Patents Form No 5
Our Ref PT501639
NEW ZEALAND PATENTS ACT 1953
Complete After Provisional No 328686 Filed 5 September 1997
COMPLETE SPECIFICATION
JOINERY CONSTRUCTION
We, ARCHITECTURAL PROFILES LIMITED, a New Zealand company of Northpark Drive, Hamilton, New Zealand hereby declare the invention, for which We pray that a patent may be granted to us and the method by which "rt is to be performed, to be particularly described in and by the following statement
INTELLECTUAL PROPERTY OFFICE"]
OF NZ
(M SEP 1998 RECEIVED i
PT0579165
INTRODUCTION
This invention relates to joinery, more particularly to building joinery, including windows, doors, vents and similar constructions arranged to provide closures for openings of buildings
BACKGROUND TO THE INVENTION
The present invention, whilst not limited thereto, has particular application to joinery intended for buildings where relative high temperature differences can exist between an interior and exterior of a building, such as in colder climates, particularly in colder relatively humid colder climates
The invention also has special application to joinery requiring a high level of aesthetic character, for example as often required in higher quality buildings, certain commercial applications and according to architectural specification
Traditionally, joinery and joinery componentry for buildings has been formed in a variety of materials including timber, metals (particularly steel and aluminium), together with certain plastics. Each of these materials incorporate certain inherent advantages, unfortunately also coupled with inherent disadvantages, typical to the materials involved, for example timber, whilst having usually highly desirable aesthetic properties, particularly on an interior of a building carries with it the disadvantages of manufacturing cost, high maintenance costs and in some instances a lack of weatherliness/durability
The more commonly used aluminium joinery, whilst often able to technically provide the appropriate performance aspects desired and meet cost criteria, is often regarded as lacking in the desired aesthetic properties Furthermore such joinery is often associated with problems connected with heat conduction and related heating and condensation control difficulties
A
V
Plastics, for example extruded PVC section manufactured joinery, whilst providing intrinsic insulation and moderate cost advantages, is often associated with compromised mechanical (particularly rigidity) properties, together with some perceived durability and aesthetic disadvantages
Logically, attempts have been made to ameliorate these problems by providing joinery which includes combinations of the best features of known joinery constructions and materials however, such combination or "composite" joinery designs and constructions have often been found to be in themselves compromised, for example in cost, in view of the fact that often joinery manufacturers and fabricators are primarily set up and have staff skill sets predominantly for one material type form of joinery and do not readily adapt to composite manufacture, resulting in cost and quality problems
Further, the performance of composite joinery is often compromised, particularly at an interface between the combined joinery construction materials, for example in condensation entrapment and the downstream deleterious effects on exposed joinery portions
Composite joinery, by its very nature involves the interconnection of differing materials, with differing performance characteristics, such as thermal co-efficients of expansion and the like These differences have led to difficulties in secure attachment of the differing components and a potential exposure to customer claims, ongoing maintenance costs and other market difficulties, to say nothing of customer satisfaction
OBJECTS OF THE INVENTION
It is an object of this invention to come some way in overcoming the abovementioned problems, or at least provide the public with a useful choice Other objects of this invention will become apparent from the following description,
BROAD DESCRIPTION OF THE INVENTION
According to one aspect of this invention, there is provided a joinery construction incorporating an outer portion capable of building exterior exposure, an inner portion capable of inner building exposure, characterised in that at least a majority of said outer portion is formed in a material type having a thermal conductivity higher than material from which the inner portion is formed, interengaging means provided to juxtapose with, space apart, and mechanically engage substantially abutting parts of said inner and outer portions in a first plane of juxtaposition, and in a second plane of justaposition spaced from said first plane of juxtaposition, at least one abutting part of said outer portion and/or said inner portion overlapped relative to a juxtaposed portion of said interengaging means to assist in maintaining engagement of said outer portion, inner portion and interengaging means as a composite member
Other aspects of this invention will become apparent from the following description which is given by way of reference to the preferred embodiment
DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is made to Figures 1 and 2 of the accompanying drawings in which
Figure 1 is a substantially diagrammatic cross-sectional side elevation through a typical joinery head frame and opening sash combination in the preferred embodiment where the composite joinery is formed in a combination of aluminium alloy extrusions to an intended building exterior, and timber to an intended building interior
Figure 2 is a similar view to that of Figure 1 with the exception that the alternative embodiment is shown as a cross-section through a sill and with fixed glazing
Referring to the drawings, particularly Figure 1, the joinery as generally indicated by arrow 1 in the preferred form, but not exclusively, includes a frame portion as generally indicated by arrow 2 and a sash portion as generally indicated by arrow 3
The frame portion 2 is suitable for mounting within a rough opening RO of a building suitably supported by packing or wedging W material Facing portions 4 of said frame 2 are in the preferred embodiment arranged to overlap building cladding C in the traditional manner for securement of frame 2 in the rough opening RO of a building Building inner lining (not shown) is arranged to trim the interior of the building and engage in a recess provided either by an interaction of a jamb liner/architrave combination or alternatively a longitudinal recess provided in the jamb liner (not shown)
The sash 3 is preferably moveable relative to the frame 2 to enable opening and closing of the sash 3 relative to a rebate 7 provided in the frame 2, sealing being provided via appropriate gaskets 8 between the sash 3 and opposing frame portions 2 as is shown in Figure 1
Alternatively, fixed glazing as shown in Figure 2 may be provided for the frame 2 by mounting a fixed adaptor 5 in the frame rebate 7 or alternatively dispensing with sash/adaptor assemblies altogether and providing direct glazing into the rebate 7 of the frame 2 (not shown), according to known techniques
Throughout this specification, references are made to "inner" and "outer" These are to be interpreted in accordance with a general orientation where "outer" means toward a normally intended exterior of the
building with which the joinery is intended to be used and "inner", being in the direction of the intended interior of the building
Further, where reference is made to the terms "upper" and "lower", these are taken to be relative to the orientation of the drawings of Figure 1 and Figure 2, where the structure depicted is intended to show a cross-section through a head (Figure 1) and a sill (Figure 2) of a joinery construction It is to be appreciated that in accordance with normal joinery construction techniques, the similar structure can also be used in jamb and head configurations
Referring particularly to Figure 1, the joinery construction incorporates both frame 2 and sash 3 portions of a composite configuration where portions normally in use exposed to an outer portion of the joinery construction including, but not essentially, both the frame 2 and sash 3 directly or indirectly, are formed in aluminium alloy extrusion, whereas,
inner portions of said joinery construction 1 are formed in a material having a higher msulative property than aluminium alloy and preferably timber
With reference to Figure 1, frame 2 and sash 3 outer portions generally indicated by arrow 10 and include portions of the sash 3 directly exposed to the exterior in use in a building, those portions which are indirectly exposed (for example by heat conduction and the like including the frame recess 7 abutment 9 and further portions 12 of the sash forming part of the general sash "extrusion" as depicted)
Outer portions also include frame 2 portions directly or indirectly exposed to the exterior of the building, including the facing portion 4,
rebate forming portions 7 and for example, flange portions 13 provided for securement of the frame 2 or within the building rough opening RO
Inner portions 11 of the joinery construction are in the embodiment depicted in Figure 1 provided as portions of timber 14 applied to the sash 3 to provide the inner exposed surface of the sash 3 and the jamb liner 6 for the frame 2
"Indirectly interior facing" parts 16 of the outer portions 10 of the sash 3 and frame 2 (in the case of the embodiment of Figure 2 the adaptor 5) incorporate an abutment face against which the inner portions 1 1 may abut The sash portion 3 preferably includes inwardly directed elongate rib 1 1 which assists securement of the inner portions 11 thereto
An inner edge portion 17a of the rib 17 is preferably orthogonally flanged so as to provide a recess generally indicated by arrow 18 into which correspondingly shaped portions of an interengaging member or gasket 9 engage in a longitudinally overlapped assembly Furthermore, adjacent edge portions of the timber inner portions 1 1 applied to the sash 3 are correspondingly shaped and grooved so as to fit in an overlapping relationship with the interengaging member 19 with parallely aligned parts thereof each longitudinally overlapped The adjacent outer frame portions 10 with the interengaging member 19 and the inner frame portions 11 with the interengaging member 19 In this way it will be appreciated that the longitudinally overlapped assembly assists to securely connect those portions together as effectively one composite building element
It will be seen that the overlapping engagement of those portions is provided in a manner whereby there is provided a first plane of juxtaposition and a second plane of juxtaposition of adjacent and juxtaposed portions of the outer portion 10 and the interengaging member 19, spaced apart in such a way that the longitudinally overlapped assembly facilitates a secure mechanical engagement of those juxtaposed portions to form the composite building element An engagement between the inner portion 11 and interengaging member 19 is similarly constructed with the abutting parts thereof in the first and second planes of juxtaposition overlapped relative to the other Such configuration is depicted in both figure 1 and figure 2 and provides for a secure overlapping engagement assembly for the composite building element, with the interengaging member 19 providing a structural connection between the outer and inner portions 10 and 11 in the composite building element
Suitable fixing means, for example screws 20 and the like are provided at regular intervals through the sash 3 outer portion 10 into the sash inner portion 11 to cooperatively maintain a secured attached relationship composite sash 3 element
In the preferred form of the invention the interengaging means 19 or gasketing means is preferably provided as an elongate strip of thermally insulative material, for example plastics, such as PVC and the like which preferably incorporates substantially moisture transmittal resistance properties In the preferred form of the invention, preferably the gasket 1 9 is arranged of a shape length and size so as to correspond with the elongate portions of the sash 3 and frame 2 so that the gasket 19 can be positioned between the inner and outer portions of the sash 3 and frame 2, in this embodiment, between the timber and metal of the inner and outer portions 11 and 10
It will be appreciated that the interengaging means or gasket 19 in providing a substantially moisture resistant barrier will effectively control the passage of any moisture through condensation and the like which forms on the inner face of the sash 3 and frame 2 outer portion 10 and will prevent such moisture contacting directly the timber inner portions 13 thus resisting an otherwise tendency for such moisture to cause damage, for example rotting and the like in that area
Whilst described with reference to the sill configuration of Figure 2, it will be appreciated that in the sill assembly of both embodiments described with reference to Figures 1 and 2, a recess 21 is provided between opposed portions of the interengaging means 19 and adjacent portions of the flange 17 so that when the whole section is positioned in the sill orientation as is shown by Figure 2, it will be appreciated that the recess 21 enclosed by opposing portions of the interengaging member 19 and the flange portion 17 is provided to collect any liquid resulting from condensation which may occur on the surface of the outer frame portion 10 opposing the interengaging member 19 or gasket
In the preferred form of the invention, suitable ports 22 are provided at intervals through the wall of the outer frame portion 10 (for example through the adaptor 5 as shown in Figure 2), such that any condensation created will drain to the exterior
It is to be appreciated that any liquid of condensation will be relatively minimal as a result of the substantially enclosed nature of the inner surfaces of the outer frame portion 10 normally liable to condensation Furthermore, the flanged nature of the engagement of the flange 17 and interengaging member 1 9 in the overlapping relationship further serves to reduce the opportunity for moisture in the recess draining other than as described hereinbefore In this way it will be seen that the normally less durable inner frame portions 11 are reduced in their exposure to moisture of condensation, are secretly secured and are arranged in a manner which also restricts the exposure of the inner surfaces of the outer frame 10 to exposure to damp air, thus reducing the opportunities for condensation and heat conduction to occur, all whilst providing beneficial aesthetics
Referring to both Figures 1 and 2, it will be appreciated that the configuration of the frame 2 rebate 7 and in particular, the height of an upper portion 7a of an upstand forming portion 9 of the rebate 7 is positioned sufficiently out of register with the timber inner portion 14 of the sash 3 or adaptor 5 such that a seal 8 may readily position therein, thus effectively separating the portions of the frame 2 and sash outer portions from the interior of the joinery when it is in a closed condition
It will be appreciated that the assemblies of both Figures 1 and 2 in providing the aforementioned separation, more effectively enable control of heat conduction through the joinery and therefore, the creation of condensation and "chilling", through the joinery
Whilst the invention has been described with reference to a preferred embodiment incorporating double glazing, the invention is not limited thereto, and in alternative embodiments of the invention, single, or alternative multiple glazing arrangements may be provided
It will appreciated that in assembly of both the preferred the joinery manufacturer provides elongate elements for the joinery 1 of the required length and configuration for normal jointing techniques, for example butt and mitre joints During assembly, inter engagement of the inner and outer frame portions with one another is attended to such that the joinery can be readily and simply constructed into the composite form and configuration as described with reference to the drawings.
In particular, it will be appreciated that convenient assembly of the inner and outer portions, particularly the inner portion 11 with the outer sash or adaptor portions can be achieved by readily sliding preformed and precut inner portions 11 into assembly with final adjustments being carried out after assembly and securement of the outer frame portions with one another, so as to achieve a high level of joint accuracy and other quality control
In the preferred embodiment of the invention, it will be appreciated that the assembly provides simple and secure attachment of the inner frame portions with the outer frame portions however in a manner which facilitates removal of the inner frame portions from the outer frame portions without necessarily requiring disassembly of joints formed in the outer frame portion, for example, should any remedial maintenance or other work be required, given that timber is generally less durable than other commonly used joinery materials
Overall, it will be appreciated that the joinery configurations as described hereinbefore with reference to Figures 1 and 2 facilitate the convenient and efficient construction of composite joinery incorporating perceived advantages of the materials used and in particular, facilitating
preferred aesthetic properties often thought to be achieved in some joinery configurations, whilst maintaining other performance attributes required
Whilst the invention has been described by way of example and with reference to typical "window" configurations, it is to be appreciated that the invention is not limited thereto and is applicable to all forms of joinery including doors, windows, vents and the like