WO1999032750A1

WO1999032750A1 - Window or door frame

Info

Publication number: WO1999032750A1
Application number: PCT/AU1998/001042
Authority: WO
Inventors: Arthur De Bono; Glenn Michael Bevan; Leonard Mckeown; Simon Floyd; Dominic Lamanna; Edward Kayser; Ross Doonan; Greg Wicks
Original assignee: James Hardie Research Pty. Limited
Priority date: 1997-12-19
Filing date: 1998-12-18
Publication date: 1999-07-01
Also published as: TW405012B; AUPP104397A0; NZ505398A

Abstract

A frame element (3) for use in a window or door frame, the frame element including: a longitudinal frame portion (14) and a longitudinal retaining formation (6, 8) associated therewith, the retaining formation (6, 8) being configured to retain a longitudinal edge (15) of a generally planar building panel (2) such that the edge (15) is disposed between the lateral edges (26, 27) of the frame portion (14) wherein the building panel forms a surround adjacent the frame element (3) when installed.

Description

WINDOW OR DOOR FRAME

FIELD OF THE INVENTION

The present invention relates generally to a new wall opening surround structure

and to an associated method of construction. The invention also relates to

improvements in window and door frame elements specifically designed for

installation with a wall opening surround structure of this kind.

BACKGROUND OF THE INVENTION

Hollow extruded aluminium, PNC or steel door and window systems have been

in use for many years as a durable, relatively low cost alternatives to their wooden

equivalents. However, whilst there are a number of high quality products which are

relatively appealing in an aesthetic sense, there is a general perception amongst the

public that windows and doors of this kind often look "cheap" because of their small

frame cross section sizes compared to those having profiled timber frames.

The problem is exacerbated where the window or door is installed in a dwelling

clad with plank siding or fibre cement sheeting and the like, since, because of the lack

of thickness in the wall which gives more interior room space, it may be difficult to

recess the frame into the wall to provide an aesthetically pleasing surround or reveal.

Brick clad wall constructions, on the other hand, are particularly suited, due to their

thickness, to formation of deep inset external reveals that effectively frame the

window or door opening, which is a factor in the perceived aesthetic superiority of

masonry dwellings over plank or sheet clad dwellings. While special preformed

surround elements may be used in clad dwellings, such componentary is usually

expensive and/or labour intensive to install. Furthermore, the preformed surrounds or trim units are commonly installed such that they simply abut the frame like picture

frames fastened to the cladding. Installation of such trim units requires that an

appropriate sealant be meticulously applied at the junction between the frame and the

surround to ensure an adequate weather seal. These factors add to the time and cost of

construction.

It is an object of the present invention to provide a new wall opening surround

structure, and an optionally associated improved system of window/door frame

elements particularly suited for installation with the new surround structure, which

overcomes or ameliorates one or more of the above disadvantages of the prior art, or at

least offers a useful alternative thereto.

In this regard, the term "surround" will be used herein to refer to any structure

around a wall opening such as a door or window which includes within its scope an

internal or external reveal or surround for the sill, jamb and head elements of the

window or door frame. However, the term "surround" as used herein excludes any

paneling or structural members of the wall itself.

With any window or door structure, it is most important for structural, sealing

and aesthetic purposes, that the window or door frame elements be neatly and

accurately connected with the opening surround structure. For these reasons, and to

minimise the skill level required for installation, a new window/door frame element

has been developed.

DISCLOSURE OF THE INVENTION

Accordingly, the present invention provides a frame element for use in a

window or door frame, the frame element including a longitudinal frame portion, and a longitudinal retaining formation associated therewith, the retaining formation being

configured to retain a longitudinal edge of a generally planar building panel such that

the edge is disposed between the lateral edges of the frame portion, wherein the

building panel forms a surround adjacent the frame element when installed.

Preferably, the retaining formation is configured such that, when installed, the

building panel forms a reveal which extends generally away from the window or door

frame.

Desirably, the building panels comprise sheets of fibre reinforced cement (FRC)

or steel. However, in some applications the internal reveals may also be made from

timber or plasterboard.

In some forms, the frame element retaining formation defines a longitudinal

channel to retain the longitudinal edge. Preferably, the channel is configured to retain

the longitudinal edge by means of a close or sliding fit. In other embodiments, the

interior walls of the channel may include one or more raised formations, such as

longitudinal ridges, to optionally receive alternative clip in components. In a

particularly preferred embodiment, the ridges are configured to allow snap-fit

interconnection of the retaining means with another window element.

Desirably, for exterior window and door surrounds at least one edge adjacent the

channel incorporates a sealing strip which, in use, abuts the building panel to reduce

the ingress of moisture or drafts.

In one embodiment where the surround is configured to form a sill oriented so as

to be generally outwardly and downwardly inclined on installation. The surround is

conveniently fabricated by adhering sheets of fibre reinforced cement directly onto a preformed core element of expanded polystyrene foam or the like. Desirably, the

sheets of fibre reinforced cement are adhered to the core element by means of a

suitable contact adhesive. Preferably, an epoxy based adhesive is used at the corners

to join the fibre reinforced cement sheets, as this is both weather resistant as well as

providing a strong joint. Alternatively, the corners may be sealed using a suitable

flexible acrylic, silicone or siliconised acrylic or other resilient weather resistant

compound.

In other embodiments, the building panel is back filled with a suitable filling

material such as a formaldehyde based foam, or light weight aggregate concrete etc.

It will be appreciated by those skilled in the art, that the novel wall opening

surround structure of the invention facilitates a very cost effective means of providing

a window, door or other wall opening surround structure, that may be conveniently

sealed against wind and rain driven moisture, has the aesthetic appeal of a masonry or

full timber structure and yet is completely compatible with most clad dwelling

structures as well as brick.

In one form the retaining formation is formed integrally with the longitudinal

frame portion. However, in other embodiments, the retaining formation is formed

separately from the longitudinal frame portion, and in this embodiment, is configured

for attachment thereto prior to or during installation. In this embodiment, the retaining

formation is preferably attached to the longitudinal frame portion prior to installation,

using, for example, rivets, screws, an interlocking clip system or adhesive. In one preferred embodiment, a pair of retaining formations are provided to

retain internal and external building panels respectively. The building panels, when

installed, define corresponding internal and external reveals.

In the preferred embodiments of the invention sheets of fibre reinforced cement

are used having a thickness of between 3mm and 20mm.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects of the invention will now be described, by way of example only,

with reference to the accompanying drawings in which:

Figure 1 is a cross sectional view of the sill portion of a window surround

structure according to the present invention;

Figure 2 is a cross sectional view of the head portion of a window surround

structure according to the present invention;

Figure 3 is a cross sectional view of a jamb portion of a window surround

structure according to the present invention;

Figure 4 is a cross sectional view of a window surround structure in accordance

with the invention utilising a window frame element having an integral retaining

formation;

Figure 5 is a cross sectional view illustrating two alternative embodiment

window surround structures in accordance with the invention used in association with

two alternative window frame elements;

Figure 6 is a sectional view of a further embodiment window surround structure

according to the invention in association with a further embodiment of a suitable

frame element; Figure 7 is a perspective view of another window surround structure in

accordance with the invention in association with a further embodiment of a suitable

frame element;

Figure 8 is a transverse sectional view of the assembly shown in figure 7;

Figure 9 is a perspective view of another window surround structure in

frame element;

Figure 10 is a transverse sectional view of the assembly shown in figure 9.

Figure 11 is a perspective view of another window surround structure in

accordance with the first aspect of the invention in association with a further

embodiment frame element in accordance with the second aspect of the invention; and

Figure 12 is a transverse sectional view of the assembly shown in figure 11.

PREFERRED EMBODIMENT OF THE INVENTION

Referring to figure 1 there is shown a transverse sectional view of the sill

portion of a window opening including a structural wall support member 1 to which is

secured an external surround structure 2 and a window frame element 3. The frame

element 3 is fixed to an elongate timber wedge section 8 via fixing elements 7 secured

through nailing fin 6. Wooden packing 9 is placed between the timber wedge 8 and

the wall support 1 to accurately position the frame element 3. Fixing elements (not

shown) extend through the timber wedge 8 into the wall support 1 to secure the frame

to the wall. Surround 2 is retained between the timber wedge 8 and the frame element

3 such that its longitudinal edge 15 is positioned between the lateral edges 26, 27 of

the frame portion 14 of the frame element 3. Given the normal drainage characteristics of wind driven rain, by concealing the longitudinal edge 15 between the

lateral edges of the frame portion 14 an effective weather seal against the ingress of

moisture may be conveniently formed. Furthermore, this configuration allows the

surround to be secured to the frame element with fixing elements in a simple and time

efficient manner. Obviously, this ultimately reduces the overall construction costs.

Construction of the wall may also conveniently include the injection of

expanding polyurethane foam into the cavity formed between the frame element 3 and

wedge 8 into which is embedded the surround 2. Further sealing is provided by a

water proof membrane 5 fitted beneath the sill surround 2 and extending between the

sill surround 2 and the external wall panel 11. For aesthetic purposes an outer coating

or rendering 4 may be applied to the external surface of the sill surround 2 and

external wall panel 11 which in turn conceals a 25 mm concrete render 17 in

accordance with the applicant's Australian copending Provisional Patent Application

No. PO7347.

On the interior of the wall, the frame element 3 is fixed to timber trim 13

through fixing elements (not shown) secured to the nailing fin 6 or wedge 8. The trim

13 includes a rebate formed to receive the interior panel 12 and the join between the

interior trim 13 and panel 12 is concealed by architrave 10.

Figures 2 and 3 show sectional views of the head and jamb respectively. In

these figures, the same reference numeral has been used to indicate corresponding

parts. Frame element 3 is fixed to elongate wooden section 18 with fixing elements

(not shown) secured through nailing fin 6. This presents a formation in which

surround 20 is retained such that its longitudinal edge 15 is concealed between the lateral sides of the frame portion 14 of the frame element 3. As with the sill shown in

figure 1, the cavity between the frame element 3 and the surround 20 may be filled

with expanding polyurethane foam 16. Furthermore, the aesthetics of the windows

surround may be improved with an external coating 4. Exterior wall panel 11 and

interior wall panel 12 are fixed directly to a structural element of the wall 1 and may

be provided with insulation 19 sandwiched between them. Again a rebated interior

wooden trim 13 abuts the frame element 3 such that the rebate engages the edge of the

interior panel 12. Architrave 10 conceals the join between the trim 13 and the panel

12.

As with the sill section shown in figure 1, the head and jam sections are also

configured such that an effective weather seal may be provided between the frame

element 3 and surround 20.

Referring to figure 4, there is shown a transverse sectional view of a window

opening including a structural wall support member 1 to which has been secured an

external surround structure 2 and a window frame element 3 in accordance with the

invention and an internal wall facing 4.

The surround structure 2 comprises an elongate angle or channel element shown

generally at 5 defining a first surface 6 that extends generally away from the plane of

the opening 7 and a second surface 8 that is contiguous with a distal edge 9 of the first

surface 6, the second surface extending in this particular embodiment in a direction

generally parallel to the plane of the opening 7. These first and second surfaces are

defined by interconnected sheets of durable sheet material such as fibre reinforced

cement (FRC) or steel. In the embodiment shown in figure 4, the surround structure 2 also defines a

third surface 10 that extends from an edge 11 of the second surface remote from the

first surface, so as to return generally inwardly toward the wall surface 12 adjacent the

window opening. In this manner the resulting structure is generally channel shaped in

cross section with side elements of uneven depth defining externally a rebated

surround with a solid appearance resembling that of equivalent masonry or wooden

structures.

Turning next to the longitudinal frame element 3, it can be seen to have an inner

surface 28 adjacent the window, light or sash and an outer surface 14 disposed

adjacent the wall structural member 1 partly defining the wall opening. Provided

adjacent one or both of the outside and inside edges 26 and 27 are retaining formations

17 and 18.

Referring firstly to the outside retaining formation 17, it can be seen that in this

preferred form it comprises a channel like structure which is adapted to locate by

preferably a sliding fit a longitudinal edge of a generally planar building panel such as

that defining the first surface 6 of the window/door surround 2. In this manner, a neat,

weatherproof and fast jointing of the frame element to the surrounding structure is

readily achieved.

In this particular embodiment, the internal retaining formation 18 engages a

"clip in" trim element which is adapted to extend from the frame element 3 to the

internal wall facing 4. To facilitate the attachment of such "clip in" fixtures, the

retaining formation or channels of this particular embodiment include longitudinally

extending fastening ridges shown generally at 20. Referring next to figure 5, there is shown a vertical section through the upper

and lower wall sections of a window opening in a clad dwelling structure, and

wherever possible, like reference numerals are used to denote corresponding features.

This particular figure illustrates the use of two separate types of frame element, the

upper adapted to facilitate construction of a generally horizontally extending generally

rectangular sectioned surround structure, of the kind shown in figure 4, whilst the

lower frame element is configured to engage directly with a surround structure in the

form of a sill, both surround structures being fabricated in accordance with a first

aspect of the invention. In the case of the sill, the first surface 6 is inclined generally

outwardly and downwardly from the window opening and the second surface 8

extends inwardly and downwardly so as to be inclined back towards the lower wall

surface 12.

As described above, the upper surround structure and sill structure are preferably

fabricated by adhering sheets of fibre reinforced cement directly onto a preformed core

element 24 of expanded polystyrene foam or the like. Alternatively, the structure

maybe hollow. Where a preformed core element is used, the sheets of fibre reinforced

cement are preferably adhered to that core element by means of a suitable contact

adhesive. However, an epoxy based adhesive is preferred for use at the comers to join

the fibre reinforced cement sheets, as this is both water resistant as well as providing a

strong joint. Alternatively, the comers maybe sealed using a suitable flexible acrylic,

silicone or siliconised acrylic or other resilient weather resistant compound. In other embodiments that are not illustrated herein, the interconnected angle or

channel-like outer surround structure is back filled with a suitable filling material such

as a formaldehyde based foam or light weight aggregate concrete etc.

Turning next to figure 6, there is shown yet a further variation of both the

surround structure and the frame element as applied once again to a clad dwelling. In

this particular embodiment, the external retaining formation 17 is formed in the frame

element 3 by means of separately manufactured frame element 21, in the form of a

simple angle section, which is secured to the main frame element 3 by any suitable

manner such as riveting as shown. In this case, the frame element 3 is attached to an

internal timber reveal 22 which in turn is connected to the structural wall support

element 1 which may be a timber or steel stud.

Turning next to figures 7 and 8, there is shown yet a further variation on the

same theme. In this particular embodiment, the outside retaining formation 17 of the

frame element 3 is formed as part of a separate slot in mounting element 23 thereby

enabling the same outer frame sill element 3 to be used in numerous applications by

substitution of different mounting elements 23. The versatility of such an arrangement

is clearly illustrated in the remaining figures 9 to 12 which illustrate how the same

basic frame element 3 can be readily adapted for brick veneer structures incorporating

a plaster board return 25 (as shown in figures 9 and 10), or brick veneer structures

incorporating a timber reveal 22 (as shown in figures 11 and 12).

The present invention provides a quick and cost effective way of forming a wall

opening surround such as a reveal or sill around a window or door frame, which may

relatively inexpensively simulate a solid masonry equivalent and yet maintain a configuration that is easily sealable against the ingress of moisture. Further, by

coupling this structure with a preferred frame structure in accordance with the second

aspect of the invention, accurate and neat interconnection of the window or door frame

to the adjacent surround structure is greatly simplified.

Although the invention has been described with reference to a number of

specific embodiments, it will be appreciated by those skilled in the art that the

invention may be embodied in many other forms.

Claims

1. A frame element for use in a window or door frame, the frame element

including:

a longitudinal frame portion and a longitudinal retaining formation associated

therewith, the retaining formation being configured to retain a longitudinal edge of a

generally planar building panel such that the edge is disposed between the lateral

edges of the frame portion wherein the building panel forms a surround adjacent the

frame element when installed.

2. A frame element according to claim 1 wherein the retaining formation defines

a longitudinal channel to retain the longitudinal edge of the building panel.

3. A frame element according to claim 2 wherein the channel is configured to

retain the longitudinal edge by means of a close or sliding fit.

4. A frame element according to claim 2 or claim 3 wherein the interior walls of

the channel include one or more raised formations.

5. A frame element according to claim 4 wherein the raised formations are

longitudinal ridges adapted to receive complementary clip in components or allow

snap fit interconnection of the retaining formation with a complementary window

element.

6. A frame element according to any one of claims 2 to 5 wherein at least one

edge of the channel incorporates a sealing strip which in use abuts the building panel

to reduce the ingress of moisture or drafts.

7. A frame element according to any one of claims 1 to 6 wherein the retaining

formation is configured such that when installed, the building panel forms a reveal

which extends generally away from the window or door frame.

8. A frame element according to any one of claims 1 to 7 wherein the surround

is configured to form a sill oriented so as to be generally outwardly and downwardly

inclined on installation.

9. A frame element according to any one of claims 1 to 8 wherein the surround

is fabricated by adhering sheets of fibre reinforced cement directly onto a preformed

core element of expanded polystyrene foam.

10. A frame element according to claim 9 wherein the sheets of fibre reinforced

cement are adhered to the core element by means of a contact adhesive.

11. A frame element according to claim 10 wherein the epoxy based adhesive is

used at the comers to join the fibre reinforced cement sheets.

12. A frame element according to any one of claims 9 to 11 wherein the comers

are joined and/or sealed using a suitable flexible acrylic, silicone or siliconised acrylic

or other resilient weather resistant compound.

13. A frame element according to any one of claims 1 to 12 wherein the retaining

formation is at least partially filled with a suitable sealing material.

14. A frame element according to claim 13 wherein the filling material is a

formaldehyde based foam or lightweight aggregate concrete.

15. A frame element according to any one of claims 1 to 14 wherein the retaining

formation is formed integrally with the longitudinal frame portion.

16. A frame element according to any one of claims 1 to 14 wherein the retaining

formation is formed separately from the longitudinal frame portion.

17. A frame element according to claim 16 wherein the retaining formation is

configured for attachment to the frame portion prior to installation.

18. A frame element according to claim 17 wherein the retaining formation is

attached to the frame portion using rivets, staples, nails, screws, adhesive or a

complementary interlocking snap fit system.

19. A frame element according to any one of claims 1 to 18 wherein a pair of

retaining formations are provided to retain internal and external generally planar

building panels respectively.

20. A frame element according to claim 19 wherein when installed, the generally

planar internal and external building panels define corresponding internal and external

reveals.

21. A frame element according to claim 20 wherein the generally planar building

panels are sheets of fibre reinforced cement between 3 mm and 20 mm thick.