would obstruct the opening of the sash.

However, this means the both the moveable sash and any fixed glazing light or dummy sash (hereinafter collectively referred to as "fixed light") needs to be either fitted from the exterior side of the frame assembly, in situ, in the structure where the window is located, or fitted to the outer frame assembly prior to the outer frame assembly being offered up to the opening of the building. However, as noted above, even if supplied to a site pre-fitted, fixed lights need to be removed to secure the window in its opening and then be refitted.

It is known for uPVC windows to reverse the upstand for the fixed light because it is possible to form the outer frame members from multiple profiles that have the upstands reversed and to bond the profiles together in a heat/ultrasonic welding process (referred to as a reverse butt weld). This enables fitters to fit the fixed light from the interior side, in situ. This is advantageous because access is easier for windows above ground level, and may enhance security as the glazing bead is on the interior and thus less susceptible to being tampered with from the exterior.

To replicate this for aluminium windows also requires the upstands of the moveable sash and the and the fixed light being on opposing sides of the frame assembly at the point where they intersect a mullion or transom. However, such a three-way joint is difficult to achieve with conventional aluminium window joining techniques, especially such that each of the profiles is accurately and securely connected. Alternative solutions, such as so-called glazing reversers, are also unsatisfactory as they require costly additional aluminium elements, in addition to the outer frame, to position the glazing bead of the fixed light on the interior of the outer frame.

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 connector configured to locate first and second frame members of a joint for a frame of a fenestration unit, the connector comprising first and second fasteners configured to secure the first and second frame members to the connector; and a first arm configured to extend within a hollow profile defined by the first frame member, and a second arm configured to extend within a hollow profile defined by the second frame member; wherein a longitudinal axis of each of the first and second fasteners is configured to be parallel to a longitudinal axis of the respective connector arm; wherein the longitudinal axis of the first connector arm is parallel to the longitudinal axis of the second connector arm; wherein each of the first and second fasteners is configured to engage the respective frame member when the respective connector arm extends within said frame member; and wherein the connector comprises an access feature configured to provide access to the first and second fasteners, wherein the access feature permits the engagement of a tool to adjust at least one of the fasteners at a nonzero angle to the longitudinal axis.

Such an arrangement provides secure location and fastening of the frame members to the connector as well as correct alignment of the first and second frame members in a direction parallel to the longitudinal axes of the connector arms. The access feature improves ease of assembly by enabling the fastener to be tightened despite access being blocked in the longitudinal direction by the other connector arm.

Optionally, the access feature may be located on a surface of the connector parallel to the longitudinal axes of the first and second connector arms.

Such an arrangement enables the tightening of the fastener by the tool at a nonzero angle to the longitudinal axes, and prevents the tool from being blocked by either the other connector arm or the frame members.

Optionally, the access feature may be an elongate slot extending in a direction parallel to the longitudinal axes of the first and second connector arms.

Advantageously, a slot is compact and simple to manufacture, as well as providing the required space to fit the tool at a range of non-zero angles to adjust the fasteners.

Optionally, the access feature may be located in between the first fastener and the second fastener.

Advantageously, the location of the access feature enables access to both the first and second fasteners at the required non-zero angle to adjust the fasteners.

Optionally, the first arm may be configured to support the first fastener and the second arm may be configured to support the second fastener.

The first and second fasteners can be supported within the connector before the joint is assembled, improving ease of assembly and transportation of the joint 35 components.

Optionally, the connector may comprise a third connector arm configured to extend within a hollow profile defined by a third frame member and further comprising a third fastener configured to extend within the hollow profile defined by the third frame member.

Such an arrangement provides secure location and fastening of the third frame member to the connector and to the first and second frame members, as well as correct alignment of the third frame member.

Optionally, the third connector arm may define a longitudinal axis extending at a non-zero angle relative to the longitudinal axes of the first and second connector arms, optionally wherein the longitudinal axis of the third connector arm may be substantially perpendicular to the longitudinal axes of the first and second connector arms.

Such an arrangement enables the securement of an additional frame member at an angle to the first and second frame members, thereby increasing the versatility of the connector for different types of frame arrangement.

Optionally, the access feature may be configured to provide access to the third fastener.

This means the same access feature can be used to access all three fasteners, thereby improving ease of assembly and simplifying the design of the connector.

Optionally, the access feature may define a centre point located along a longitudinal axis of the third fastener, optionally wherein the first and second fasteners may be located equidistant from the longitudinal axis of the third fastener.

Such an arrangement enables access to the third fastener in a direction parallel to the longitudinal axis of the third fastener, whilst ensuring the first and second fasteners can be accessed by the tool through the same range of non-zero angles.

Optionally, the connector comprises a partition wall, wherein the partition wall may be located between the first and second fasteners and between the third fastener and the access feature, optionally wherein the partition wall comprises an access aperture configured to provide access to the third fastener, and wherein the access aperture may be at least partially aligned with the access feature.

The partition wall separates the three fasteners and correctly locates the third fastener, whilst enabling access to the third fastener.

Optionally, the third fastener may be confined in a first axial direction, towards a free end of the third connector arm, optionally wherein the third fastener may be confined in a second axial direction opposing the first axial direction.

This ensures that the connector is "pulled" into the frame member during assembly -i.e. there is one operation of both inserting the connector and securing it in place with the fastener, simplifying assembly. Confinement in the second axial direction ensures the connector is "pushed" out of the frame member during disassembly, thereby simplifying disassembly.

Optionally, the first and/or second fastener may be confined in a first axial direction, towards a free end of the respective connector arm, optionally wherein the first and/or second fastener may be confined in a second axial direction opposing the first axial direction.

Optionally, each fastener may be a threaded fastener, optionally wherein each fastener may be a self-tapping threaded fastener, and/or wherein each fastener may comprise a frusto-conical leading end.

Self-tapping fasteners do not require pre-formed threads, thereby simplifying the manufacturing process.

Optionally, each fastener may comprise at least one threaded axial portion and at least one unthreaded axial portion, optionally wherein each connector arm may be configured to engage the respective fastener at the unthreaded portion.

The unthreaded portion improves ease of engagement of the fasteners with the connector arm.

A second aspect of the teachings provides a joint for a frame of a fenestration unit, the joint comprising first and second frame members defining first and second hollow profiles; and a connector according to any preceding claim configured to secure the first and second frame members in relation to one another.

Such an arrangement provides secure location and fastening of the frame members to the connector as well as correct alignment of the first and second frame members in the direction parallel to the longitudinal axes of the connector arms. The access feature improves ease of assembly by enabling the fastener to be adjusted despite access being blocked in the longitudinal direction by the other connector arm.

Optionally, the first frame member may comprise a frame access feature and wherein the second frame member may comprise a frame access feature.

Such an arrangement enables access of the tool to the first and second fasteners through the frame member at the requires non-zero angles of the tool.

Optionally, the frame access feature of the first frame member may be aligned with the frame access feature of the second frame member in a direction parallel to the longitudinal axes of the first and second connector arms, optionally wherein the frame access features of the first and second frame members may be at least partially aligned with the access feature of the connector in a direction perpendicular to the longitudinal axes of the first and second connector arms.

The alignment of the frame access features enables access to both the first and second fasteners via both frame access features. This increases the range of angles at which the tool can access the first and second fasteners, thereby improving ease of assembly.

Optionally, the frame access feature of the first frame member may be an elongate slot, and wherein the frame access feature of the second frame member may be an elongate slot.

Advantageously, a slot is compact and simple to manufacture, as well as providing the required space to fit the tool at a range of non-zero angles whilst the fasteners are adjusted.

Optionally, each frame member profile may define at least two projections extending from the hollow profile to engage said fastener.

The projections of the frame member profile engaging the fastener reduce the amount of material required, in contrast to the fastener engaging a solid profile wall of the frame member. The reduced amount of material makes it easier for a thread to be formed, should the fastener be e.g. a self-tapping screw. There being at least two projections ensures stability of the connection between the fastener and the frame member, and so between the connector and the frame member.

Optionally, each projection of the frame member may engage the fastener at an engagement point, and wherein the projections may be configured such that the engagement points are equidistant about a periphery of the fastener.

The equidistant engagement points improve stability of the connection between each fastener and the respective frame member.

Optionally, the first and second frame members each comprise a first and second exterior hollow profile may be located on an opposing side of the longitudinal axes of the first and second frame members to the first and second hollow profiles, and wherein a second connector may be received in the first and second exterior hollow profiles.

This ensures both the interior and exterior sides of the frame members are correctly aligned and secured together.

Optionally, the joint may comprise a third frame member defining a third hollow profile, wherein the connector comprises a third arm configured to secure the third frame member in relation to the first and second frame members, optionally wherein the third frame member may be configured to extend substantially perpendicularly from the first and second frame members.

Optionally, the first frame member may comprise an interior upstand located on a first side of the longitudinal axes of the connector arms, and wherein the second frame members may comprise an exterior upstand located on an opposing second side of the longitudinal axes of the connector arms.

The upstands create a sealing surface, for example for a frame of a sash window to abut against, as well as creating a uniform appearance. The upstands being located on opposing sides improves the assembly process when there are two glazing units fitted to the frame members, because one of the glazing units can be fitted from the interior side of the frame members.

A third aspect of the present teachings provides a fenestration unit comprising a joint according to the second aspect.

Optionally, the fenestration unit may comprise a sash moveable relative to the fenestration unit, and optionally a fixed light or a dummy sash fixed relative to the fenestration unit.

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 fenestration unit haying a joint according to an embodiment of the present teachings; Figure 2 is an isometric view of the joint of Figure 1 in an assembled state; Figure 3 is an underside isometric view of the joint of Figure 2 in an assembled state; Figure 4 is an isometric view of the joint of Figure 2 in a first partially assembled state having a connector according to an embodiment of the present teachings; Figure 5 is an isometric view of the joint of Figure 2 in a second partially assembled state; Figure 6 is an isometric view of the joint of Figure 2 in a third partially assembled state; Figure 7 is an isometric view of the connector of Figure 4; Figure 8 is a side view of the connector of Figure 4; Figure 9 is a side view of the connector of Figure 4 being adjust by a tool; and Figure 10 is a cross-sectional view through the joint of Figure 2.

DETAILED DESCRIPTION OF EMBODIMENT(S)

Referring firstly to Figure 1, a fenestration unit is generally indicated at 10. The fenestration unit 10 has a fixed outer frame 12 for installing in an opening in a wall of a building (not shown). The interior face of the fenestration unit 10 is shown. The fenestration unit 10 of this embodiment is a window, but in other embodiments may be a door or other type of fenestration, such as a vent or a cladding panel.

A sash 14 is moveably mounted within the outer frame 12 (via suitable hinges -not shown) on a first side of the outer frame 12, and a fixed light 16 is mounted on a second side of the outer frame 12 adjacent the sash. The fixed light 16 is fixed relative to the outer frame 12 by a bead 16a. When the sash 14 is in a closed position, the sash 14 and the fixed light 16 are substantially co-planar.

It shall be appreciated that the term 'exterior' refers to the area outside of the building in which the fenestration unit is fitted, and the term 'interior' refers to the area within the building in which the fenestration unit is fitted. Therefore, for example, 'exterior side' refers to the side closest to the outside of the building, and 'interior side' refers to the side closest to the inside of the building.

The outer frame 12 is made up of a plurality of frame members 12a-g. In this embodiment, the outer frame 12 is made up of four horizontal frame members 12a-d. The lowermost horizontal frame members 12a, 12b each define a longitudinal axis, and the longitudinal axes are coaxial. The uppermost horizontal frame members 12c, 12d each define a longitudinal axis, and the longitudinal axes are coaxial. Two vertical frame members 12g, 12e are located vertically on first and second sides of the outer frame 12 to form a substantially rectangular outer frame 12. The uppermost horizontal frame members 12c, 12d and the lowermost horizontal frame members 12a, 12b are secured together using connectors 18, illustrated in Figures 4 and 5. The corners may be connected by L-shaped connectors of the type shown in our patent GB2569209B.

A third vertical frame member 12f, known as a mullion, is located in between the sash 14 and the fixed light 16 and extends between the lowermost horizontal frame members 12a, 12b and the uppermost frame members 12c, 12d.

The outer frame 12 is a metallic frame, i.e. a frame having frame members 12 that are at least in part metallic. A metallic frame 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 may comprise external and internal structural metallic profiles with a thermal break 23 of plastics or foam material sandwiched therebetween.

The sash 14 includes an inner frame 14a and a glazing unit 15a. The sash 14 comprises an upstand/rebate (not shown) at its exterior side to retain the glazing unit 15a and a bead 14b in the interior side for greater security. The fixed light comprises a glazing unit 15b only. It shall be appreciated that although the glazing units 15a, 15b are double glazing units, alternative glazing units, for example triple glazing or opaque panels, may be used.

Fenestration units 10 of this type are typically used in external walls of domestic and commercial buildings. It is therefore necessary that the fenestration unit meets requirements for thermal insulation, sealing against water ingress, draughts etc. Typically, the sash inner frame 14a and the outer frame 12 are aluminium. The sash inner frame 14a, and the outer frame 12 of this embodiment comprise a 6063T6 aluminium alloy. However, it shall be appreciated that any other suitable material may be used. In one alternative, the sash, the dummy sash and the outer frame are of some other suitable material, such as some other 6063 series aluminium alloy, or a 6060 series aluminium alloy. The bead 16a may be formed primarily from aluminium, primarily from uPVC or a composite of the two.

The sash 14 is mounted to the frame members 12b, 12c, 12g, 12f via a suitable hinge mechanism (not shown).

A joint for the frame 12 is shown in Figures 2 and 3 in an assembled state, indicated generally at 20. The joint 20 includes first and second frame members 12a, 12b, i.e. the lowermost horizontal frame members in a reversed butted arrangement.

In this embodiment, the joint 20 also includes the third frame member 12f, however it shall be appreciated that in alternative embodiments, the third frame member 12f may be omitted. As can be seen in Figure 6, the third frame member 12f has a Z profile so that its upstands match those on the first and second frame members 12a, 12b. The third frame member 12f is a mullion (i.e. substantially vertical). However, it shall be appreciated that in alternative embodiments, the third frame member 12f may be a transom (i.e substantially horizontal) connected to two vertical frame members.

A second joint 21 of substantially the same configuration is located at an opposing side of the frame 12, however for reasons of conciseness and brevity only the joint 20 will be described hereafter. When the joint 20 is in the assembled state shown in Figure 2, the frame members 12a, 12b, 12f meet to form a substantially T-shaped joint. The third frame member 12f extends substantially perpendicularly from the first and second frame members 12a, 12b.

The first frame member 12a and the second frame members 12b each include an upstand 13a, 13b and each define a hollow profile 22a, 22b. The upstand 13a of the first frame member 12a is an exterior upstand 13a located towards the exterior side of the frame 12. The upstand 13b of the second frame member 12b is an interior upstand 13b located towards the interior side of the frame 12. The exterior and the interior upstands 13a, 13b are located on opposing sides of the longitudinal axis defined by the first and second frame members 12a, 12b.

The interior upstand 13b acts as a sealing surface for the sash 14 to abut against when the sash 14 is in the closed position. Accordingly, the upstand 13b must be located on the interior side of the frame 12 to enable the sash 14 to open and close towards the exterior side of the frame 12 without obstructing the opening and closing of the sash 14.

The exterior upstand 13a being located on the exterior side of the frame 12 improves ease of assembly. This is because the fixed light 16 can be fitted from the interior side of the frame 12, which is significantly easier for the fitter if the window is not at ground level, for example once the outer frame 12 and sash 14 have been fitted in the opening. The fitter can access a higher floor of the building without ladders, scaffolding or powered access equipment to fit the fixed light from inside. Due to the weight of the outer frame 12, the sash 14 and the fixed light 16, it is significantly easier for the fitter to fit the outer frame 12 and the sash 14 in the opening without the fixed light 16. The fixing of the bead 16a on the interior side also may enhance the overall security of the window, since the bead cannot be unclipped from outside to remove the glazing 15b and provide access the building. Further, this construction enables the three frame members to be reverse butted together with a neat mitred interface that is aesthetically pleasing.

It shall be appreciated that in alternative embodiments, any suitable shape of frame member may be used. For example, the upstands may be located on the same side of the frame or the upstands may be omitted entirely. In addition there may be additional mullions and/or transoms as required by the window layout.

The frame members of this embodiment are manufactured by extrusion. Such a method allows the hollow profiles of the frame members to be produced along the length of the frame members. Frame members can therefore be cut to a required length whilst retaining the necessary profile.

The joint 20 includes the connector 18, as shown in Figures 4 to 6. The connector 18 locates the frame members 12a, 12b, 12f in relation to one another, and is substantially T-shaped. The connector 18 has a first arm 24a, a second arm 24b and a third arm 24c. The connector 18 also includes an access feature 19 configured to provide access to the connector 18.

It shall be appreciated that in alternative embodiments where there are two frame members, the third arm of the connector may be omitted. The first arm 24a has a first, free end 26a and a second end 26b, the second arm 24b has a first, free end 28a and a second end 28b, and the third arm 24c has a first, free end 30a and a second end 30b. The second ends 26b, 28b, 30b meet to form the substantially T-shaped connector.

The connector 16 of this embodiment is formed by injection moulding, and is of glass filled nylon. In an alternative embodiment the connector is of some other material suitable for injection moulding. In alternative embodiments the connector is die-cast, and is of some other suitable material, such as a zinc based alloy.

As illustrated in Figure 4, a longitudinal axis of the first arm 24a is substantially parallel to a longitudinal axis of the second arm 24b. In this embodiment, the longitudinal axes of the first and second arms 24a, 24b are coaxial. A longitudinal axis of the third arm 24c extends substantially perpendicularly to the longitudinal axes of the first and second arms 24a, 24b. However, in alternative embodiments the third arm 24c may extend at any non-zero angle. This makes the connector suitable for connecting angled frame members, and therefore improves the versatility of the connector. In this embodiment, the third arm 24c is located equidistant the first end 26a of the first arm 24a and the first end 28a of the second arm 24b.

The joint 18 has first, second and third fasteners 32a, 32b, 32c. It shall be appreciated that in alternative embodiments where the third arm is omitted, the third fastener 32c may be omitted. The fasteners 32a, 32b, 32c each have a leading end located towards the first ends 26a, 28a, 30a and a trailing end located towards the second ends 26b, 28b, 30b.

The fasteners 32a, 32b, 32c secure the respective first, second and third frame members 12a, 12b, 12f to the connector 18. In addition, the fasteners 32a, 32b, 32c act to bring the first, second and third frame members 12a, 12b, 12f together, as described in further detail below. It shall be appreciated that in alternative embodiments where there are only two connector arms and two frame members, the third fastener may be omitted.

The hollow profiles 22a, 22b, 22c of the first, second and third frame members 12a, 12b, 12f extend along the longitudinal axis of the respective frame member 12a, 12b, 12f. The hollow profile 22a, 22b, 22c may have any suitable cross-sectional profile. In this embodiment, the hollow profiles 22a, 22b, 22c have a substantially rectangular cross-sectional profile. As illustrated in Figures 4 to 6, each of the frame members include two hollow profiles located on opposing sides of the longitudinal axis of the respective frame member. The thermal break 23 is located in between the two hollow profiles of the respective frame member. The joint 20 therefore includes two connectors 18 of substantially the same configuration located on the opposing sides of the frame members in the hollow profiles. However, for reasons of conciseness and brevity, only one of the connecters 18 will be described hereafter.

The connector first arm 24a is configured to extend within the hollow profile 22a to locate the first frame member 12a. When the first arm 20a extends within the hollow profile 22a the first fastener 32a engages the first frame member 12a. The connector second arm 24b is configured to extend within the hollow profile 22b to locate the second frame member 12b. When the second arm 20b extends within the hollow profile 22b the second fastener 32b engages the second frame member 12b. The connector third arm 24c is configured to extend within the hollow profile 22c to locate the third frame member 12c. When the third arm 20c extends within the hollow profile 22c the third fastener 32c engages the third frame member 12f.

The engagement of the fasteners 32a, 32b, 32c with the respective frame members 12a, 12b, 12f secures the frame members 12a, 12b, 12f to the connector 18, creating a secure joint 20.

The fasteners 32a, 32b, 32c are supported by the respective connector arm 24a, 24b, 24c, improving ease of assembly of the joint 20. The fasteners 32a, 32b, 32c can be fitted to the connector 18 before the frame members 12a, 12b, 12f are attached thereto.

The hollow profiles 22a, 22b, 22c of this embodiment are configured to engage the respective fastener 32a, 32b, 32c when the respective connector arm 24a, 24b, 24c extends within the frame member 12a, 12b, 12f, i.e. when the joint 20 is in the assembled state shown in Figure 2, and when the joint 20 is in a partially assembled state. That is, when the joint 20 is in the partially assembled state of Figures 4 to 6, where the first, second and/or third frame members 12a, 12b, 12f are partially fitted over the first, second and third connector arms 24a, 24b, 24c, engagement between the first, second and third fasteners 32a, 32b, 32c and the profiles 22a, 22b can be initiated.

As illustrated in Figure 10, each hollow profile 22a, 22b, 22c defines at least two projections 34 extending from the hollow profile 22a, 22b, 22c to engage the respective fastener 32a, 32b, 32c at discrete, separate engagement points, wherein each engagement point is distinct from the next. The projections 34 are arranged about the fasteners 32a, 32b, 32c such that engagement points provide balanced support, e.g. such that the engagement points are evenly arranged about a periphery of each fastener 32a, 32b, 32c. The projections 34 define a longitudinal axis extending substantially parallel to the longitudinal axis of the respective connector arm 24a, 24b, 24c. Put another way, the projections 34 are substantially linear.

Advantageously, this arrangement provides stability to the engagement between the fastener 32a, 32b, 32c and the respective frame member 12a, 12b, 12f whilst reducing the amount of material used in the hollow profile 22a, 22b, 22c. Providing an engagement point rather than a solid block or face of a profile wall or the like for fastener engagement can also improve ease of engagement, in particular wherein the fastener is a self-tapping screw, due to the reduced amount of material used.

In this embodiment, engagement of the projections 34 of the fastener 32a, 32b, 32c at the engagement points cover less than 25% of the total circumference of each fastener 30a, 30b, 30c. In alternative embodiments, the engagement points cover less than 50% of the total periphery of each fastener, or less than 35%.

In this embodiment, each frame member hollow profile 22a, 22b, 22c defines four projections 34. Two projections 34 extend from a first side 38a of the hollow profile 22a, 22b, 22c and two projections 34 extend from a second side 38b of the hollow profile 22a, 22b, 22c. The projections 34 oppose one another, and are arranged so that the four engagement points are equidistant one another about the periphery of the respective fastener 30a, 30b, 30c. In an alternative embodiment with a profile defining four projections, the projections are arranged such that the engagement points form opposing pairs, i.e. so that the projections extending from a first side of each profile create engagement points that oppose those created by the projections extending from a second side of each profile, yet the engagement points are not equidistant from one another.

In alternative embodiments (not shown) each frame member profile defines two projections, or three projections, or five or more projections. In some embodiments with even numbers of projections, the projections are arranged in pairs. In some such embodiments, the pairs of projections are equidistant one another about the periphery of each fastener.

The fasteners 32a, 32b, 32c are in this embodiment supported by the connector arms 24a, 24b, 24c in such a way as to allow limited transverse movement of the fasteners 32a, 32b, 32c in particular with respect to the inner and outer sides 38a, 38b of the hollow profile 22a. The fasteners 32a, 32b, 32c can thus self-centre with respect to the projections 34, so that the fasteners 32a, 32b, 32c are held equally between all four projections 34.

The projections 34 extend from the respective hollow profile 22a, 22b, 22c in a radial directions. The projections 34 extend radially inwardly from an outer wall to engage the respective fastener 32a, 32b, 32c.

The projections 34 of this embodiment are angled. A first end 34a of each projection 34 extends substantially perpendicularly from the outer side 38a. A second end 34b configured to engage a fastener 30a, 30b, 30c extends at an angle relation to the first end 34a. The second end 34b is angled inwardly, towards the second end 34b of the remaining projection 34, so that the second ends 34b can engage a fastener 32a, 32b, 32c between them in a radial direction of the fastener 32a, 32b, 32c. This ensures positive engagement. In this embodiment, the first end 34a is at an angle of approximately 60° to the second end 34b. In an alternative embodiment the first end is at an angle of between 300 and 1200, depending on the size and shape of the fastener.

In an alternative embodiment, the projections are not angled, but extend in a straight line along their length. In an alternative embodiment each hollow profile defines a combination of angled and straight projections.

The fasteners 32a, 32b, 32c of this embodiment are threaded fasteners. In this embodiment, the fasteners 32a, 32b, 32c are self-tapping grub screws. In an alternative embodiment, some other suitable type of fastener is provided. For example, some other type of threaded fastener is provided, or some other type of fastener that allows for adjustment.

The projections 34 of this embodiment are configured to extend substantially to a minor diameter of each fastener 32a, 32b, 32c, as illustrated in Figure 10. That is, projections 34 extend to substantially the full depth of the trough of the fastener thread. A high level of engagement between the fasteners 32a, 32b, 32c and the respective frame members 12a, 12b, 12f is thus achieved.

The fasteners 32a, 32b, 32c extend in a longitudinal direction in relation to the respective frame members 12a, 12b, 12f. The fasteners 32a, 32b, 32c each have a longitudinal axis. The fasteners 32a, 32b, 32c are supported by the connector 18 such that the fastener longitudinal axis is substantially parallel to the frame member longitudinal axis and to the longitudinal axis of the respective connector arm 24a, 24b, 24c.

The connector arms 24a, 24b, 24c provide support for the projections 34, improving stability and load distribution of the frame 12. In this embodiment, the connector arms 24a, 24b, 24c define a support 36a, 36b, 36c for each projection 34 of the respective frame member 12a, 12b, 12f and are configured to provide support for the projections 34 when the joint 20 is in the assembled state. Free movement between the frame members 12a, 12b, 12f and the connector 18 is therefore limited, stabilising the joint 20.

In this embodiment each support is in the form of a channel 36a, 36b, 36c, shown in Figures 7 to 9. The channels 36a, 36b, 36c are configured to receive the respective projection 34. Each channel 36a, 36b, 36c has a cross-section shape to correspond to that of the projections 34. Each channel 36a, 36b, 36c is substantially uniform in cross-sectional profile, allowing the frame members 12a, 12b, 12f to be fitted to the connector 18 along the longitudinal axes during assembly.

The corresponding shape of the projections 34 and the channels 36a, 36b, 36c also provide location of the connector arms 24a, 24b, 24c in the frame members 12a, 12b, 12f.

The frame member hollow profiles 22a, 22b, 22c each have an inside edge and an outside edge 40a, 40b extending between the first and second sides 38a, 28b. A centreline extends between the inside and outside edges, equidistant to the inside and outside edges.

As shown in Figure 10, the projections 24 are configured to engage each fastener 32a, 32b, 32c such that the fastener longitudinal axis x lies substantially on the centreline C. That is, each fastener 32a, 32b, 32c is centrally located in the inner-outer direction in relation to the respective hollow profile 22a, 22b, 22c. The freedom of movement provided to the fasteners 32a, 32b, 32c by the connector arms 24a, 24b, 24c allows the fasteners 32a, 32b, 32c to self-centre with respect to the projections 34. The central location of the fasteners 32a, 32b, 32c in the transverse direction aids load distribution within the outer frame 12. That is, when tightened, the pressure exerted by one frame member on the other frame member at the joint is substantially uniform across the joint.

In an alternative embodiment, the fastener longitudinal axis x is within 5mm of the centreline C, in a perpendicular direction. In alternative embodiments, the fastener longitudinal axis x is within 4mm, or within 3mm, of the centreline C, in a perpendicular direction. In alternative embodiments, the fastener longitudinal axis x is within a quarter, or within a fifth, of the total distance between the inside edge 44 and the outside edge 46 of the centreline C. In this embodiment, the projections 34 are configured to engage each fastener 32a, 32b, 32c such that the fastener longitudinal axis x is substantially centrally located between the first and second side 38a, 38b of each profile 22a, 22b, 22c. This arrangement aids even load distribution within the profiles 22a 22b, so that the pressure exerted by one frame member on the other frame member at the joint 20 can be substantially uniform across the hollow profiles 22a, 22b, 22c of the joint 20.

In alternative embodiments the fastener longitudinal axis is located closer to one or other of the profile sides 38a, 38b. The fasteners 32a, 32b, 32c of this embodiment are aligned with one another in relation to the profile sides 38a, 38b. This further aids an even loading across the joint. In an alternative embodiment, the fasteners are offset with one another with respect to the profile sides. This could enable tools to be simultaneously engaged with each of the fasteners of one connector, which could potentially enable faster adjustment.

In this embodiment, each connector arm 20a, 20b defines a recess 48a, 48b, 48c configured to engage the respective fastener 32a, 32b, 32c in a push-fit. That is, the recesses 48a, 48b, 48c are dimensioned such that a fastener of a predetermined size will not fall from the recess 48a, 48b, 48c without intervention.

The fasteners of this embodiment are grub screws 32a, 32b, 32c having threaded axial portions 68a, 68b, 68c. The fasteners 32a, 32b, 32c also include an unthreaded portion 69a, 69b, 69c located closer to the first ends 26a, 28a, 30a than the threaded portion 68a, 68b, 68c. The recesses 48a, 48b, 48c of this embodiment are configured to engage the respective fastener 32a, 32b, 32c in a push-fit at the unthreaded portion 69a, 69b, 69c, as illustrated in Figure 8.

Each recess 48a, 48b, 48c has concave inner and outer walls configured to receive the fastener 32a, 32b, 32c at the unthreaded portion 69a, 69b, 69c, and so to retain the fastener 32a, 32b, 32c in place within the connector 18 in the radial direction.

Each recess 48a, 48b, 48c is open on the sides parallel to the first and second sides 38a, 38b of the hollow profiles 22a, 22b, 22c, as illustrated in Figure 7.

It shall be appreciated that in alternative embodiments, there may be any suitable number of unthreaded portions, for example an additional unthreaded portion located towards the second ends 26b, 28b, 30b of the connector arms and retained in a push-fit arrangement. Alternatively, the unthreaded portion may be omitted.

As illustrated in Figure 8, each recess 48a, 48b, 48c has a first end wall 54a, 54b, 54c and a lug 55a, 55b, 55c. The first end wall 54a, 54b, 54c locates each fastener 32a, 32b, 32c in an axial direction towards the first ends 26a, 28a, 30a. The fastener 32a, 32b, 32c is therefore confined in the axial direction. The first end wall 54a, 54b, 54c is therefore proximal the first end 26a, 28a, 30a of the respective connector arm 24a, 24b. 24c. In this embodiment, a space defined between the first and second fasteners 32a, 32b is open.

The lug 55a, 55b, 55c locates each fastener 32a, 32b, 32c in a second axial direction towards the second ends 26b, 28b, 30b. The lug 55a, 55b, 55c is located in between the threaded 68a, 68b, 68c and unthreaded portion 69a, 69b, 69c of the fastener 32a, 32b, 32c. In alternative embodiments, the lug 55a, 55b, 55c may be located at any suitable location in relation to the fastener.

Each fastener 32a, 32b, 32c includes a step 57a, 57b, 57c corresponding to the respective lug 55a, 55b, 55c. The step 57a, 57b, 57c is located between the lug 55a, 55b, 55c and the first end 26a, 28a, 30a. In alternative embodiments, the step may be located anywhere on the fastener depending on the location of the lug. The step 57a, 57b, 57c abuts against the lug 55a, 55b, 55c and has a radius greater than a radius of the lug 55a, 55b, 55c. The fasteners 32a, 32b, 32c are therefore confined in both axial directions.

It shall be appreciated that in alternative embodiments, any suitable arrangement may be used to confine the fastener in either axial direction. Alternatively, the fastener may only be confined in one axial direction, for example the first axial direction.

The recess 48c of the third connector arm 24c includes a second end wall 56 located towards the second end 30b of the third connector arm 24c. The second end wall 56 also acts to confine the third fastener 32c in the second axial direction towards the second end 30b of the connector arm 24c, thus confining the third fastener 32c in both axial directions.

In an alternative embodiment, the recesses of the first and second fasteners each include a second end wall, and the length of the space between the end walls of each recess 48a, 48b, 48c is the same as the length of each fastener 32a, 32b, 32c. As well as further assisting retention of the fasteners 32a, 32b, 32c within their respective recesses 48a, 48b, 48c the length of the fasteners 32a, 32b, 32c being the same as the length of the recesses 48a, 48b, 48c improves ease of adjustment of the frame members 12a, 12b, 12f in relation to the connector 18.

In alternative embodiments, the leading end of each fastener 32a, 32b, 32c at least partially conical, or frusto-conical. The conical shape of the leading end aids self-tapping of each fastener 32a, 32b, 32c with the projections 34.

The access feature 19 of the connector 18 is configured to provide access to the trailing end for a tool T, for example a ball-ended tool, for which the trailing end is configured for engagement e.g. with a female Torx profile for engagement with a ball ended T25 Torx driver. The access feature 19 provides access to the first, second and third fasteners 32a, 32b, 32c, and permits engagement of the ball-ended tool to adjust at least one of the first and second fasteners 32a, 32b at a non-zero angle to the longitudinal axis.

In this embodiment, the access feature 19 is located on a surface 66 of the connector 18 parallel to the longitudinal axes of the first and second connector arms 24a, 24b. Specifically, the access feature 19 is located on a surface 66 of the connector 18 that is also perpendicular to the longitudinal axis of the third connector arm 24c.

In this embodiment, the access feature 19 is an elongate slot 19 extending in a direction parallel to the longitudinal axes of the first and second connector arms 24a, 24b. The elongate slot 19 creates the required space to fit the tool at a range of non-zero angles, to adjust both the first fastener 30a and the second fastener 30b. In order to facilitate access to the first and second fasteners 30a, 30b, the access feature 19 is located in between the first fastener 30a and the second fastener 30b, for example equidistant from the first end 26a and the first end 26b.

The access feature 19 defines a centre point located along a longitudinal axis of the third fastener 30c. This enables access to the third fastener 30c in a direction parallel to the longitudinal axis of the third fastener 30c.

In this embodiment, the connector 18 also includes a partition wall 58. The partition wall 58 is located between the first and second fasteners 32a, 32b and between the third fastener 32c and the access feature 19. The end wall 56 is formed as part of the partition wall 58. The partition wall defines an access aperture 59. In this embodiment, the aperture 59 is smaller than the diameter of the fastener 32c so that the end wall 56 retains the fastener 32c within the recess 48c. The access aperture 59 together with the access feature 19 enables the tool T to engage and drive the third fastener 32c substantially co-axially, as shown in dashed lines in Figure 9.

A frame access feature 70a is provided on the first frame member 12a, and a frame access feature 70b is provided on the second frame member 12b. In this embodiment, the frame access features 70a, 70b are elongate slots 70a, 70b.

As illustrated in Figure 3, the frame access feature 70a of the first frame member 12a is aligned with the frame access feature 70b of the second frame member 12b in a direction parallel to the longitudinal axes of the first and second connector arms 24a, 24b. The frame access members 70a, 70b are of substantially the same width and length, and form one continuous slot 70a, 70b when the joint 20 is assembled.

The frame access features 70a, 70b are at least partially aligned with the access feature 19 of the connector in a direction perpendicular to the longitudinal axes of the first and second connector arms 24a, 24b. This enables access to the first, second and third fasteners 32a, 32b, 32c via both frame access features, thereby improving ease of assembly. This will be described in more detail below in relation to the assembly process.

In alternative embodiments where the longitudinal axes of the first and second fasteners 32a, 32b are offset from one another in the transverse direction, the frame access features 70a, 70b may also offset in the transverse direction by the same amount. Alternatively, there could be two frame access features provided on each frame member, one for accessing each of the first and second fastener 32a, 32b.

Referring to Figures 4 to 6, assembly of the fenestration unit 10 may be carried out as follows: The ends of the frame members 12a, 12b and 12f are cut at suitable mitre angles and offsets to cleanly mate when assembled. The fasteners 32a, 32b, 32c are preferably fitted to the connector 18 prior to transport to the site, reducing the number of on-site operations required.

The first and second frame members 12a, 12b are located on the connector 18, as illustrated in Figure 4. The tool is inserted into the trailing end of the first fastener 32a and the fastener 32a is adjusted using the tool to at least partially engage the frame member 12a, as illustrated in Figure 9. The tool passes through the frame access feature 70a, 70b as well as through the access feature 19.

As the fastener 32a is tightened and exerts a force on the end wall 56 in the direction towards the first end 26a, the connector 18 is "pulled" into the frame member, as illustrated in Figure 5. Put another way, there is one operation of both inserting the connector and securing it in place with the fastener, simplifying assembly. As the connector 18 is pulled into the frame member 12a, the tool moves within the frame access feature 70a, 70b in a direction away from the third frame member 12f. The use of the elongate slot 70a, 70b facilitates the relative movement. The direction of the tool is reversed, and the process is repeated for the second frame member 12b and the second fastener 32b.

The third frame member 12f is located in the connector 18, as illustrated in Figure 6. The tool is inserted into the trailing end of the third fastener 32c and the fastener 32a is adjusted using the tool to at least partially engage the frame member 12f.

The tool passes through the frame access feature 70a, 70b, through the access feature 19 and through the access aperture 59. The third fastener 32c is tightened in substantially the same manner as the first and second fasteners 32a, 32b.

The remaining frame members 12c, 12d, 12e, 12g are assembled to form the outer frame 12. Next, the moveable sash 14 is offered up to the outer frame 12 and fitted within the outer frame 12. The outer frame 12 and the sash 14 are fitted within the wall opening. Due to the location of the upstand 13b of the second frame member 12b, the dummy sash 16 can be fitted from the interior side of the fenestration unit in order to complete the assembly process.

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 outer frame may be assembled away from the site e.g. at a fabrication plant. The moveable sash may be fitted into the outer frame after the outer frame is fitted to the building and this still reduces the operations that may be required to be carried out at height.

Claims

Claims 1. A connector configured to locate first and second frame members of a joint for a frame of a fenestration unit, the connector comprising: first and second fasteners configured to secure the first and second frame members to the connector; and a first arm configured to extend within a hollow profile defined by the first frame member, and a second arm configured to extend within a hollow profile defined by the second frame member; wherein a longitudinal axis of each of the first and second fasteners is configured to be parallel to a longitudinal axis of the respective connector arm; wherein the longitudinal axis of the first connector arm is parallel to the longitudinal axis of the second connector arm; wherein each of the first and second fasteners is configured to engage the respective frame member when the respective connector arm extends within said frame member; and wherein the connector comprises an access feature configured to provide access to the first and second fasteners, wherein the access feature permits the engagement of a tool to adjust at least one of the fasteners at a non-zero angle to the longitudinal axis.
2. The connector according to claim 1, wherein the access feature is located on a surface of the connector parallel to the longitudinal axes of the first and second connector arms.
3. The connector according to claim 1 or claim 2, wherein the access feature is an elongate slot extending in a direction parallel to the longitudinal axes of the first and second connector arms.
4. The connector according to any preceding claim, wherein the access feature is located in between the first fastener and the second fastener.
5. The connector according to any preceding claim, wherein the first arm is configured to support the first fastener and the second arm is configured to support the second fastener.
6. The connector according to any preceding claim, comprising a third connector arm configured to extend within a hollow profile defined by a third frame member and further comprising a third fastener configured to extend within the hollow profile defined by the third frame member.
7. The connector according to claim 6, wherein the third connector arm defines a longitudinal axis extending at a non-zero angle relative to the longitudinal axes of the first and second connector arms, optionally wherein the longitudinal axis of the third connector arm is substantially perpendicular to the longitudinal axes of the first and second connector arms.
8. The connector according to claim 6 or claim 7, wherein the access feature is configured to provide access to the third fastener.
9. The connector according to any one of claim 6 to claim 8, wherein the access feature defines a centre point located along a longitudinal axis of the third fastener, optionally wherein the first and second fasteners are located equidistant from the longitudinal axis of the third fastener.
10. The connector according to any one of claim 6 to claim 9, comprising a partition wall, wherein the partition wall is located between the first and second fasteners and between the third fastener and the access feature, optionally wherein the partition wall comprises an access aperture configured to provide access to the third fastener, and wherein the access aperture is at least partially aligned with the access feature.
11. The connector according to any one of claim 6 to 10, wherein the third fastener is confined in a first axial direction, towards a free end of the third connector arm, optionally wherein the third fastener is confined in a second axial direction opposing the first axial direction.
12. The connector according to any preceding claim, wherein the first and/or second fastener is confined in a first axial direction, towards a free end of the respective connector arm, optionally wherein the first and/or second fastener is confined in a second axial direction opposing the first axial direction.
13. The connector according to any preceding claim, wherein each fastener is a threaded fastener, optionally wherein each fastener is a self-tapping threaded fastener, and/or wherein each fastener comprises a frusto-conical leading end.
14. The connector according to any preceding claim, wherein each fastener comprises at least one threaded axial portion and at least one unthreaded axial portion, optionally wherein each connector arm is configured to engage the respective fastener at the unthreaded portion.
15. A joint for a frame of a fenestration unit, the joint comprising: first and second frame members defining first and second hollow profiles; and a connector according to any preceding claim configured to secure the first and second frame members in relation to one another.
16. A joint according to claim 15, wherein the first frame member comprises a frame access feature and wherein the second frame member comprises a frame access feature.
17. The joint according to claim 16, wherein the frame access feature of the first frame member is aligned with the frame access feature of the second frame member in a direction parallel to the longitudinal axes of the first and second connector arms, optionally wherein the frame access features of the first and second frame members are at least partially aligned with the access feature of the connector in a direction perpendicular to the longitudinal axes of the first and second connector arms.
18. A joint according to claim 16 or claim 17, wherein the frame access feature of the first frame member is an elongate slot, and wherein the frame access feature of the second frame member is an elongate slot.
19. A joint according to any one of claim 15 to claim 18, wherein each frame member profile defines at least two projections extending from the hollow profile to engage said fastener.
20. A joint according to claim 19, wherein each projection of the frame member engages the fastener at an engagement point, and wherein the projections are configured such that the engagement points are equidistant about a periphery of the fastener.
21. A joint according to any one of claim 15 to claim 20, wherein the first and second frame members each comprise a first and second exterior hollow profile located on an opposing side of the longitudinal axes of the first and second frame members to the first and second hollow profiles, and wherein a second connector is received in the first and second exterior hollow profiles.
22. A joint according to any one of claim 15 to claim 21, comprising a third frame member defining a third hollow profile, wherein the connector comprises a third arm configured to secure the third frame member in relation to the first and second frame members, optionally wherein the third frame member is configured to extend substantially perpendicularly from the first and second frame members.
23. A joint according to any one of claim 15 to claim 22, wherein the first frame member comprises an interior upstand located on a first side of the longitudinal axes of the connector arms, and wherein the second frame members comprises an exterior upstand located on an opposing second side of the longitudinal axes of the connector arms.
24. A fenestration unit comprising a joint according to any one of claim 15 to 23.
25. A fenestration unit according to claim 24, comprising a sash moveable relative to the fenestration unit, optionally comprising a fixed light and/or a dummy sash fixed relative to the fenestration unit.