NZ537854A - Corner connector - Google Patents

Abstract

A connection system for use in connecting joinery comprises a first section of joinery, a second section of joinery, both the first and the second sections of joinery having a profile formed therein, and a connector, the connector having first and second arms which interconnect, the arms having an upper surface, the arms being adapted to engage with the profiles formed in the first and second sections of joinery, so that, in use, the connector engages the first and second sections of joinery, and wherein a pathway adapted to receive a fluid sealant is provided by a channel formed in the upper surface of the first and second arms between the connector and the first section of joinery, and between the connector and the second section of joinery, the pathway being accessible via one or more ingress apertures and excitable via one or more egress apertures, an aggress aperture being located at the distal end of the pathway from the ingress aperture, and wherein in use, the fluid sealant forms a seal in the plane of the arms' upper surface, between the first and second sections of joinery and the connector, wherein the moisture which negotiates its way past the seal and into the connector is substantially confined and directed by drainage means.

Description

53'8 5 U inteSteetuai Propsiiy Office of N.Z. 2 0 JAM 2005 R F O EIV E P PATENTS FORM NO. 5 Fee No. 4: $250.00 PATENTS ACT 1953 COMPLETE SPECIFICATION CORNER CONNECTOR We, Window Technologies Limited, a New Zealand company of 19 Anaheim Boulevard, Howick, Auckland, New Zealand hereby declare the invention for which We pray that a patent may be granted to us, and the method by which it is to be performed to be particularly described in and by the following statement: JAWS Ref: 230236/37 CORNER CONNECTOR TECHNICAL FIELD This invention relates to an improvement in corner connectors and in particular, though not solely, this invention relates to a modified connector system for use 5 with joinery and the connection of such joinery at corners.

BACKGROUND ART As explained at present in NZ patent application number 507741/510827 (hereinafter referred to as the "main invention") a number of disadvantages exist with existing joinery connection systems.

In particular, the methods by which the joinery is joined (or connected), sealed from environmental conditions and the drainage provisions applied to existing systems tend to fail in a number of regards. For example, drainage capacity and abilities of systems which are used to connect and join sections of joinery (especially of aluminium, or similar, extruded joinery sections) have been 15 developed, but not fully investigated. These problems are especially apparent when attempting to join and connect sections of joinery generally orthogonal to one another.

In addition, the systems by which joinery connections are made tend to involve an under-optimised useage of quantity of glues/adhesives or similar fluid sealants.

Therefore, the present invention attempts to alleviate these concerns and provide an enhanced and improved version of the main invention, and an alternative joinery connector and connection system.

It is therefore an object of the present invention to provide a connector to go at least some way towards addressing the foregoing problems or to at least 2 provide the public and/or industry with a useful choice.

Normally joinery, and in particular metal joinery such as aluminium window or door frame joinery, is screwed together by using stainless steel self tapping screws that thread into the screw-ports in the frame sections. The window or door frame has 5 holes punched or drilled through the ends of one frame member that enables the self tapping screws to be located through these holes into the screw-ports in the second frame member. Normally (but not always) these frames are mitred (45 degree cut) to form a 90 degree corner when they join together, alternatively they can sometimes be square cut and one of the members is machined on the end to 10 form a mating situation with the other member. There are frames and sashes in the window industry that do not have screw-ports, instead they have slots or keyways to accept gussets for alignment and staking angles for a crimping process to occur which acts as a connection for the 2 members to stay together.

Problems that exist with the frames that screw together are numerous, often the 15 screws can break off at the head and it can be a time consuming process to get them out. There may also be a general weakening of the frame member due to the method employed in removing the screw. Sometimes the joint can fail (break apart) if the frame receives racking or twisting treatment prior to it being installed into the building. Moreover, if it does not visibly break apart it can have the seal 20 broken which in turn means the joint will not be water-proof and the subsequent leaking can cause major damage to timber framework, floor or internal linings. This sometimes goes undetected which can cause structural problems, with timber framework and/ or joists rotting out over a period of time.

The Building Research Association of New Zealand (BRANZ) are sufficiently 25 concerned about the weather tightness of buildings that they have seminars in New Zealand to raise awareness of the problems and hopefully provide some education to the building industry on how to design and construct buildings that do not leak. Windows receive more attention than most other building products 3 at these seminars, not only with regards to the importance of flashings but also with regards to joints.

Screws on the outer flange of the window facing are often an interference point for flashings, particularly at the head where the flashing can sit on the screw-head at 5 each end and sag in the middle of the frame. This looks unsightly and also presents a potential leak area where the screw head is keeping the flashing from sitting hard against the frame flange.

It is now a requirement in New Zealand that metal-framed windows with single glazing must be constructed with a means of condensation disposal (or having a 10 condensation collection channel design of sufficient capacity to allow natural evaporation) and furthermore drainage outlets must have the capacity to expel all condensed water and shall have means of preventing condensed water from being blown back by wind pressure.

There are numerous methods existing in the market-place that have been 15 designed to achieve this requirement. Some systems will drain condensation via a plastic "diverter" that is housed in the glazing cavity of the frame sill member. This method would generally need a valve or flap to prevent condensed water blowing back and perhaps one weakness with the design is that they can tend to block up with dirt and grime after a period of time because of the small nature of the 20 components. Others have a "pocket" designs that locate under the sill frame member providing a pathway for condensed water to flow from out through a hole in the condensation channel, through a "baffled" area of the pocket and on through an egress hole at the front of the window frame. A plastic hood that also helps prevent blowback of condensed water sometimes covers this exit hole.

It has become relatively common in the window industry to "back-seal" the bottom corners of the window or doorframes. This is usually done with a silicone or urethane type sealant spread around the underside of the bottom corner joints, it 4 can be a messy process and can be wasteful with regards to the amount of sealant used. The back-sealing is done in an attempt to safeguard the chances of the primary seal failing, which can occur if the frames are subject to racking or twisting during the manufacturing operation or somewhere between the manufacturing and 5 installation stages of the product.

A failure of both the primary seal and the back seal can cause what is often non visible damage to the framework of the building, or at least non visible until such time as the timber has rotted or fungi has grown and spread within the framework of the building. Some manufacturers do not back seal the frames at all and 10 therefore place a heavy reliance on the primary seal doing its job through-out the stresses and strains the window or doorframe undergoes between manufacturing and installation, not to mention the heavy reliance on staff to apply the primary seal correctly. This is normally being applied to a very thin surface area so manufacturers who rely only on a primary seal are risking problems, and more 15 importantly the Customers may well bear the cost that comes back in later years due to the damage caused by leaking.

It should also be mentioned that buildings endure significant movement over their lifetime due to expansion and contraction rates differing between building materials, yet another reason for the sealing of joints to completed in a way that 20 can accommodate these sorts of stresses.

It is therefore an object of the present invention to provide a corner connector which attempts to or at least goes some way towards addressing the foregoing problems and which will at least provide the industry/public with a useful choice.

All references, including any patents or patent applications cited in this 25 specification are hereby incorporated by reference. No admission is made that any reference constitutes prior art. The discussion of the references states what their authors assert, and the applicants reserve the right to challenge the accuracy and pertinence of the cited documents. It will be clearly understood that, although a number of prior art publications are referred to herein, this reference does not constitute an admission that any of these documents form part of the common general knowledge in the art, in New Zealand or in any other country.

It is acknowledged that the term 'comprise' may, under varying jurisdictions, be attributed with either an exclusive or an inclusive meaning. For the purpose of this specification, and unless otherwise noted, the term 'comprise' shall have an inclusive meaning - i.e. that it will be taken to mean an inclusion of not only the listed components it directly references, but also other non-specified components 10 or elements. This rationale will also be used when the term 'comprised' or 'comprising' is used in relation to one or more steps in a method or process.

Further aspects and advantages of the present invention will become apparent from the ensuing description which is given by way of example only.

DISCLOSURE OF INVENTION Accordingly, in a first aspect, the invention consists in a connection system for use in connecting joinery, said connection system for use in connecting joinery comprising: (a) a first section of joinery, (b) a second section of joinery both the first and the second sections of joinery having a profile formed therein, and (c) a connector, said connector having first and second arms which interconnect, 6 said arms having an upper surface, the arms being adapted to engage with the profiles formed in said first and second sections of joinery, so that, in use, the connector engages the first and second sections of joinery, and wherein a pathway adapted to receive a fluid sealant is provided by a channel formed in the upper surface of said first and second arms between said connector and said first section of joinery, and between said connector and said second section of joinery, the pathway being accessible via one or more ingress apertures and exitable via 10 one or more egress apertures, an egress aperture being located at the distal end of the pathway from the ingress aperture, and wherein in use, the fluid sealant forms a seal in the plane of the arms' upper surface, between the first and second sections of joinery and the connector, wherein moisture which negotiates its way past the seal and into the connector is substantially confined and directed by drainage means.

Preferably, the pathway is configured to have a larger cross-sectional area at the proximal end of the pathway tapering to a smaller cross-sectional area at the distal end.

Preferably, wherein the pathway is configured to have a larger cross-sectional area at the proximal end of the pathway tapering to a smaller cross-sectional area at the distal end.

Preferably, adjacent and substantially in-line with the ingress aperture is a fluid 7 flow director.

Preferably, said fluid flow director directs fluid once flowing into said pathway via said ingress aperture into an arm or arms of said pathway.

Preferably, the profile formed in the first and/or second sections of joinery is in the 5 form of a shaped channel.

Preferably, said connector is adapted to slide into and/or along said profiles.

Preferably, said connection system also includes retention means to secure the connector to the first and/or second sections of joinery.

Preferably, said retention means is provided by, or in the form of, a crimping 10 system.

Preferably, said crimping system includes crimping means having one or more crimping teeth which, when the crimping means is actuated, are adapted to crimp the first and/or second sections of joinery to the connector.

Preferably, there is provided a connection system substantially as described above 15 wherein the connector is provided with one or more recesses, said recesses being adapted to align substantially with the one or more crimping teeth of the crimping means.

Preferably, the recesses are slightly misaligned with respect to the crimping teeth.

Preferably, the recesses in the connector are positioned so as to be slightly closer 20 to the join, whereby the action of crimping also forces the first and second sections of joinery together.

Preferably, the recesses are angled indentations. 8 Preferably, the crimping teeth are angled protrusions adapted to substantially match the angled indentations in the connector.

Preferably, the fluid sealant introduced into the pathway creates a seal between said first and second sections of joinery.

Preferably, said fluid sealant is injected into the pathway via the ingress aperture.

Preferably, said connector is further provided with a drainage cavity to collect and disperse water or condensation.

Preferably, said connector is shaped to include a gap between the connector and the first and second sections of joinery, the gap communicating with said drainage 10 cavity allowing water or condensation to exit via an aperture in the connector.

Preferably, the drainage cavity connector aperture is provided with a swing-flap adapted to prevent blow-back of water or condensation into the drainage cavity.

Preferably, the first and the second arms are substantially orthogonal to one another.

Preferably, the first and said second arms interconnect to form a corner.

It is envisaged that the connection system may be suitable for joining any type of joinery, whether metal or otherwise. However, it is believed that the connection system, and methods of use of the same, may be particularly suitable (although not exclusively) for use with metal joinery, and aluminium joinery in particular. In 20 such use, the connection system does away with screws as they are normally used in these corner junctions, but does not discount the use of screws as an additional fastening method between the sections of joinery and the connector.

The first and second sections of joinery may preferably have a profile formed 9 therein. Any suitable profile may be utilised as required or as desired, although a profile in the form of a channel may be particularly suitable. In such an embodiment the connector may be provided with a complimentary or matching profile whereby it may slide into and/or along the profiles formed in the first and 5 second sections of joinery. Preferably, the design of the connector should result in a relatively tight or snug fit between the connector arms (first and second arms) and the first and second sections of joinery.

The arrangement and construction may be preferably be such that once the connector has been engaged with the first and second sections of joinery a join is 10 thus formed between the first and second sections of joinery.

The connection system may preferably include retention means to secure the connector firmly to the first and/or second sections of joinery and/or the first and second sections of joinery to each other. Any suitable retention means which allows for the first and second sections of joinery to be firmly retained to or about 15 the connector may be utilised, as required or as desired, or as dictated by the type or intended uses of the first and second sections of joinery.

For example, the connector may be glued to the first and second sections of joinery. Alternatively, the connector may be riveted, nailed or screwed to the first and second sections of joinery.

Preferably however the retention means may be provided by, or be in the form of, a crimping system. For example, the crimping system may include crimping means having one or more crimping teeth which, when the crimping means in actuated, are adapted to crimp the first and/or second sections of joinery to the connector. This could be accomplished by way of a press tool applying pressure against the 25 first and/or second sections of joinery to the extent that it breaks the surface of the joinery and forces a portion of same into the connector.

The connector may be made of any suitable material as required or as desired, or as dictated by the intended use of the joinery. For example, the connector may be comprised of wood or plastic or metal. It is envisaged that plastic may be a preferred material given that the connector could be readily made, in a consistent 5 manner, for example by the use of injection moulding techniques.

To assist in retaining the connector to the first and second sections of joinery, there may be provided one or more recesses in the connector. The recesses may preferable be adapted to align substantially with the one or more crimping teeth of the crimping means once the connector has been connected to the first and 10 second sections of the joinery and prior to the crimping means being actuated.

In one embodiment, the recesses may be slightly misaligned in respect of the crimping teeth, so that as the crimping teeth bite through the joinery they engage an edge of the recess, and as the crimping teeth bite down further it will be appreciated that it will have a pulling effect on the connector by virtue of the 15 misalignment. Preferably, the recesses in the connector may be positioned so as to be slightly closer as to the join whereby the act of crimping also forces the first and second sections of joinery together and/or serves to place pressure on the join, therefore ensuring a snug, tight and strong join.

In another embodiment, the recesses may be angled to assist in the crimping teeth 20 entering same recess and also to assist in the action of forcing the first and second sections together (assuming that the recesses are slightly misaligned with the crimping teeth, as described above).

In such an embodiment, the crimping teeth may be similarly shaped (that is, to match the shape or cross-section of the angled recesses) to assist in the crimping 25 and also in the forcing together of the first and second sections of joinery about the join. 11 The connection system may further include sealing means to create a seal between the first and second sections of joinery. The creation of such a seal serves to waterproof the join.

For example, a suitable sealant could be spread around the underside and edges 5 of the join, although as described previously this can sometimes be a messy process and can be wasteful with regards to the amount of sealant used.

In another embodiment, the connector may be provided with a pathway cavity which may preferably follow the contour of the underside of the join between the first and second sections of joinery. Such a pathway cavity may be accessed by 10 any suitable means such as a hole or valve or similar facility that allows for sealant to be forced into the pathway cavity (for example by pumping, injecting or by the use of a sealant gun).

The pathway cavity may preferably be provided with an egress hole (or holes) at its end so that it can be seen when enough sealant has been applied, that is, sealant 15 will be forced out of the egress hole one the pathway cavity is adequately filled throughout.

Any suitable method for connecting the first and second sections of joinery, utilising the connection system as described above, may be utilised as required or as desired. For example, the connector may be manually fitted to the first and 20 second sections of joinery, the crimping means may be applied manually by the use of a suitable press tool, and the sealant may be applied either manually or automatically.

In one embodiment the first and second sections of joinery may be joined to the connector about or with the use of a suitable mitre. Use of such a mitre will ensure 25 that a consistent angle between the first and sections of joinery (usually 90°) is achieved each time. Furthermore, the use of such a mitre will ensure that there is a 12 tight fit between the first and second sections of joinery. It is envisaged that when the first and second sections of joinery are being joined to or about the connector they may also be clamped together in position.

Preferably, the operation of crimping and sealing may be conducted automatically, 5 with the sealing step immediately following the crimping step. For example, an automated station could be utilised which securely holds the first and second sections of joinery together about the connector, and at the desired or required angle. The crimping means may then be actuated, followed immediately by the application of the sealant into the pathway cavity of the connector.

The step of applying the sealant could be preset so that sealant is forced into the pathway cavity for only a set period of time, which will usually be in the range of 5 - 25 seconds depending on the type of sealant used, its viscosity, humidity and/or temperature.

It would readily be able to determine how long is required for any particular sealant 15 because as soon as sealant it seen to exit the egress hole at the end of the pathway cavity it will be apparent that enough sealant has been applied. Once this period of time has been determined the automated crimping/sealing step/apparatus could then be set to this length of time for joining all other sections of joinery that are to be joined at the same time.

In a further embodiment, the corner connector could have a foam sealant product set into the pathway cavity prior to the connector being introduced to the first or second sections or joinery. This foam sealant may preferably be compressed between the join that is formed between the first or second sections of joinery. This foam sealant may preferably be compressed between the join that is formed 25 between the first section of joinery and the second section of joinery, thereby creating a method of joining that is free of any excess sealant needing to be cleaned off the joinery. This is beneficial in reducing assembly times for the 13 manufacture of window and door frames.

The connector could have a foam sealant pad applied to the cut end of the first section of joinery and/or the cut end of the second section of joinery before being introduced into the connector. This foam sealant pad may preferably have been 5 shaped to match the profile of the cut ends of the first and/or second sections of joinery ensuring an effective coverage over the cut ends. This foam sealant pad would be compressed between the first and second sections of joinery when the crimping step takes place. This method of sealing the join is free of any excess sealant needing to be cleaned off the joinery. This is beneficial in reducing assembly times for the manufacture of window or door frames.

The connection system and/or connector may be further provided with a drainage cavity to collect and disperse any water or condensation. Any suitable drainage cavity may be utilised as long as it is effective in collecting and dispersing any water or condensation.

For example, the connector may be provided with a drainage cavity to collect and disperse condensation which is deliberately directed into the connector through a hole in the condensation channel on the inside of the window or door frame.

The connector may also be provided with egress ports for the dispersal of condensation and/or water collected because of a join failure.

In particular, in the event of moisture managing to find its way past (or through) the join formed by the fluid sealant between the first and second sections of joinery with the connector (in the pathway cavity/channel region), the moisture is advantageously confined and directed by a drainage means into the connector, collected and subsequently drained out of the connector via drainage ports.

In this modified form of the connection system over the main invention, and as 14 illustrated in the drawings, fluid sealant is specifically not intended to be applied to the rear of the connector and to instead substantially remain within the upper surface pathway cavity/channel of the connector arms.

The said connector may also be provided with a swing flap located in the portion of 5 the connector that engages into the sill member of the frame. This flap may hang in a near perpendicular position due to gravity, but the bottom edge of the flap may be retained slightly off perpendicular. Preferably this may be by way of a small pip on the bottom edge of the flap to keep the flap slightly off perpendicular (open). When the wind flow or air pressure is substantial enough this flap swings to a 10 position varying somewhere between near perpendicular and near horizontal. When the flap is at a full horizontal position during moments of high wind flow or air pressure it has reduced the risk of water "blowing back" through the hole in the condensation channel, as the flow of air that would normally cause this "blow-back" has effectively been stopped. Wind occurs in gusts that would seldom see this flap 15 in the full horizontal (closed) position for any great length of time, hence during moments of reduced wind gusts the flap will "open" back towards the more perpendicular position allowing any water with-in the drainage cavities to escape via the egress port. & The connector may be used without the flap described above should the joinery be 20 situated in a geographical area that does not experience wind speeds that necessitate the use of the flap.

The sill frame member may have an outlet hole punched or drilled to align with the egress port in the connector, this hole may be positioned at the lower front face of the sill frame member or alternatively on the underside of the sill frame flange.

Each end of the connector may have a raised flange on each end. This creates a catchment area to capture any water that may penetrate over the head flashing, flowing along the head of the window and down the jambs.

Each end of the connector may be partially open at the catchment area so that water captured form the head or jambs of the frame can be directed into the connector at the bottom corners of the window for dispersal to the outside through the egress port.

BRIEF DESCRIPTION OF DRAWINGS Further aspects of the present invention will become apparent from the ensuing description that is given by way of example only and with reference to the accompanying drawings in which: Figure 1 is an top perspective view of one possible embodiment of the 10 present intention, Figure 2 is a bottom perspective view of the embodiment shown in Figure 1, Figure 3 a rear semi-elevation view of the same embodiment illustrated in Figures 1 and 2, Figure 4 is an underneath perspective view of the embodiment illustrated in 15 Figures 1 -3; and Figure 5 is a simplified schematic view of a work station for use in connecting joinery.

BEST MODES FOR CARRYING OUT THE INVENTION Having regard to Figure 1, there is shown a connection system for connecting 20 joinery, the connection system being generally indicated by arrow 1. No joinery sections are shown in any of Figures 1-4, however the first and second sections of joinery slide over and along the arms 2, 3 of the connector 1. The connector has a profile or shape which the sections are able to be located around, and in which the 16 connector is able to slide into the profile and shape of the joinery section.

The connector has a pathway 4 which is adapted to receive a fluid sealant and is in the form of a channel (also illustrated as 4) which is formed between the profile or shape of the joinery section and the profile and shape of the connector 1 itself. 5 The channel is ideally formed between the connector 1 and the sections of joinery (not shown).

The pathway 4 is accessible via an ingress aperture 5, and exitable via an egress aperture 6. The egress aperture is located at the distal end 7 of the pathway 4 from the ingress aperture 5.

The pathway 4 is configured to have a larger cross-sectional area, generally indicated by arrow 8 at the proximal end 9 of the pathway 4, which then tapers or is shaped to converge to a smaller cross-sectional area generally indicated by arrow 10, at the distal end 7.

As illustrated in Figures 1 and 2, adjacent and substantially in-line with the ingress 15 aperture 5 is a fluid flow director or directing means 11. The fluid flow director 11 directs fluid (such as adhesive or a similar sealing-type fluid) once flowing into said pathway via said ingress aperture, into an arm or arms 2, 3 of said pathway 4. The pathway 4 is located upon the upper surface of the connector arms 2, 3. Advantageously the curved and/or shaped pathway allows fluid to flow more easily 20 through and along the channel/pathway 4 before then exiting at the egress aperture 6.

This shaped and curved channel ideally has enhanced fluid flow characteristics beyond a simple pathway which follows a contour or direct profile of a joinery section. For example, the pathway illustrated in the main invention is linear and 25 corners are relatively perpendicular, whereas when fluid (generally speaking) is required to traverse a corner in the pathway/channel 4, the present invention 17 provides a more gradual or curved shape for the fluid to more easily follow (with the exception perhaps of the line which the fluid must follow when exiting the pathway/channel via the egress aperture 6.

The ingress aperture in the present invention is relocated to be substantially in-line 5 and adjacent to the flow direction means 11, as illustrated in Figures 1 and 2. In the main invention, this ingress aperture was not required to be located generally adjacent or in-line with the flow directing means 11, or in such close proximity to the pathway/channel 4. In the present invention, this relocation or ingress aperture 5 allows for a generally reduced amount of fluid sealant or adhesive needing to be 10 injected or introduced into the pathway in order to create a useful seal between the connector 1 and joinery sections (not shown).

Generally, once the first and second sections of joinery have been engaged by the connector a join is formed, in that, the sections are substantially held in position and located by the connector. The joinery sections may comprise the corner of an 15 aluminium window frame. Furthermore, the connector 1 is comprised of a plastic material, for example a glass-reinforced nylon, or high density polyethylene or other materials which can be moulded or shaped as necessary.

The connection system and connector 1 also includes a retention means in the form of a crimping system. The connector 1 is provided with a number of recesses 20 12. In total, each side of the connector is provided with four recesses 12, giving a total of eight recesses all together, although of course more or less recesses may also perform a suitable crimp and retention means. As illustrated, ideally the recesses 12 are angled indentations.

The crimping system further includes crimping means (not shown) which have a 25 series of angled crimping teeth and which are adapted to crimp the first and second sections of joinery to the connector 1 in the region of the recesses 12. 18 The crimping system's teeth bite into the section of joinery and push a portion of the section of joinery down into the recesses 12.

Although not illustrated, the arrangement and construction of the crimping system is such that the recesses 12 are aligned slightly closer to the joined corner, this 5 region indicated by arrow 13, of the joinery sections than the exact spot where the crimping teeth are to bite into the sections of joinery. Accordingly, this should allow the action of crimping to force the first and second sections of joinery together in a direction toward the corner joint 13.

In the embodiment shown, a preferred misalignment of the crimping teeth with 10 respect to the recesses 12 would be approximately 1 - 2mm.

The connection system 1 further includes sealing means to create a seal between the first and second sections of joinery. The sealing means is in the form of an ingress aperture 5 formed in the connector 1 which leads to a pathway 4 formed in the connector.

In the main invention, the sealant was required to be injected and be forced to travel along a cavity channel/pathway on the underside of the connector, around the back of the connector (still in the pathway) and finally reach the channel/pathway formed in the connector across the top surface of the connector arms 2, 3.

However, in the present invention, as the ingress aperture 5 has been relocated, the fluid sealant can be injected almost directly to the top surface of the connector to thus form a sealed joint between the joinery sections and the connector. In various alternative embodiments of the present invention, joint sealants or other adhesives may be initially also applied to surfaces on the joinery sections which 25 will contact with the connector 1 in order to further created a joint between the joinery sections and the connector. 19 As in the main invention, the pathway/channel splits into two separate channels across the top of each arm 2, 3. Each of these are provided with an egress hole 15. Ideally fluid sealant is introduced or injected into the ingress aperture so that the fluid completely or substantially fills the pathway 4 between the connector and 5 the joinery sections surrounding it, and any excess sealant exits the pathway via egress aperture 6.

Once sealant is observed oozing or flowing out of the egress aperture, fluid sealant should no longer be injected into the pathway 4 as is should be an indication that sealant has filled the pathway cavity.

With reference to figure 1 it can be seen that there is an area of the connector 1 that leaves a gap 15 between the connector 1 and a section of joinery. This gap 15 is to allow any water that might enter the window frame system at the head of the window (due to pressure forcing water up under the head flashing or the likes), or condensation accumulated within the joinery section itself, to run down the jambs 15 of the window and into the connector 1 drainage cavity. A raised edge 16 captures the water and diverts it through gap 15 into a drainage cavity (not shown) where it enters cavity 16 and eventually exits via the drainage system consisting of a port or aperture 17.

A swing-flap (not shown) optionally can be formed or positioned to cover the port 20 17 to help prevent "blow-back" of liquid which usually drains out of the port 17 back into the drainage cavity/connector as a result of wind.

The design and configuration of the rear of the connector allows for any liquids which drain or enter into the connector to more easily flow to a port or aperture 17 for subsequent drainage. Compared to the main invention, the present invention 25 no longer has a sealed (or joint formed) section which is formed and which is continuous along the rear inside edge of the connector, as a result of introducing fluid sealant into the pathway cavity. As a result of the improved present invention, fluid sealant no longer is required to travel around the rear inside of the connector (at the corner section of the connector) as it is introduced via ingress port which has been relocated to be substantially adjacent and in-line with the pathway/channel 4.

Moisture pathways 18 and 19 illustrate possible pathways moisture may take in draining through the connector and exiting via a drainage port. Pathway 19 in particular shows the flow path which errant moisture may take if it manages to evade or find its way past the fluid sealant join between the joinery sections and connector (and for which the present invention is designed to cope with). The 10 modified drainage system of this invention helps to confine and direct moisture which negotiates the fluid sealant join/seal - especially by providing the drainage means 20.

This modified system has been advantageously designed to cope with errant water which approaches or enters the connector in the event of a fluid sealant joint 15 failure.

The system and work station used for crimping a section of joinery onto the connector via recesses 12 remains the same as for the main invention, and is reiterated below, and illustrated in Figure 5.

(A) CRIMPING / SEALING WORK-STATION DESIGN Scope The concept is based around providing a consistent method of assembling and sealing window or doorframes at the mitred corners. The result is expected to be a very high quality mitred join that has been produced in a time that reflects significant labour savings and a very high "leak resistant" joint. Also adding to the 25 labour savings and offering material savings is the automated sealing process, it is 21 proposed that this will measure an accurate amount of sealant to fill the special designed cavity with-in the connector to the point that sealant is forced to expose itself out the "tell tale" egress holes. It is also desirable that the pressure will also force the sealant to expose itself in the form of a small beading of sealant being 5 visible along the inside platform of the frame, thus ensuring that sealant has forced itself between the cut ends of the mitre.

The size of window frames varies considerably and the following outlines the common variations: Say largest window = 2.4M high x 5.0M wide 10 Say smallest window = 300mm high x 300mm wide Say average size = 1.2M high x 1.6M wide Description of the design and procedure The workstation consists of one fixed bench "B" that has the crimp unit and sealant applicator mounted on to the base of "A". The crimp unit consists of eight punch 15 heads that match the shape and position of the recesses in the nylon corner connector. The sealant applicator is cylinder shaped and accepts a standard cartridge of sealant (3M Scotch Seal 5300 as an example). This cartridge screws into the bottom of the cylinder, which is linked to a nozzle. The cylinder has a cap screwed onto the top of it; this cap is linked to a compressed air line, which forces 20 the sealant through the nozzle when activated. A set of clamp jaws (E) are mounted in a recessed position under bench "B", these jaws rise up vertically and then move horizontally towards the mitred corner of the frame, clamping the corner firmly, the jaws are designed to apply a force to the frame members that ensures the mitred joint is held firmly together before the crimping action happens.

Assembly Process 22 Commence assembly of a four sided window. This is done by using table "B" with table "D" positioned at a place on the track system that suits the size of the window and where necessary also employing the telescopic extension arms "C" to support the frame. (It is envisaged that on a house lot a process of working from the 5 smallest window up to the largest would be used to minimize the activity needed in changing table "B" position and the telescopic arm positions.) Note that it is envisaged the frame might be fully assembled as a 4 sided frame before introducing any of the corners to the crimping head, or alternatively the crimping head could be actively crimping one corner whilst the operator is busy assembling 10 another corner with a connector. This latter method would be more economical because the operator is being productive whilst the machine is going through the clamping, crimping and sealing cycle.

Crimping/ Sealing Process After the frame is assembled (either as a four sided frame or by doing just the one 15 corner at a time) it is introduced into the crimping machine, one corner at a time. The machine crimps and seals with-in the same action. The process happens in the following order: (a) The clamping jaws (E) rise up from their "sub table" position and immediately move horizontally towards the mitred corner assembly, the jaws clamp the corner assembly against the 90-degree fence that forms part of the table assembly and immediately apply a sideways force that ensures the mitres are firmly mated together. (b) The crimping head then moves downwards, clamping the frame corner and piercing (crimping) the aluminium extrusion at positions that match the recesses in the nylon corner connector. (c) The sealant applicator cylinder moves inwards with the crimping head 23 assembly and the nozzle is introduced to the injection hole in the corner connector immediately after the crimping action has happened. Sealant is forced under pneumatic pressure into the injection hole where it travels along the pathway cavity in the corner connector, finally showing itself out 5 of the "tell tale" hole at the inside corner of the connector. (d) The sequence described in A, B and C all happens in a time frame of around 15 seconds. The machine is set to reverse these sequences immediately the sealing action has been completed. When the clamp returns to the "sub table" position the machine is ready to have the next 10 frame corner introduced. Note that the clean up time with regards to excess sealant is expected to be minimal due to the design of the corner connector component and the manner in which the frame assembly is clamped during the crimping and sealing process.

Aspects of the present invention have been described by way of example only and 15 it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof. 24

Claims (23)

WHAT WE CLAIM IS

1. A connection system for use in connecting joinery comprising: (d) a first section of joinery, (e) a second section of joinery both the first and the second sections of joinery having a profile formed therein, and (f) a connector, said connector having first and second arms which interconnect, said arms having an upper surface, 10 the arms being adapted to engage with the profiles formed in said first and second sections of joinery, so that, in use, the connector engages the first and second sections of joinery, and wherein a pathway adapted to receive a fluid sealant is provided by a channel formed in the upper surface of said first and second arms between said connector and said first section of joinery, and between said connector and said second section of joinery, the pathway being accessible via one or more ingress apertures and exitable via one or more egress apertures, an egress aperture being located at the distal end of the pathway from the ingress 20 aperture, and wherein in use, the fluid sealant forms a seal in the plane of the arms' upper surface, between the first and second sections of joinery and the 25 connector, wherein moisture which negotiates its way past the seal and into the connector is substantially confined and directed by drainage means.

2. A connection system as claimed in claim 1, wherein the pathway is 5 configured to have a larger cross-sectional area at the proximal end of the pathway tapering to a smaller cross-sectional area at the distal end.

3. A connection system as claimed in claim 1 or claim 2, wherein adjacent and substantially in-line with the ingress aperture is a fluid flow director.

4. A connection system as claimed in claim 3, wherein said fluid flow director 10 directs fluid once flowing into said pathway via said ingress aperture into an arm or arms of said pathway.

5. A connection system as claimed in any one of claims 1 to 4, wherein the profile formed in the first and/or second sections of joinery is in the form of a shaped channel. 15

6. A connection system as claimed in any one of claims 1 to 5, wherein said connector is adapted to slide into and/or along said profiles.

7. A connection system as claimed in any one of claims 1 to 6, wherein said connection system also includes retention means to secure the connector to the first and/or second sections of joinery. 20

8. A connection system as claimed in claim 7, wherein said retention means is provided by, or in the form of, a crimping system.

9. A connection system as claimed in claim 8, wherein said crimping system includes crimping means having one or more crimping teeth which, when the 26 crimping means is actuated, are adapted to crimp the first and/or second sections of joinery to the connector.

10. A connection system as claimed in claim 9, wherein the connector is provided with one or more recesses, said recesses being adapted to align 5 substantially with the one or more crimping teeth of the crimping means.

11. A connection system as claimed in claim 10, wherein the recesses are slightly misaligned with respect to the crimping teeth.

12. A connection system as claimed in claim 10 or claim 11, wherein the recesses in the connector are positioned so as to be slightly closer to the join, whereby the action of crimping also forces the first and second sections of joinery together.

13. A connection system as claimed in any one of claims 10 to 12, wherein the recesses are angled indentations.

14. A connection system as claimed in claim 13, wherein the crimping teeth are angled protrusions adapted to substantially match the angled indentations in the connector.

15. A connection system as claimed in any one of claims 1 to 14, wherein the fluid sealant introduced into the pathway creates a seal between said first and second sections of joinery. 20

16. A connection system as claimed in any one of claims 1 to 15, wherein said fluid sealant is injected into the pathway via the ingress aperture.

17. A connection system as claimed in any one of claims 1 to 16, wherein said connector is further provided with a drainage cavity to collect and disperse water or condensation. 15 27

18. A connection system as claimed in claim 17, wherein said connector is shaped to include a gap between the connector and the first and second sections of joinery, the gap communicating with said drainage cavity allowing water or condensation to exit via an aperture in the connector. 5

19. A connection system as claimed in claim 17 or claim 18, wherein the drainage cavity connector aperture is provided with a swing-flap adapted to prevent blow-back of water or condensation into the drainage cavity.

20. A connection system as claimed in any one of the preceding claims, wherein said first and said second arms are substantially orthogonal to one another.

21. A connection system as claimed in any one of the preceding claims, wherein said first and said second arms interconnect to form a corner.

22. A connection system substantially as herein described and as illustrated with reference to any one of Figures 1 to 4.

23. A connector for use with the connection system as herein described and as illustrated with reference to any one of Figures 1 to 4. WINDOW TECHNOLOGIES LIMITED by its Attorneys JAMES & WELLS