WO2005047633A1 - A frameless window construction - Google Patents

A frameless window construction Download PDF

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Publication number
WO2005047633A1
WO2005047633A1 PCT/AU2004/001560 AU2004001560W WO2005047633A1 WO 2005047633 A1 WO2005047633 A1 WO 2005047633A1 AU 2004001560 W AU2004001560 W AU 2004001560W WO 2005047633 A1 WO2005047633 A1 WO 2005047633A1
Authority
WO
WIPO (PCT)
Prior art keywords
sheet
aperture
construction
sheets
surround
Prior art date
Application number
PCT/AU2004/001560
Other languages
French (fr)
Inventor
Frank Matich
Original Assignee
Armacel Pty Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2003906295A external-priority patent/AU2003906295A0/en
Application filed by Armacel Pty Limited filed Critical Armacel Pty Limited
Priority to AU2004289706A priority Critical patent/AU2004289706A1/en
Priority to GB0610128A priority patent/GB2423952A/en
Priority to CA002546707A priority patent/CA2546707A1/en
Publication of WO2005047633A1 publication Critical patent/WO2005047633A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/16—Lining or labelling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/02—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor using sheet or web-like material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/70—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/681—Component parts, details or accessories; Auxiliary operations
    • B29C70/682—Preformed parts characterised by their structure, e.g. form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/685—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks by laminating inserts between two plastic films or plates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/72—Encapsulating inserts having non-encapsulated projections, e.g. extremities or terminal portions of electrical components
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/74—Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/74—Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
    • B29C70/745—Filling cavities in the preformed part
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/30—Coverings, e.g. protecting against weather, for decorative purposes
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/30—Coverings, e.g. protecting against weather, for decorative purposes
    • E06B3/301—Coverings, e.g. protecting against weather, for decorative purposes consisting of prefabricated profiled members or glass
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/54—Fixing of glass panes or like plates
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/54—Fixing of glass panes or like plates
    • E06B3/5409—Means for locally spacing the pane from the surrounding frame
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/54—Fixing of glass panes or like plates
    • E06B3/5427—Fixing of glass panes or like plates the panes mounted flush with the surrounding frame or with the surrounding panes
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/54—Fixing of glass panes or like plates
    • E06B3/56—Fixing of glass panes or like plates by means of putty, cement, or adhesives only
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/54—Fixing of glass panes or like plates
    • E06B3/58—Fixing of glass panes or like plates by means of borders, cleats, or the like
    • E06B3/5892—Fixing of window panes in openings in door leaves
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/66—Units comprising two or more parallel glass or like panes permanently secured together
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/70—Door leaves
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/70—Door leaves
    • E06B3/7001—Coverings therefor; Door leaves imitating traditional raised panel doors, e.g. engraved or embossed surfaces, with trim strips applied to the surfaces
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B7/00—Special arrangements or measures in connection with doors or windows
    • E06B7/16—Sealing arrangements on wings or parts co-operating with the wings

Definitions

  • the present invention relates to windows and, in particular, to a frameless window construction.
  • windows are fabricated from glass or a sheet of plastics material such as Perspex which is a substitute for glass.
  • the sheet of glass is held in a frame which is in turn held in an aperture in a surround such as a wall or a door.
  • the sheet of glass must be sealed relative to the frame and this has traditionally be done by means such as putty or a resilient elastomeric bead.
  • the seal between the aperture and the frame is not a good seal for the purpose of air-conditioning, heating and like aspects of building construction.
  • PCT/AU2004/000826 (previously Australian Patent Application No. 2003 903 211 lodged 25 June, 2003) which discloses the encapsulation of an interior member which is neither at least partially fluid permeable nor is perforated to become so.
  • the disclosure of that specification is also hereby incorporated by cross-reference.
  • thermoformable sheet intended to form the external skin
  • US Patent 5,003,745 discloses a door (20) or similar structure having depression (101,301) and not an aperture.
  • a vacuum formed plastics sheet (10) is adhesively affixed to each side of the door (20) so as to provide a protective covering.
  • the depression (101,301) accommodates undulations (102) in the sheet (10) and permits a plurality of such doors (20) to be stacked without the undulations (102) of one door coming into contact with another door.
  • the door (20) including a transparent window or any type of aperture.
  • GB 2 338 681 discloses a transparent sheet formed from plastics resin material and located within a frame 96 (Fig 6) or 104 (Fig 8).
  • US 2003/0198790 Al discloses a window formed from backing sheet (10) with a thermoformed plastic sheet (4) and a removable protection film (16). Again, a frame (1) is used to locate the window thus formed within its aperture.
  • US 2002/0144483 A 1 discloses a frame (1) similar to an insect screen frame but provided with a transparent plastics film (2). The frame is intended to lie adjacent to an existing window to provide thermal insulation, rather than form a window in its own right.
  • the object of the present invention is to simplify the construction of windows by removal of the previous requirement for a frame.
  • a preferred aspect of the present invention is to utilise the AR ACEL process in the window construction.
  • a method of forming a frameless window construction for at least partially occluding an aperture in a surround comprising the steps of: (a) heating a sheet ofthermoformable plastics material to soften same, (b) occluding said aperture from one side thereof with said heated sheet whilst applying a pressure differential to opposite sides thereof to abut said sheet against said surround, and (c) allowing said sheet to cool.
  • a frameless window construction comprising a surround having a substantial surface area and an aperture therein, at least one continuous substantially transparent or translucent thermoformable plastics sheet covering substantially all of said surround surface area and at least partially occluding said aperture, and there being no frame enveloped by the periphery of said aperture and defining the perimeter of said window.
  • Fig 1 is a perspective view of a door having an aperture therein
  • Fig 2 is a perspective view of the door of Fig. 1 showing an initial step in window construction
  • Fig. 3 is a perspective view of the door of Figs. 1 and 2 showing a subsequent step in the window construction
  • Figs. 4-6 show still further stages in the window construction
  • Fig 7 is a cross-sectional view taken along the line VII -VII of Fig. 6
  • Fig 8 is a view similar to Fig. 7 but illustrating a second embodiment
  • Fig. 9 is a cross sectional view of a third embodiment showing the initial step in its fabrication
  • Fig. 10 is a view similar to Fig.
  • Fig. 11 shows the result of the procedures illustrated in Figs. 9 and 10 installed in a roof
  • Fig. 12 is a perspective view of another door having an aperture and showing the initial step of the fabrication of a two pane window
  • Figs. 13-17 each illustrate a subsequent step in the manufacturing process
  • Fig. 18 illustrates the door with the completed two pane window.
  • a door 1 has an aperture 2 within which it is intended to form a window.
  • the door 1 is placed on the horizontal platen (not illustrated) of a conventional ARMACEL apparatus and a spacer 4 having the same size and shape as the aperture 2 but being only of approximately half the thickness of the door 1, is located in the aperture 2.
  • a heated sheet 5 of thermoformable plastics material is brought down over the upper surface of the door 1 and a pressure differential is applied in known fashion to the sheet 5 so as to draw same against the door 1.
  • Fig. 3 where the sheet 5 is firmly adhered to the door 1 and is trimmed along the broken lines in Fig. 3.
  • the spacer 4 is preferably treated with a release agent such as petroleum jelly, which ensures that the sheet 5 does not adhere to the spacer 4.
  • a release agent such as petroleum jelly
  • a layer of Mylar or Melamine or stainless steel, or the like, can be placed on the spacer 4 and subsequently separated from the sheet 5.
  • a second sheet 7 is applied to the previously lower, and now upper, surface of the door 10 utilising the same process as in Fig. 2 with the result, after trimming, being illustrated in Fig. 6.
  • the two sheets 5, 7 are adhered together and form a window 9 as well as encapsulate the door 1.
  • the spacer 4 is illustrated in each of its two positions in order to correctly indicate that the thickness of the spacer 4 determines the final position of the window 9.
  • FIG. 8 A second embodiment is illustrated in Fig. 8 in which a grille 13 is positioned between the two sheets 5 and 7 and thus reinforces the window 9. Apart from the grille 13, the second embodiment of Fig. 8 is substantially identical to the first embodiment of Figs. 1-7.
  • FIGs. 9-11 illustrate the manufacture of a skylight 20 having a rectangular surround 21 and a slightly smaller rectangular aperture 22.
  • a spacer 24 having a size and shape corresponding to the aperture 22 and a thickness corresponding to that of the surround 21 is located in the aperture 22, treated with a release agent, and then the assembly is partially encapsulated using a first sheet 25 which is trimmed to the dimensions illustrated in Fig. 9.
  • a release agent a layer of Mylar, Melamine or stainless steel, as referred to above, can be used.
  • the surround 21 is inverted and a second sheet 27 applied and trimmed as illustrated in Fig. 10 so as to form a window 29 which is substantially flush with one (upper) surface of the surround 21.
  • the surround 21 is positioned on a roof 28 in the manner of a conventional skylight.
  • the first sheet 25 is uppermost there is no possibility of leakage between the window 29 and surround 21 and thus a substantial disadvantage of conventional skylights is thereby overcome.
  • the encapsulated material of the surround 21 is also effectively hermetically sealed against ingress of moisture and the like.
  • the door 31 has an aperture 32 as before into which is positioned a spacer 34 having the same size and shape as the aperture 32 but a thickness which is two thirds the thickness of the door 31.
  • the upper surface of the door 31 has a first sheet 35 applied thereto which, because of the thickness of the spacer 34 is located approximately one third of the distance into the aperture 32.
  • a portion of the first sheet 35 is trimmed and removed so as to create a first opening 33.
  • Fig. 12-18 the construction of window 39 having two panes in a door 31 will now be described.
  • the door 31 has an aperture 32 as before into which is positioned a spacer 34 having the same size and shape as the aperture 32 but a thickness which is two thirds the thickness of the door 31.
  • the upper surface of the door 31 has a first sheet 35 applied thereto which, because of the thickness of the spacer 34 is located approximately one third of the distance into the aperture 32.
  • a portion of the first sheet 35 is trimmed and removed so as to create a first opening 33.
  • the door 31 is inverted and second spacer 44 which again has the same size and shape as the aperture 32 but a thickness only approximately one third of the thickness of the door 31, is located within the aperture 32.
  • the second spacer 44 is flexible but is unable to be compressed to any significant degree.
  • the second sheet 37 is applied to the door 1 and again a portion is cut from the second sheet so as to create an opening 43 in the second sheet 37.
  • the second spacer 44 is removed from between the two sheets 35 and 37 through either one of the first opening 33 or the second opening 43 (the latter alternative being illustrated in Fig. 17).
  • the door 31 has a window 39 with two panes respectively formed by the first sheet 35 and the second sheet 37, the sheets being overlapped and the first opening 33 and second opening 43 being misaligned so that the window 39 prevents any access, for example by a human arm, through the aperture 32.
  • the first and second openings 33, 43 do provide ventilation so that the window 39 whilst being closed to intruders is open to air currents such as cooling breezes, conditioned air flows, and the like.
  • the windows 9, 29 and 39 are able to be fabricated from a wide range of materials as indicated in the abovementioned PCT specifications, the contents of which are incorporated herein by cross reference.
  • the plastics materials ABS and APET, in particular, are suited to such an application since it is very tough.
  • Such sheet plastics material is able to be cut with a knife, in much the same way that glass is able to be cut with a diamond tip glass cutter.
  • most glass windows suffer breakage as a result of accidental impact rather than deliberate action carried out with the use of a tool.
  • the plastics material of the above described windows is substantially unaffected by such accidental impacts.
  • the plastics material can be coloured or tinted to various degrees and thus the window is able to be transparent, translucent, or even, if desired, opaque. Most importantly, the overall cost of construction is substantially reduced because the frame and its installation procedures are absent.
  • the spacer 4 is provided with a corrugated surface, the corresponding window 9 has a rippled appearance.
  • the spacer 24 has a domed upper surface, the window 29 of the skylight 21 is similarly domed.
  • coloured shaped sheets can be sandwiched between the sheets 5 and 7, for example, to produce a lead light or stained glass window effect.

Landscapes

  • Engineering & Computer Science (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Manufacturing & Machinery (AREA)
  • Securing Of Glass Panes Or The Like (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

A frameless window construction for walls, doors (1, 31) and other such objects having an extensive surface area is disclosed. The door (1) has an aperture (2) and a thermoformable plastics sheet (5) is used to simultaneously coat the extensive surface and occlude the aperture. Preferably a second sheet (7) is used to coat the other side of the door. If desired a grille (13) can be located in the aperture (2) between the two sheets (5, 7). No frame positioned within the aperture (2) and defining the visible area of the window, is used in the construction.

Description

A Frameless Window Construction
Field of the Invention
The present invention relates to windows and, in particular, to a frameless window construction.
Background Art
Conventionally windows are fabricated from glass or a sheet of plastics material such as Perspex which is a substitute for glass. The sheet of glass is held in a frame which is in turn held in an aperture in a surround such as a wall or a door. The sheet of glass must be sealed relative to the frame and this has traditionally be done by means such as putty or a resilient elastomeric bead. Furthermore, it is necessary to seal the frame into the aperture and this is often accomplished by means such as flashing which do not provide an airtight seal, but instead are merely watertight and rely on the influence of gravity to move water downwardly in order to provide a barrier against water penetration. As such, the seal between the aperture and the frame is not a good seal for the purpose of air-conditioning, heating and like aspects of building construction.
The ARMACEL process and apparatus for forming structural articles, especially from weak substrates such as polystyrene and cardboard, and articles so formed, are disclosed in the applicant's International PCT Patent Application No. PCT/AU95/00100 entitled "A method and apparatus for forming structural articles" (WO 95/23682), International PCT Patent Application No. PCT/AU96/00541 entitled "Layered Structural Article" (WO 97/09166) and International PCT Patent Application No. PCT/AU00/00250 (WO 00/59709) - the contents of all three of which are hereby incorporated into the present specification by cross reference. A further specification, unpublished as at the priority date, is that of International Application No. PCT/AU2004/000826 (previously Australian Patent Application No. 2003 903 211 lodged 25 June, 2003) which discloses the encapsulation of an interior member which is neither at least partially fluid permeable nor is perforated to become so. The disclosure of that specification is also hereby incorporated by cross-reference.
These specifications disclose forming structural articles from a shape defining interior member and at least one external skin. The basic steps of the method comprise: 1. heating a thermoformable sheet intended to form the external skin,
2. bringing the heated sheet alongside the interior member,
3. applying a fluid pressure differential between opposite surfaces of the interior member and the sheet to conform the sheet to the shape of the interior member and mutually engage same, and
4. maintaining the fluid pressure differential until the sheet has cooled.
Prior art searches conducted after the priority date have disclosed the following patent specifications, none of which are known to the applicant to have been used commercially.
1. US Patent 5,003,745 discloses a door (20) or similar structure having depression (101,301) and not an aperture. A vacuum formed plastics sheet (10) is adhesively affixed to each side of the door (20) so as to provide a protective covering. The depression (101,301) accommodates undulations (102) in the sheet (10) and permits a plurality of such doors (20) to be stacked without the undulations (102) of one door coming into contact with another door. There is no suggestion of the door (20) including a transparent window or any type of aperture.
2. GB 2 338 681 discloses a transparent sheet formed from plastics resin material and located within a frame 96 (Fig 6) or 104 (Fig 8). 3. US 2003/0198790 Al discloses a window formed from backing sheet (10) with a thermoformed plastic sheet (4) and a removable protection film (16). Again, a frame (1) is used to locate the window thus formed within its aperture. 4. US 2002/0144483 A 1 discloses a frame (1) similar to an insect screen frame but provided with a transparent plastics film (2). The frame is intended to lie adjacent to an existing window to provide thermal insulation, rather than form a window in its own right.
Object of the Invention
The object of the present invention is to simplify the construction of windows by removal of the previous requirement for a frame. A preferred aspect of the present invention is to utilise the AR ACEL process in the window construction. Summary of the Invention
In accordance with a first aspect of the present invention there is disclosed a method of forming a frameless window construction for at least partially occluding an aperture in a surround, said method comprising the steps of: (a) heating a sheet ofthermoformable plastics material to soften same, (b) occluding said aperture from one side thereof with said heated sheet whilst applying a pressure differential to opposite sides thereof to abut said sheet against said surround, and (c) allowing said sheet to cool. In accordance with a second aspect of the present invention there is disclosed a frameless window construction comprising a surround having a substantial surface area and an aperture therein, at least one continuous substantially transparent or translucent thermoformable plastics sheet covering substantially all of said surround surface area and at least partially occluding said aperture, and there being no frame enveloped by the periphery of said aperture and defining the perimeter of said window.
Brief Description of the Drawings
Preferred embodiments of the present invention will now be described with reference to the drawings in which: Fig 1 is a perspective view of a door having an aperture therein, Fig 2 is a perspective view of the door of Fig. 1 showing an initial step in window construction, Fig. 3 is a perspective view of the door of Figs. 1 and 2 showing a subsequent step in the window construction, Figs. 4-6 show still further stages in the window construction, Fig 7 is a cross-sectional view taken along the line VII -VII of Fig. 6, Fig 8 is a view similar to Fig. 7 but illustrating a second embodiment, Fig. 9 is a cross sectional view of a third embodiment showing the initial step in its fabrication, Fig. 10 is a view similar to Fig. 9 but showing the result of a second step, Fig. 11 shows the result of the procedures illustrated in Figs. 9 and 10 installed in a roof, Fig. 12 is a perspective view of another door having an aperture and showing the initial step of the fabrication of a two pane window, Figs. 13-17 each illustrate a subsequent step in the manufacturing process, and Fig. 18 illustrates the door with the completed two pane window.
Detailed Description
Turning now to Fig. 1, in a first embodiment a door 1 has an aperture 2 within which it is intended to form a window. In order to do so, the door 1 is placed on the horizontal platen (not illustrated) of a conventional ARMACEL apparatus and a spacer 4 having the same size and shape as the aperture 2 but being only of approximately half the thickness of the door 1, is located in the aperture 2. Then, as seen in Fig. 2, a heated sheet 5 of thermoformable plastics material is brought down over the upper surface of the door 1 and a pressure differential is applied in known fashion to the sheet 5 so as to draw same against the door 1. This results in the situation illustrated in Fig. 3 where the sheet 5 is firmly adhered to the door 1 and is trimmed along the broken lines in Fig. 3. The spacer 4 is preferably treated with a release agent such as petroleum jelly, which ensures that the sheet 5 does not adhere to the spacer 4. Alternatively a layer of Mylar or Melamine or stainless steel, or the like, can be placed on the spacer 4 and subsequently separated from the sheet 5.
Next the door 1 is inverted with the spacer 4 placed underneath sheet 5 and within the aperture 2 in order to support the sheet 5 in subsequent processing steps. Next, as illustrated in Fig. 5, a second sheet 7 is applied to the previously lower, and now upper, surface of the door 10 utilising the same process as in Fig. 2 with the result, after trimming, being illustrated in Fig. 6. As seen in Fig. 7 the two sheets 5, 7 are adhered together and form a window 9 as well as encapsulate the door 1. In Fig 7 the spacer 4 is illustrated in each of its two positions in order to correctly indicate that the thickness of the spacer 4 determines the final position of the window 9. In addition, in relation to Fig. 7, and similar such subsequent figures, it is to be understood that the small spacing illustrated between the sheets 5, 7 and the adjacent objects to which the sheets are adhered does not exist in practice but it is only illustrated for the purposes of explanation. A second embodiment is illustrated in Fig. 8 in which a grille 13 is positioned between the two sheets 5 and 7 and thus reinforces the window 9. Apart from the grille 13, the second embodiment of Fig. 8 is substantially identical to the first embodiment of Figs. 1-7.
A third embodiment of the present invention is illustrated in Figs. 9-11 which illustrate the manufacture of a skylight 20 having a rectangular surround 21 and a slightly smaller rectangular aperture 22. As seen in Fig. 9, a spacer 24 having a size and shape corresponding to the aperture 22 and a thickness corresponding to that of the surround 21 is located in the aperture 22, treated with a release agent, and then the assembly is partially encapsulated using a first sheet 25 which is trimmed to the dimensions illustrated in Fig. 9. Instead of using a release agent, a layer of Mylar, Melamine or stainless steel, as referred to above, can be used.
Then the surround 21 is inverted and a second sheet 27 applied and trimmed as illustrated in Fig. 10 so as to form a window 29 which is substantially flush with one (upper) surface of the surround 21. As seen in Fig. 11 the surround 21 is positioned on a roof 28 in the manner of a conventional skylight. However, as the first sheet 25 is uppermost there is no possibility of leakage between the window 29 and surround 21 and thus a substantial disadvantage of conventional skylights is thereby overcome. Furthermore, the encapsulated material of the surround 21 is also effectively hermetically sealed against ingress of moisture and the like.
Turning now to Figs. 12-18, the construction of window 39 having two panes in a door 31 will now be described. The door 31 has an aperture 32 as before into which is positioned a spacer 34 having the same size and shape as the aperture 32 but a thickness which is two thirds the thickness of the door 31. As illustrated in Fig. 13, the upper surface of the door 31 has a first sheet 35 applied thereto which, because of the thickness of the spacer 34 is located approximately one third of the distance into the aperture 32. Then, as indicated in Fig. 14, a portion of the first sheet 35 is trimmed and removed so as to create a first opening 33. Next, as illustrated in Fig. 15, the door 31 is inverted and second spacer 44 which again has the same size and shape as the aperture 32 but a thickness only approximately one third of the thickness of the door 31, is located within the aperture 32. The second spacer 44 is flexible but is unable to be compressed to any significant degree. Then the second sheet 37 is applied to the door 1 and again a portion is cut from the second sheet so as to create an opening 43 in the second sheet 37. Next the second spacer 44 is removed from between the two sheets 35 and 37 through either one of the first opening 33 or the second opening 43 (the latter alternative being illustrated in Fig. 17).
Finally, as illustrated in Fig. 18, the door 31 has a window 39 with two panes respectively formed by the first sheet 35 and the second sheet 37, the sheets being overlapped and the first opening 33 and second opening 43 being misaligned so that the window 39 prevents any access, for example by a human arm, through the aperture 32. However, the first and second openings 33, 43 do provide ventilation so that the window 39 whilst being closed to intruders is open to air currents such as cooling breezes, conditioned air flows, and the like.
The windows 9, 29 and 39 are able to be fabricated from a wide range of materials as indicated in the abovementioned PCT specifications, the contents of which are incorporated herein by cross reference. The plastics materials ABS and APET, in particular, are suited to such an application since it is very tough. Such sheet plastics material is able to be cut with a knife, in much the same way that glass is able to be cut with a diamond tip glass cutter. However, most glass windows suffer breakage as a result of accidental impact rather than deliberate action carried out with the use of a tool. Importantly, the plastics material of the above described windows is substantially unaffected by such accidental impacts. Furthermore, the plastics material can be coloured or tinted to various degrees and thus the window is able to be transparent, translucent, or even, if desired, opaque. Most importantly, the overall cost of construction is substantially reduced because the frame and its installation procedures are absent. The foregoing describes only some embodiments of the present invention and modifications, obvious to those skilled in the art, can be made thereto without departing from the scope of the present invention. For example, if the spacer 4 is provided with a corrugated surface, the corresponding window 9 has a rippled appearance. Similarly, if the spacer 24 has a domed upper surface, the window 29 of the skylight 21 is similarly domed. In a further variation, coloured shaped sheets can be sandwiched between the sheets 5 and 7, for example, to produce a lead light or stained glass window effect.
The term "comprising" (and its grammatical variations) as used herein is used in the inclusive sense of "having" or "including" and not in the exclusive sense of "consisting only of.

Claims

1. A method of forming a frameless window construction for at least partially occluding an aperture in a surround, said method comprising the steps of: (a) heating a sheet ofthermoformable plastics material to soften same, (b) occluding said aperture from one side thereof with said heated sheet whilst applying a pressure differential to opposite sides thereof to abut said sheet against said surround, and (c) allowing said sheet to cool.
2. The method claimed in claim 1 including the steps of:- (d) heating a second sheet of thermoformable plastics material to soften same, (e) occluding said aperture from the other side thereof with said heated second sheet whilst applying a pressure differential to opposite sides of said second sheet to abut said second sheet against said surround other side, and (f) allowing said second sheet to cool.
3. The method as claimed in claim 2 including the step of:- (g) inserting a spacer means into said aperture prior to applying said pressure differential.
4. The method as claimed in claim 3 including the step of (h) cutting away a portion of each said sheet whereby each said sheet only partially occludes said aperture, said cut away portions being mis-aligned with each other.
5. The method as claimed in claim 2 including the step of: (i) abutting said sheets in said aperture.
6. The method as claimed in claim 5 including the step of: (j) locating a grille in said aperture intermediate said sheets.
7. The method as claimed in any one of claims 1-6 including the step of: (k) selecting said thermoplastic sheet or sheets to have a property selected from the group consisting of substantial transparency, substantial translucency, colouration and tint.
8. A frameless window construction comprising a surround having a substantial surface area and an aperture therein, at least one continuous substantially transparent or translucent thermoformable plastics sheet covering substantially all of said surround surface area and at least partially occluding said aperture, and there being no frame enveloped by the periphery of said aperture and defining the perimeter of said window.
9. The construction as claimed in claim 8 and having two spaced apart said sheets which overlap each other and which each extend part way across said aperture.
10. The construction claimed in claim 8 wherein said at least one sheet extends fully across said aperture.
11. The construction as claimed in claim 10 wherein said surround has a pair of opposite said surface areas and said construction has a pair of said sheets, one of said sheets extending over one surface area of said surround, and the other one of said sheets extending over the other surface area of said surround.
12. The construction as claimed in claim 11 wherein said pair of sheets in said aperture abut each other.
13. The construction as claimed in claim 12 wherein a grille is interposed between said pair of sheets.
14. The construction as claimed in any one of claims 11-13 wherein said pair of sheets is located substantially flush with one of said pair of opposite surround surface areas.
15. The construction as claimed in any one of claims 1 1-13 wherein said pair of sheets is located intermediate said pair of opposite surround surfaces.
16. The construction as claimed in any one of claims 8-15 wherein said thermoformable plastics material is substantially transparent or translucent.
17. The construction as claimed in any one of claims 8-16 wherein said thermoformable plastics is coloured or tinted.
PCT/AU2004/001560 2003-11-14 2004-11-12 A frameless window construction WO2005047633A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
AU2004289706A AU2004289706A1 (en) 2003-11-14 2004-11-12 A frameless window construction
GB0610128A GB2423952A (en) 2003-11-14 2004-11-12 A frameless window construction
CA002546707A CA2546707A1 (en) 2003-11-14 2004-11-12 A frameless window construction

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2003906295 2003-11-14
AU2003906295A AU2003906295A0 (en) 2003-11-14 A Frameless Window Construction

Publications (1)

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WO2005047633A1 true WO2005047633A1 (en) 2005-05-26

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KR (1) KR20070001897A (en)
CN (1) CN1890449A (en)
CA (1) CA2546707A1 (en)
GB (1) GB2423952A (en)
RU (1) RU2006117984A (en)
WO (1) WO2005047633A1 (en)
ZA (1) ZA200603964B (en)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007133160A1 (en) * 2006-05-11 2007-11-22 Vest-Wood Sverige Ab A method to glaze a door
US10801252B2 (en) 2016-06-25 2020-10-13 Alexander Uskolovsky Window assembly

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2338681A (en) * 1998-06-24 1999-12-29 Stephen E Howes Making decorative windows
US20020144483A1 (en) * 2001-04-09 2002-10-10 Mark Shippen Energy screen kits for window insulation

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2338681A (en) * 1998-06-24 1999-12-29 Stephen E Howes Making decorative windows
US20020144483A1 (en) * 2001-04-09 2002-10-10 Mark Shippen Energy screen kits for window insulation

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007133160A1 (en) * 2006-05-11 2007-11-22 Vest-Wood Sverige Ab A method to glaze a door
US10801252B2 (en) 2016-06-25 2020-10-13 Alexander Uskolovsky Window assembly

Also Published As

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CN1890449A (en) 2007-01-03
GB2423952A (en) 2006-09-13
ZA200603964B (en) 2007-09-26
CA2546707A1 (en) 2005-05-26
KR20070001897A (en) 2007-01-04
GB0610128D0 (en) 2006-06-28
RU2006117984A (en) 2007-12-20

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