WO2022235171A1 - Improvements to building elements, and methods of manufacture and installation of building elements - Google Patents

Improvements to building elements, and methods of manufacture and installation of building elements Download PDF

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Publication number
WO2022235171A1
WO2022235171A1 PCT/NZ2022/050051 NZ2022050051W WO2022235171A1 WO 2022235171 A1 WO2022235171 A1 WO 2022235171A1 NZ 2022050051 W NZ2022050051 W NZ 2022050051W WO 2022235171 A1 WO2022235171 A1 WO 2022235171A1
Authority
WO
WIPO (PCT)
Prior art keywords
frame member
building
building element
waterproofing
tray
Prior art date
Application number
PCT/NZ2022/050051
Other languages
French (fr)
Inventor
David Frank Burggraaf
Grant Robert Douglas Watson
Original Assignee
Architectural Profiles 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
Application filed by Architectural Profiles Limited filed Critical Architectural Profiles Limited
Publication of WO2022235171A1 publication Critical patent/WO2022235171A1/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B7/00Special arrangements or measures in connection with doors or windows
    • E06B7/14Measures for draining-off condensed water or water leaking-in frame members for draining off condensation water, throats at the bottom of a sash
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/02Base frames, i.e. template frames for openings in walls or the like, provided with means for securing a further rigidly-mounted frame; Special adaptations of frames to be fixed therein
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/62Tightening or covering joints between the border of openings and the frame or between contiguous frames
    • E06B1/68Tightening or covering joints between the border of openings and the frame or between contiguous frames by profiled external parts
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/70Sills; Thresholds
    • E06B1/702Window sills
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00Window 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
    • E06B3/96Corner joints or edge joints for windows, doors, or the like frames or wings
    • E06B3/9616Corner joints or edge joints for windows, doors, or the like frames or wings characterised by the sealing at the junction of the frame members
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00Window 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
    • E06B3/96Corner joints or edge joints for windows, doors, or the like frames or wings
    • E06B3/964Corner joints or edge joints for windows, doors, or the like frames or wings using separate connection pieces, e.g. T-connection pieces
    • E06B3/9641Corner joints or edge joints for windows, doors, or the like frames or wings using separate connection pieces, e.g. T-connection pieces part of which remains visible
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/04Frames for doors, windows, or the like to be fixed in openings
    • E06B1/34Coverings, e.g. protecting against weather, for decorative purposes
    • E06B1/342Reveal covering members disposed alongside of a window frame
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/56Fastening frames to the border of openings or to similar contiguous frames
    • E06B1/60Fastening frames to the border of openings or to similar contiguous frames by mechanical means, e.g. anchoring means
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/56Fastening frames to the border of openings or to similar contiguous frames
    • E06B1/60Fastening frames to the border of openings or to similar contiguous frames by mechanical means, e.g. anchoring means
    • E06B1/6046Clamping means acting perpendicular to the wall opening; Fastening frames by tightening or drawing them against a surface parallel to the opening
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/62Tightening or covering joints between the border of openings and the frame or between contiguous frames
    • E06B1/64Tightening or covering joints between the border of openings and the frame or between contiguous frames by loosely-inserted means, e.g. strip, resilient tongue
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00Window 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
    • E06B3/04Wing frames not characterised by the manner of movement
    • E06B3/263Frames with special provision for insulation
    • E06B3/26301Frames with special provision for insulation with prefabricated insulating strips between two metal section members
    • E06B3/26303Frames with special provision for insulation with prefabricated insulating strips between two metal section members with thin strips, e.g. defining a hollow space between the metal section members
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00Window 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
    • E06B3/32Arrangements of wings characterised by the manner of movement; Arrangements of movable wings in openings; Features of wings or frames relating solely to the manner of movement of the wing
    • E06B3/34Arrangements of wings characterised by the manner of movement; Arrangements of movable wings in openings; Features of wings or frames relating solely to the manner of movement of the wing with only one kind of movement
    • E06B3/42Sliding wings; Details of frames with respect to guiding
    • E06B3/46Horizontally-sliding wings
    • E06B3/4609Horizontally-sliding wings for windows
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00Window 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
    • E06B3/54Fixing of glass panes or like plates
    • E06B3/58Fixing of glass panes or like plates by means of borders, cleats, or the like
    • E06B3/5807Fixing of glass panes or like plates by means of borders, cleats, or the like not adjustable
    • E06B3/5821Fixing of glass panes or like plates by means of borders, cleats, or the like not adjustable hooked on or in the frame member, fixed by clips or otherwise elastically fixed

Definitions

  • the present technology relates to improvements to building elements, and methods of manufacture and installation of building elements.
  • the invention has particular application to waterproofing window and / or door assemblies with glazing.
  • building elements which can be used to provide different parts of a building.
  • some building elements are used to cover an opening in the external cladding of a building.
  • a window can cover an opening in the cladding while allowing natural light into the building and people to look into or out from the building.
  • doors allow people to move through the opening while also closing the opening when required.
  • the building elements have a barrier of some form that is mounted in a frame, and the frame is fixed to the building so that the barrier extends across the opening.
  • the barrier is glazing i.e., one or more panes of glass.
  • window design and manufacture is to provide window frames made from aluminium extrusions which support and retain one of more panes of glass e.g., one pane for a single-glazed window assembly, two panes for a double-glazed window assembly or three panes for a triple-glazed window assembly. These window assemblies are installed into a frame formed in a building.
  • a window disrupts the surrounding membrane, i.e. cladding, of the building in which it is installed. This can therefore create areas in the building membrane where moisture may enter the building or into the frame of the building. Over time, this penetration of moisture can cause significant damage to the building. This can arise for various reasons including improper installation of the window assembly due to poor workmanship or error, or inherent problems due to the design of the window assembly. As a result, windows are a key concern for weatherproofing of a building. In New Zealand at least, poor window installation can be a significant factor in moisture penetrating into the building. This may affect the components of the building, such as wood and fabrics, that are contacted by the moisture and also lead to the formation of mould on interior surfaces.
  • glass has a relatively low thermal insulation value. Therefore, construction techniques such as double-glazing aim to reduce heat loss through a window. That notwithstanding, the installation of a window in a building can introduce "thermal leaks" such as gaps between the window and components of the building it is installed e.g. the window frame or the cladding. Those gaps allow air flow and lead to loss of heat from the interior of the building to its exterior. In modern buildings, in New Zealand at least, the existence of building cavities can exacerbate this as these allow cold external air to circulate well into the wall space and compromise the performance of the building's insulation materials.
  • Another challenge for window design, construction and installation is optimising the overall aesthetics of the building in which they are installed. This requires balancing various considerations such as the size and shape of the frame and position of the glass pane(s) relative to the building's walls and cladding. However, the position of the glass pane(s) can create challenges for window design, construction and installation. Accordingly, to achieve desired aesthetics, there are number of problems that need to be overcome.
  • a building element wherein the building element includes: a plurality of frame sub-assemblies that are attached to each other, and a waterproofing system.
  • a frame sub-assembly wherein the frame sub-assembly includes: an inner frame member, an outer frame member, and a waterproofing system.
  • a building element wherein the building element includes: an inner frame member, an outer frame member, and a waterproofing system, wherein the waterproofing system includes a drain, wherein the inner frame member and the outer frame member are attached to each other, and further wherein the waterproofing system is positioned and arranged to, in use, collect moisture and direct the moisture towards the drain.
  • a frame sub-assembly wherein the frame sub-assembly includes: an inner frame member, an outer frame member, and a waterproofing system, wherein the waterproofing system includes a drain, wherein the inner frame member and the outer frame member are attached to each other, and further wherein the waterproofing system is positioned and arranged to, in use, collect moisture and direct the moisture towards the drain.
  • a building element configured to be secured to a support element of a building
  • the building element includes: an inner frame member, an outer frame member, and wherein the outer frame member includes a fin that is orientated to be positioned relative to the support element of the building, and further wherein a fastener can extend through the fin and into the support element to secure the building element to the building.
  • a method of installing a building element to a building including the steps of:
  • the technology may include one or more of the following steps in any order:
  • the present specification describes technology relating to improvements to building elements.
  • the technology may preferably find application in a building element in combination. Accordingly, reference will be made herein as such.
  • building elements according to the present technology may include at least one barrier arrangement.
  • the barrier arrangement may include glazing, i.e. includes at least one pane of glass, but even more preferably, two panes of glass to provide a double-glazed barrier arrangement or three panes of glass to provide a triple-glazed barrier arrangement.
  • the barrier arrangement being the panes of glass.
  • the barrier arrangement may be panes of transparent plastics material.
  • the building element may be a window assembly.
  • it may be a non-opening window, a hinged window, or a sliding window such as a stacking window.
  • the building element may also be a sliding or hinged door.
  • waterproofing system should be understood as meaning one or more components which can collect moisture in a window assembly.
  • the waterproofing system may be configured to partially or completely collect failure water, e.g. water that seeps down through a window frame that has been damaged or incorrectly installed.
  • the waterproofing system may partially or completely prevent failure water entering into a building cavity or damaging components of the building, e.g. stud, jambs etc.
  • the waterproofing system may be attached to at least one frame member forming the building element.
  • the waterproofing system may be attached to both of an inner frame member and an outer frame member.
  • the waterproofing system may be at least partially formed integrally with one or both of an inner frame member and an outer frame member.
  • the building element including an inner frame member and an outer frame member.
  • inner frame member is closer to the middle or interior of the building than the outer frame member.
  • each of the members may include a channel configured to receive a portion of a connector.
  • the channels may be shaped and dimensions to prevent the connector being pulled out laterally to thereby attach the members together.
  • alternate attachment arrangements are envisaged within the scope of the present technology.
  • the outer frame member may include at least one fin.
  • the fin may be configured to provide one or more functional benefits.
  • the fin may be positioned and orientated to facilitate attachment of the outer frame member of the building element to a surface of another building element, for example, a support element of the frame of the building.
  • the fin may be structured to provide structural support to the outer frame member, e.g. it facilitates supporting an upper portion of the frame member (and therefore hold the building element in position).
  • the fin may be shaped and orientated to facilitate creation of a seal between the fin and the support element of the building to which it is attached.
  • the fin may be provided with a seal, e.g. a foam tape, which can, for example, be positioned, and optionally compressed, by the fin and the support element.
  • a seal such as a waterproof tape could be attached to the fin and support element to provide a barrier that seals the gaps therebetween.
  • the outer frame member may include a flashing portion.
  • attachment of the waterproofing system to the building element can occur during manufacture or assembly of the building element. Therefore, the building element can be shipped or transported to a building site at which it is to be installed into a building.
  • the waterproofing system may be attached to at least one of the inner frame member and the outer frame member.
  • the attachment may be a direct attachment, in which a component of the waterproofing system is attached directly to a component of the building element, e.g. by a fastener such as a screw, or inserting a portion of one component into a corresponding receiving portion such as a channel on the other component.
  • the attachment may be indirect e.g., there is one or more components between the waterproofing system and the building element.
  • the waterproofing system may comprise a waterproofing tray.
  • the waterproofing tray may be shaped and dimensioned to span a region of the building element at which an inner frame member and an outer frame member are attached to each other.
  • the waterproofing tray may be shaped and dimensioned to span a region of the building element in which the barrier arrangement is supported.
  • the waterproofing tray may include a bearing surface for a frame component that receives the glazing of the barrier arrangement.
  • the waterproofing tray may have an inner portion and an outer portion.
  • the inner portion may be the part of the waterproofing tray which is located closer to the inside of a building than the barrier arrangement.
  • the outer portion may be the part of the waterproofing tray that is located closer to the outside of a building than the barrier arrangement.
  • one or both of the inner frame member and outer frame member is configured to receive at least part of one or both of the inner portion and outer portion of the waterproofing tray.
  • the waterproofing system may include at least one corner piece.
  • the corner piece may be shaped and dimensioned to be extend through a corresponding opening in a frame sub-assembly of the building element, e.g., in an outer frame member.
  • the waterproofing system may include at least one end.
  • the building element may include at least one cavity. Even more preferably, the building element may include at least one cavity proximate the at least one end of the waterproofing system.
  • the at least one cavity may include an opening to facilitate exit of moisture from the cavity.
  • the opening may be one or more of a drainage opening through which moisture on the waterproofing tray can flow, or a slot configured to align with another component of the waterproofing system, e.g. a / the corner piece of the waterproofing system.
  • the at least one cavity may be defined by a surface of the waterproofing tray and a surface of at least one of the outer frame member and the inner frame member.
  • Figure 1A is a first perspective view of a building element according to one aspect of the technology in the form of a window assembly
  • Figure IB is a second perspective view of the window assembly of Figure 1A;
  • Figure 2A is a first perspective view of a waterproofing tray according to one aspect of the technology;
  • Figure 2B is a second perspective view of the waterproofing tray of Figure 2A
  • Figure 2C is an end view of the waterproofing tray of Figures 2A and 2B
  • Figure 3A is a first perspective view of a corner piece according to one aspect of the technology
  • Figure 3B is a second perspective view of the corner piece of Figure 3A
  • Figure 3C is a third perspective view of the corner piece of Figures 3A and 3B
  • Figure 4A is a first perspective view of an end cap according to one aspect of the technology
  • Figure 4B is a second perspective view of the end cap of Figure 4A
  • Figure 5A is a first perspective view of a corner piece and waterproofing tray relative to each other;
  • Figure 5B is a second perspective view of the corner piece and waterproofing tray of Figure 5A, together with an end cap;
  • Figure 5C is a third perspective view of the corner piece and waterproofing tray of Figures 5A and 5B, together with the end cap;
  • Figure 6A is a first end view of an inner frame member of the building element according to one aspect of the technology
  • Figure 6B is a first perspective view of the inner frame member of Figure 6A
  • Figure 6C is a perspective view of a glazing member according to one aspect of the technology
  • Figure 6D is a first end view of the glazing member of Figure 6C
  • Figure 7A is a first end view of an outer frame member of the building element according to one aspect of the technology
  • Figure 7B is a first perspective view of the outer frame member of Figure 7A;
  • Figure 8A is an end view of an outer frame member and an inner frame member attached to each other according to one aspect of the technology
  • Figure 8B is a perspective view of Figure 8A;
  • Figure 8C is an end view of a seal according to one aspect of the technology;
  • Figure 8D is a perspective view of the seal of Figure 8C
  • Figure 8E is an end view of a pair of connectors used to connect the outer frame member to the inner frame member according to one aspect of the technology
  • Figure 8F is a perspective view of the connectors of Figure 8E;
  • Figure 8G is a cross-sectional view of a waterproofing system attached to an assembled frame sub- assembly of the building element
  • Figure 8H is a first perspective view of Figure 8G
  • Figure 9A is first perspective view of a head flashing for the building element according to one aspect of the technology
  • Figure 9B is a cross-sectional view of the head flashing of Figure 9A;
  • Figure 10A is a first perspective view of a top end cap according to one aspect of the technology;
  • Figure 10B is a side view of the top end cap of Figure 10A;
  • Figure IOC is a second perspective view of the top end cap of Figures 10A and 10B;
  • Figure 11A is a front perspective view of a window assembly according to one aspect of the present technology;
  • Figure 11B is a first close-up front perspective view of area A shown in Figure 11A;
  • Figure 11C is a further close-up front perspective view of area A shown in Figure 11A;
  • Figure 11D is a second close-up rear perspective view of area A shown in Figure 11A;
  • Figure 11E is a further close-up rear perspective view of section A shown in Figure 11A;
  • Figure HF is a view of Figure HE with the end cap removed;
  • Figure 11G is a bottom perspective view through cross-section A-A shown in Figure 11A
  • Figure 12A is a first perspective view of a building with a window assembly according to an aspect of the technology
  • Figure 12B is a cross-sectional view through section C-C shown in Figure 12A
  • Figure 12C is a close-up view of section D-D shown in Figure 12A from a first perspective view
  • Figure 12D is a second close-up of section D-D shown in Figure 12A from a second perspective view
  • Figure 12E is a end view of section D-D shown in Figure 12A
  • Figure 12F is a first close-up view of section E-E shown in Figure 12A from a first perspective view
  • Figure 12G is a side on view of section E-E shown in Figure 12A
  • Figure 12H is a cross-sectional view through section F-F shown in Figure 12A
  • Figure 121 is a close-up view of a portion of section F-F shown in Figure 12H
  • Figure 13 is a cross-sectional view of a portion of a window frame sub-assembly according to the
  • Figure 14 is a cross-sectional view of another embodiment of a building element according to another aspect of the present technology in the form of an opening sash window;
  • Figure 15 is a cross-sectional view of another embodiment of a building element according to another aspect of the present technology in the form of an opening hinged door ;
  • Figure 16 is a cross-sectional view of another embodiment of a building element according to another aspect of the present technology in the form of sliding window or door;
  • Figure 17 is a cross-sectional view of another embodiment of a building element according to another aspect of the present technology illustrating an alternative attachment arrangement. 6. Description of Preferred Embodiments of the Invention
  • FIGS 1A and IB show a building element according to an aspect of the invention in the form of a window assembly 100.
  • Reference herein to the building element as a window assembly should not be seen as limiting on the scope of the present technology.
  • the window assembly 100 is designed and configured to be completely or substantially assembled including one or more of the components described herein. It can then be shipped as a complete or substantially complete unit to the location at which it is to be installed in a building (not shown in Figures 1A or IB).
  • the window assembly 100 includes an integrated waterproofing system as will be described in more detail below.
  • the window assembly 100 has an outer side (being the closest side of the window assembly in Figure 1) and an inner side (being the closest side of the window assembly in Figure 2).
  • the window assembly 100 generally comprises a plurality of inner frame members 200, a plurality of outer frame members 300, and one or more panes of glass e.g., two panes of 102, 104 as illustrated in the Figures.
  • the inner frame members 200 and the outer frame members 300 are attached to each other to create a frame sub-assembly which can receive and support the panes of glass 102, 104.
  • the inner frame members 200 and outer frame members 300 are each formed as extrusions from an extrudable material e.g., aluminium, as standard lengths.
  • an extrudable material e.g., aluminium
  • the inner frame member 200 and the outer frame member 300 could be formed from other materials such as plastics, fibreglass, composites, or steel. Therefore, the discussion herein should not be seen as limiting on the scope of the present invention.
  • the members 200, 300 are cut to length according to the required dimensions for the window assembly 100.
  • the ends to the frame members 200, 300 can be angle cut e.g., to create an angle corresponding to an angle created on another frame member 200, 300 respectively.
  • the angle may be substantially 45° which allows two frame sub-assemblies according to the present technology to be joined together to form a corner with an angle of substantially 90°.
  • the angle cut ends form a joint between two sides e.g. between the top side and a lateral side, and between the bottom and a lateral side.
  • the shape of the frame members 200, 300 is chosen so that they may form either at top, bottom or lateral side edge of the window assembly 100 when assembled together.
  • the waterproofing tray 400 is a moulding of plastics material, such as uPVC, which is attached to the window frame to help form the window assembly 100. It should be appreciated that, as when installed the waterproofing tray contacts both the inner frame member and the outer frame member, the use of plastics material or similarly thermally inert material at least minimises, if not eliminates, thermal transfer between the respective frame members.
  • the waterproofing tray 400 has a body having a first arm 402 and a second arm 404 which are orientated substantially perpendicularly to each other.
  • the first arm 402 includes a top surface 406, an under surface 408, and an edge portion 410 which is distal to the second arm 404.
  • the first arm 402 has a lip 412 located at the edge portion 410, and which is defined by a curved portion of the first arm 402 which wraps around and back over the first arm 402 to define a channel 413 between the top surface 406 and the lip 412.
  • the under surface 408 is substantially flat, such that in use, it better transfers any loading through to the building element or support beneath.
  • the waterproofing 400 tray includes a plastic portion 416 which is similarly formed from a material which is substantially or completely thermally insulating e.g. a plastics material such as uPVC.
  • the plastic profile 416 provides a broad flat surface area that, in use, bears the weight of the aluminium frame and glazing above. The extent of the flat surface is such that it can be used with aluminium frames of a variety of sizes.
  • the plastic profile 416 is configured with a plurality of stems e.g. three stems as indicated as 416A, 416B and 416C, that contact the top surface 406 of the waterproofing tray 400. One stem 416C tucks under detail fold 411 of the tray 400.
  • the plastic portion is a separate component, formed separately from the waterproofing tray 400 for ease of manufacture.
  • this may be formed as an integral structure to the waterproofing tray.
  • the extrusion may only include the equivalent of the stem structures, not the broad flat surface of the plastic portion.
  • the second surface 410 may be orientated to provide a slight downward slope from the inner to the outer directions e.g., in the direction towards the outside of a building in which the window assembly is installed. This may assist in ensuring moisture collected by the waterproofing tray 400 is directed out of the window assembly (by other features as are discussed in more detail below).
  • the plastic profile 416 does not extend along the entire length of the waterproofing tray 400.
  • it may be spaced from at least one end 428 of the waterproofing tray 400 to define a gap Z.
  • the gap Z could be provided at both end 428 and the distal end (not illustrated in Figures 2A to 2C) of the waterproofing tray 400.
  • a reclined flange 430 is provided on the second surface 410 of the arm 402, close to the edge 410. Together, the flange 430 and the lip 412 define a gap indicated generally as 422. A further gap between the flange and the plastic profile 416 is indicated by line R.
  • the angle of the reclined flange 430 better facilitates the insertion of the waterproofing tray 400 to the sill frame.
  • the reclined flange 430 includes a line of weakness 431 along which a portion may be removed, if necessary, to provide clearance to the corner piece that is shown in Figures 3A to 3C or other features of the window assembly.
  • the second arm 404 has an edge 424 which is distal to the first arm 402.
  • the edge 424 is shaped as a step.
  • waterproofing tray 400 including its structure and function should become clearer from further discussion later in the present specification.
  • FIGS 3A, 3B and 3C show views of a corner piece 500 according to an aspect of the present technology.
  • the corner piece 500 is designed and configured to facilitate attaching components of the window assembly 100 together.
  • the illustrated example is handed, i.e. provided in left and right forms but it should be appreciated that in some instances, it may be non-handed although in such a scenario may require additional connecting fittings.
  • the corner piece 500 has a first arm 502 and a second arm 504 which are substantially perpendicular to each other.
  • Each of the first arm 502 and the second arm 504 has an inner surface 506, 508 respectively, and an outer surface 510, 512 respectively.
  • the inner surfaces 506, 508 are shaped to lie against the edge surface 410 of the waterproofing tray 400.
  • Each of the first arm 502 and the second arm 504 has flanges 514, 516 respectively.
  • the flanges 514, 516 are configured to wrap around the edges (not illustrated in Figures 3A, 3B and 3C) formed in the outer frame member 300. Excess water is allowed to exit the window assembly via flange 514. This aspect of the technology will be discussed in more detail below.
  • An edge 518 of the arm 502 is shaped to define a flange which corresponds to a profile of the outer frame member 300.
  • a toothed feature 522 may be formed into the edge 518, this engaging with the profile of the outer frame member.
  • the opposing edge of the other arm 504 may be similarly configured.
  • Bosses 520 and 520a containing fittings for a screw may be provided to the corner piece 500 to allow it to be secured to the window frame. In use, this would be orientated such that the screw passes through boss 520 from the underside 512 of the corner piece 500.
  • Boss 520a is positioned such that a screw being inserted through this passes through the inner frame member (refer to Figures 6A and 6B).
  • the end cap 600 has a first portion formed by a first arm 602 and a second arm 604 that are substantially perpendicular to each other, and a third arm 606 and fourth arm 608 that are substantially perpendicular to each other.
  • FIGS 5A to 5C illustrate how a corner piece 500 and a cap 600 attached to one end of a waterproofing tray 400 and a plastic profile 416. To better show the relationship of the waterproofing tray 400 and the corner piece 500 the cap is not shown in Figure 5A.
  • the components of Figures 5A to 5C may be attached or otherwise secured to the respective parts of the window frame using mechanical fasteners, such as screws, or with an adhesive or sealant which is applied to one or more of the components.
  • the adhesive or sealant attaches the components together and may also create a seal to prevent passage of moisture through the gaps between the components.
  • the attachment of components 400, 500, and 600 may not occur all at the same time.
  • the corner piece 500 may be joined to the window frame at the time of constructing the corner.
  • the waterproofing tray 400 is then rotated or pivoted into place against the outer frame member.
  • the end cap 600 is then sealed to the corner to make a waterproof corner.
  • a corner piece 500 and cap 600 are also attached to the distal end of the waterproofing tray 400 but have not been shown in Figures 5A, 5B and 5C for sake of clarity.
  • the waterproofing system of the present technology may provide a number of advantages. For instance, having a waterproofing tray 400 with at least one corner piece 500 attached thereto allows the components to be formed as individual components and then cut to a desired length. This facilitates, inter alia, providing a relatively wider range of lengths for a building element while minimising the number of components that must be manufactured and held in stock.
  • the window assembly 100 includes at least one frame sub-assembly 700 formed from a plurality of inner frame members 200, a plurality of outer frame members 300, and panes of glass 102, 104. Multiple of the frame sub-assemblies 700 can be secured together to form at least a portion of the window assembly 100. For instance:
  • a first frame sub-assembly 700 will provide a bottom window frame jamb and therefore will be substantially horizontal when the window assembly 100 is installed.
  • a window frame sub-assembly 700 will provide a head jamb and therefore be orientated substantially horizontal when the window assembly 100 is installed. • A third frame sub-assembly 700 will provide a left frame jamb and therefore will be substantially vertical when the window assembly 100 is installed.
  • a fourth frame sub-assembly 700 will provide a right jamb and therefore will be substantially vertical when the window assembly 100 is installed.
  • first frame sub-assembly the second frame sub-assembly, the third frame sub-assembly and the fourth frame sub-assembly.
  • FIGS 6A and 6B show views of an inner frame member 200 according to an aspect of the technology.
  • the inner frame member 200 includes at least one connection channel, e.g. a first connection channel 202A and a second connection channel 202B, and a frame portion 204.
  • the first connection channel 202A and the second connection channel 202B are each configured to receive a connector (not shown in Figures 6A and 6B) to facilitate attaching the inner frame member 200 to the outer frame member 300.
  • At least one seal connector e.g. a channel 206, is provided to receive a seal (not shown in Figures 6A and 6B).
  • a reveal connector is provided to facilitate attaching a reveal (not shown in Figures 6A and 6B) to the inner frame member 200.
  • the reveal connector is preferably provided in the form of a channel 208 defined by a flange 210 and a leg 212.
  • the channel 208 is shaped and dimensioned to receive a portion of the reveal (not shown in Figures 6A and 6B).
  • the leg 212 is shaped and dimensioned to facilitate it being inserted into the channel 413 of the waterproofing tray 400. As can be seen in Figure 6A, at least a portion of the leg 212 can be formed to be relatively thin compared to other portions of the leg 212. This may make it easier for fasteners (not shown in Figure 6A) to extend through the leg 212 and into a reveal (not shown in Figure 6A) disposed in the channel 208.
  • a receiver 214 can be optionally provided.
  • the receiver 214 is located and orientated to align with boss 520a when the frame sub-assembly 700 is assembled. This may facilitate a fastener extending through the boss 520a of the corner piece 500.
  • the receiver 214 is provided in the form of a screw pipe formed in the inner frame member 200. Flowever, the receiver 214 could take other forms, e.g. a threaded aperture or flange through which a fastener can extend.
  • the outer frame member 300 includes at least one connection channel e.g., a first connection channel 304A and a second connection channel 304B.
  • the first connection channel 304A and the second connection channel 304B are each configured to receive a connector (not shown in Figures 7A and 7B) to facilitate attaching the outer frame member 300 to the inner frame member 200. This aspect of the technology will be discussed in more detail below.
  • a fin 306 is provided which has a lip 308.
  • the lip 308 is shaped to create a ledge when the outer frame member 300 is orientated substantially horizontally e.g., used as a sill in a window assembly 100 (as is discussed in more detail below).
  • the lip 308 and the fin 306 define a channel 308A. In use, this channel 308a receives the edge 424 of the waterproofing tray 400.
  • the fin 306 is a structure that is orientated and dimensioned to provide other functions for the window assembly 100.
  • fasteners (not illustrated in Figures 7A and 7B) can extend through the fin 306 and into a support frame in a building to mount the window assembly 100 in position.
  • a sealant e.g., tape can be applied to the fin 306 on one or more sides of the window assembly 100 and a support frame in a building.
  • tape can be applied to at least one, and preferably two or three, of the fins 306 forming the window assembly 100. This can attach fins 306 to an appropriate part of a building in which the window assembly is installed, e.g. a lintel and trimmer stud (neither shown in Figures 7A and 7B) to which they are adjacent when installed.
  • the lip 308 may include at least one drainage means(not shown) formed after extrusion of the outer frame member 300 e.g., by drilling, cutting or punching. Flowever, alternate ways of allowing moisture to exit the window assembly 100 are described in Figure 8G.
  • a flashing portion 312 extends away from the channel 304 so as to be outward of a building when the window assembly 100 is installed.
  • the flashing portion 312 is formed integrally to other parts of the outer frame element 200, e.g. during extrusion of the outer frame element 300. This may be particularly beneficial as it enables a window assembly 100 to be assembled in a factory and transported to the construction site for installation into the building. As a result, that embodiment reduces the chances that a window may be improperly installed. Alternatively, it can reduce "on site" labour and installation costs or speed up installation of a window.
  • the flashing portion 312 may also be formed separately and attached to the outer frame member 300. In the embodiments where the flashing portion 312 is formed separately from the outer frame member 300, it can be permanently attached to the outer frame member 300 prior to the window assembly 100 leaving a factory. As a result, these embodiments may still provide the advantages of a flashing portion 312 which is integrally formed with the outer frame member 300.
  • a channel 314 is defined by a first lip 316 and a second lip 318.
  • the channel 314 is shaped and dimensioned to receive corresponding parts of a glazing member (not illustrated in Figures 7A and 7B but examples shown in Figures 6C and 6D) and attach the glazing member to the outer frame member 300.
  • At least one receiver e.g., two receivers 320, 322 can be optionally provided to the outer frame member 300.
  • the receiver 320 is located and orientated to align with the boss 520 of the corner piece when a frame sub-assembly 700 is assembled. This may facilitate a fastener extending through the boss 520 and attaching to the outer frame member 300.
  • the receiver 320 for the corner piece is provided in the form of screw pipes formed into the outer frame member 300.
  • the receiver 320 (and also 322) could take other forms e.g., a threaded aperture or flange through which a fastener can extend.
  • other attachment mechanisms may be used such as adhesive or welding.
  • the outer frame member 300 may also be provided with supplementary receivers e.g., 324, 326.
  • the receivers 324, 326 facilitate attaching additional components to the outer frame member 300, for example flashings to improve aesthetic appearances.
  • the slot(s) 328 are located and orientated to receive a portion of a corner piece 500 and allow that component to extend from an inner side of the arm 306 to an outer side of the arm 306.
  • the arm (306) may be formed with drainage means for moisture. When assembled, this may enable moisture on an upper surface of the waterproofing tray 400 to exit from the window assembly 100.
  • FIGS 6C and 6D show views of a glazing member 350 according to an aspect of the technology.
  • the glazing member 350 is configured to attach to at least one of the outer frame member 300 and the inner frame member 200.
  • the glazing member 350 has a first arm 352 and a second arm 354.
  • the first arm 352 and the second arm 354 meet in a region 358.
  • the first arm 352 has a distal end 356 which is shaped to define a retention part 360.
  • the retention part 360 can take various shapes, however as illustrated in the Figures it is a leg shape.
  • the second arm 354 is shaped to define a bearing surface 364.
  • the region 358 is shaped to define a step 362.
  • the step 362 and the retention part 360 engage corresponding features of at least one of the outer frame member 300 and the inner frame member 200. This attaches the components together.
  • bearing surface 364 and a corresponding feature on at least one of the outer frame member 300 and the inner frame member 200 define a channel (not indicated in Figures 6C and 6D).
  • the channel (not shown in Figures 6C and 6D) can receive a barrier arrangement e.g. the panes of glass 102, 104.
  • FIGS. 8A and 8B show a frame sub-assembly 700, formed by attaching an inner frame member 200 and an outer frame member 300 together.
  • a connector 702 is shaped and dimensioned to be received in each of the connection channel 202 and the connection channel 304.
  • the window frame sub-assembly 700 includes two connectors 702 such as shown in Figures 8E and 8F. The use of these connectors 702 attaches the inner frame member 200 and an outer frame member 300 together.
  • the lateral edges of the connector 702 have a substantially triangular or dovetail shape which facilitates them sliding along the length of the channels 202, 304 respectively.
  • the respective shapes of the connector 702 and the channels 202, 304 assists in preventing the connector being pulled out of the channels 202, 304 in the directions indicated by arrows X and Y in Figure 8A.
  • a seal 704 is provided in the seal connector 206.
  • the frame sub-assembly 700 illustrated in Figures 8A, 8B, 8G and 8H can be used to form the sill, head or jambs of the window assembly 100. This should become clearer from the following description.
  • FIG. 8G is a cross-sectional view of the waterproofing system attached to the frame sub-assembly 700.
  • the waterproofing tray 400 is attached to both of the inner frame member 200 and the outer frame member 300.
  • the step 426 is inserted into the channel 308A while the leg 212 is inserted into the channel 413. This may be achieved by aligning the step 426 and the channel 308A, and the leg 212 and the channel 413, and then sliding the components relative to each other.
  • the waterproofing tray 400 may be bent or otherwise deformed to push the step 426 into the channel 308A and the leg 212 into the channel 413.
  • the leg 212 and the channel 413 are shaped and dimensioned to have a tight fit with each other. This creates a substantial or complete air seal between the two components. As a result, when a window assembly 100 including the frame sub-assembly 700 with the waterproofing tray 400 fitted thereto, is installed in a building there is a barrier to air movement. As a result, the present technology may assist in providing a more thermally efficient window.
  • a portion of the plastic profile 416 is in contact with a bearing surface 216 on the inner frame member 200, while another portion of the plastic profile 416 is in contact with a bearing surface 332 on the outer frame member 300.
  • the plastic profile 416 is also in contact with the connector 702.
  • the edge 424 is positioned in the lip 308 while the step 426 sits over the lip 426.
  • the waterproofing tray is made from plastics material, there will some natural deformation and undulations which will form gaps through which moisture will be able to pass.
  • caps 600 are attached to the distal ends of the frame sub-assembly 700 e.g., in the configuration discussed above with respect to Figures 5A to 5C.
  • a surface of the second arm 604 is in contact with the stems 416A, 416, B and 416C of the plastic profile 416 while a surface of the fourth arm 608 is in contact with a surface 425 of the second arm 404.
  • a seal 334 is provided to an inner surface 336 of the fin 306.
  • the seal 334 can be compressed against a surface of a building component e.g., an outer surface of wall framing members, a floor member, a concrete floor pad (footing), or some other structural component.
  • the seal 334 prevents moisture passing from the outside of the fin 306 to the inside. This can assist to limit moisture passing into a building in which the window assembly is installed. Moisture is instead able to exit via gravity through the drainage means 330, which is a space between the step 426, receivers 326 and the arm 306.
  • the seal 334 provides an insulating barrier to prevent heat loss through a gap between the surface and a surface of the building.
  • the seal 334 forms the air seal along the lower edge of the exterior side of the window assembly.
  • an air seal is formed between the channel 413 and leg 212 of the inner frame member on the interior side of the window assembly
  • the seal 334 is preferably an adhesive foam tape e.g. a closed cell foam tape such as that sold under the brand name InsealTM.
  • foam allows the seal 334 to be compressed to improve its ability to prevent ingress of moisture into the building or heat loss.
  • the foam expands against a fastener(s) that extends through the seal 334.
  • the seal 334 can take other forms such as a wet sealant applied as a strip or bead to the fin 306.
  • the seal 334 may be applied as a wet sealant to the fin 306 as part of install of the window assembly 100 after it has been positioned in building.
  • the seal 334 may be an expanding foam as should be known to one skilled in the art.
  • a reveal 360 is attached to the inner frame member 200, e.g. a portion of the reveal 360 is inserted into the channel 208 and secured in place such as by a fastener (like the staple 362 illustrated in Figure 8A) or an adhesive.
  • FIGS. 9A and 9B illustrate views of a head flashing 800 according to an aspect of the technology.
  • the head flashing 800 includes a flashing portion 802 which has a leg 804 and a turned out lip 806, directing any water outwards, located at the distal end of the leg 804.
  • An upstand 808 is orientated to extend away from the flashing portion 802, and to be substantially vertical when installed in a building (not shown in Figures 9A and 9B).
  • a declined or otherwise angled ledge 810 extends from the upstand 808.
  • the ledge 810 is orientated to extend outwardly, and away from the inside of a building in which the window assembly 100 is installed. The decline is sufficient to allow water to directed outwards, away from the window assembly. It also includes a flange 811 which helps when presenting the head flashing to wall cladding (not shown).
  • the ledge 810 has a series of perforations 809 which provides a plurality of ventilation apertures.
  • the ventilation apertures 809 allow moisture to drain from the building in which the window assembly 100 is installed, and air circulation into the building cavity.
  • the ventilation apertures 809 are not so large as to allow vermin such as spiders to pass.
  • the ledge 810 may alternatively have a serrated edge, the gaps between adjacent serrations forming the ventilation apertures.
  • a receiver 812 is formed into the head flashing 800 and is positioned and orientated to receive a fastener (not illustrated in Figures 9A and 9B).
  • the head flashing 800 is preferably fitted to the window assembly 100 after that has been at least partially installed in a building. However, in some embodiments, the head flashing 800 may be fitted to a window assembly 100 at a factory or otherwise during assembly of the window assembly 100.
  • FIGS. 10A, 10B and IOC show views of a head flashing bracket 900 according to an aspect of the technology.
  • the head flashing bracket 900 moulded from plastics material, is configured to facilitate attaching the head flashing 800 to a window frame sub-assembly 700 and holding the head flashing in the required position.
  • the head flashing bracket includes a body 902, which has a slot formed therein.
  • the slot 902 is dimensioned and orientated to facilitate the body receiving part of the flashing portion 802.
  • An alignment arm 904 extends away from the body 902 and includes a channel 906.
  • the channel 906 is aligned with the slot 902 and can also receive a side edge of the flashing portion 802.
  • the arm 904 provides a raised barrier which can in use prevent or limit water on top of the flashing portion 902 running off the lateral sides where it could enter into the building around the window assembly 100. Instead, water is directed to run of the head flashing distal to the upstand 808.
  • a receiver 908 is positioned and orientated to align with the receiver 812 which the head flashing cap 900 and the head flashing 800 are assembled together.
  • a fastener (not illustrated in Figures 10A to IOC) can extend through the receiver 908 and into the receiver 812 to secure the two components together.
  • ejector pin marks some of which are indicated by 910, from the plastic moulding used to form the head flashing bracket, are visible.
  • Figures 11A to 11M show various views of a substantially assembled window assembly 100 according to the technology. They show how frame sub-assemblies 700 can be used together to form the window assembly 100.
  • Panes of glass 102, 104 and seals 704 are attached.
  • the corner piece 500 provides a joint between the different frame sub-assemblies forming the window assembly 100 e.g. a substantially 90° joint between a window jamb and a sill, the area of the window assembly most prone to moisture penetration.
  • the corner piece 500 may also be used as a jointer between a window head and a window jamb (this area does not suffer moisture penetration problems to the same extent as the lower corners of the window assembly 100).
  • the corner piece 500 attaches two frame sub-assemblies e.g., fasteners such as screws (not illustrated in Figure 11F) extend through apertures 508 and into the corresponding receivers 214, 320.
  • the corner piece 500 extends through the slot 328 and sits over an edge of the fin 306.
  • FIGS 12A to 121 and 13 show various views of a window assembly 100 installed in a building 1000. For sake of clarity, only a portion of the building 1000 is shown in the Figures.
  • the building 1000 includes a support frame having a plurality of support elements (not shown in Figure 12A) that define an opening in the support frame.
  • the opening (not indicated in the Figures) is the space which the window assembly 100 will fill and cover.
  • the opening (not indicated in the Figures) is defined by a first trimmer stud 1002, a second trimmer stud 1004, a trimmer 1006 and a lintel 1008.
  • a moisture impermeable layer (such as building wrap 1010 indicated in the Figures) is attached to the building 1000 and cut to create an opening (not marked in the Figures).
  • the building wrap 1010 may be folded over trimmer studs 1002, 1004, the trimmer 1006 and the lintel 1008 and secured in place.
  • a waterproofing material e.g., a bituminous adhesive tape (not shown in the Figures) as known to one skilled in the art may be attached to one or more of the trimmer studs 1002, 1004, the trimmer 1006 and the lintel 1008.
  • a waterproofing material e.g., a bituminous adhesive tape (not shown in the Figures) as known to one skilled in the art may be attached to one or more of the trimmer studs 1002, 1004, the trimmer 1006 and the lintel 1008.
  • the waterproofing system avoids the need to attach waterproofing materials directly to the structural components of the building 100.
  • the window assembly 100 is positioned in the opening (not indicated in the Figures) in the building 1000.
  • the first frame sub-assembly is located above and substantially parallel to the trimmer 1006
  • the second frame sub-assembly is substantially parallel to the lintel 1008
  • the third frame sub- assembly is substantially parallel to the trimmer stud 1002
  • the fourth frame sub-assembly is located below and substantially parallel to the trimmer stud 1004.
  • the window assembly 100 is secured to the trimmer studs 1002, 1004, the trimmer 1006 and the lintel 1008 by fasteners (not shown in Figures 12A to 121).
  • the fasteners may be screws, nails of other suitable fasteners that extend through the arm 306 and the seal 334 of each of the window frame sub- assemblies, and into the corresponding trimmer stud 1002, 1004 the trimmer 1006 and the lintel 1008.
  • fasteners can be used to attach the frame sub-assemblies forming the jamb and head of the window assembly 100 to the respective fins 306.
  • a seal 334 is not provided between the fin 306 and the respective trimmer stud 1002, 1004 and lintel 1008.
  • tape may be attached to cover a gap between a respective one of the trimmer studs 1002, 1004, and the lintel 1008 and the respective fin 306.
  • the tape creates a seal to prevent passage of moisture and air through the gap.
  • the tape (not illustrated) provides at least one of an air and a moisture seal.
  • the seal 334 is resilient and expands to press against the fastener(s). This may substantially limit or prevent ingress of moisture into the building 1000 around the fastener. Flowever, in some instances, the fastener(s) may pass through the fin 306 beneath the seal 334.
  • the panes of glass 102, 104 are positioned to be substantially inline with a plane (not marked) on which the trimmer studs 1002, 1004, the trimmer 1006 and the lintel 1008 lie.
  • the panes of glass 102, 104 are in-line with the frame of the building 1000.
  • the location of the panes of glass 102, 104 which provide a thermal insulation for the building 1000 is located in line with the frame of the building 1000. This may improve the thermal performance of the window assembly 100 compared to other windows e.g., those in which the glass is located in line with, or on the outside of, the cladding.
  • the weight of the panes of glass 102, 104 is not cantilevered outside of the trimmer 1006 and lintel 1008.
  • the present technology may simplify installation of the window assembly 100 in the building 100. For instance, it may remove the need to use components such as a WANZ (Window Association of New Zealand) bar to support the weight of a window inside a building as is currently required by many prior art windows.
  • WANZ Winddow Association of New Zealand
  • the waterproofing tray 400 extends from an inner side of the window assembly 100 past an outer surface of a support to which the window assembly 100 is attached. For instance, as can be seen in the Figures, the waterproofing tray 400 extends from an inner side of the window assembly 100, underneath the panes of glass 102, 104 to an outer side of the trimmer 1006.
  • the waterproofing tray 400 can therefore collect moisture which may seep downwards for any of various reasons.
  • the waterproofing tray 400 extends from an inner most edge of the inner frame member 200 and to the fin 306 so as to span substantially the entire width of the support element. This can enable the waterproofing system to direct moisture out through the drainage means 330. Alternatively, if moisture is collected on the corner piece 500 it can flow of the portion of the corner piece 500 which extends through the slot 328. This is a way to prevent or eliminate moisture coming into contact with the walls and frame of the building 1000.
  • the cavities may be important for thermal performance of the window assembly.
  • An outer cavity 1100 is defined by an upper surface the waterproofing tray 400 and an inner surface of the outer frame member 300.
  • the outer cavity 110 can be considered to be bordered at its inner side by the plastic profile 416.
  • the cavity 1100 is "open" to atmospheric pressure due to one or more of the slots 328 and drainage means 330. This allows the outer cavity 1100 to be pressure equalised to atmospheric pressure. However, the slots 328 and drainage means 330 still provides outlets through which moisture collected by the waterproofing tray 400 can exit the window frame assembly 100.
  • the slots 328 are relatively small compared to the outer frame member 300. As a result, the slots 328 and the drainage means 330 provide minimal to no adverse effect on the thermal performance of the window assembly.
  • An inner cavity 1200 is defined by an upper surface of the waterproofing tray 400 and the inner frame member 200.
  • the inner cavity 1200 is bounded on its outer side by the stem of the plastic profile 416.
  • the plastic profile 416 does not extend the full length of the inner frame, thus creating the gap Z.
  • the gap Z provides an opening through which moisture can pass. This can allow moisture to flow from the cavity 1200. This is therefore a failsafe to collect water that seeps down onto the waterproofing tray and direct that out through the drainage means 330 or the slot 328.
  • the gap Z is sized and dimensioned to allow moisture which can find its way between waterproofing tray 400 and the ledge 430 to drain out of that region of the window assembly 100.
  • the gap Z is not so large as to allow significant thermal convection from cavity 110 to cavity 1200. It therefore does not significantly affect thermal performance of the window assembly 100.
  • the waterproofing system may provide several benefits. For instance, it could act as both a failsafe to collect failure moisture in the window assembly and direct this out of the window assembly 100, while improving thermal performance of the building in which the window assembly 100 is installed.
  • the plastic profile 416 when located atop the waterproofing tray 400, provides a bearing surface on which another component of the window assembly 100 can bear or touch. For instance, as is shown in Figure 13, the plastic profile 416 provides a bearing surface on which an underside of the structure that forms the channel 202A can bear. This may assist the waterproofing system to thermally insulating the inner region of the window assembly 100 from the outer region of the window assembly 100.
  • Figure 13 shows how a fastener (not shown) would be able to pass through the fin 306 and into the trimmer 1006.
  • the seal 334 wraps around and conforms to the fastener and therefore prevents or eliminates moisture moving from the waterproofing tray 400 back towards the trimmer 1006.
  • the window assembly 100 can be installed in the building 1000 to define a trim gap 1300 as should be known to one skilled in the art.
  • the trim gap 1300 is defined by a lower surface (the first surface 408) of the waterproofing tray 400 and an upper surface of the trimmer 1006.
  • the trim gap 1300 can be filled with insulation materials (not indicated in the figures). This is possible because the waterproofing system of the present technology is separate from, and not dependent on, the structure components of the building 1000, e.g. the trimmer 1006.
  • the ability to provide insultation materials in the trim gap 1300 may improve the thermal performance of the window assembly 100 when mounted in a building 1000.
  • trim gap 1300 may be achieved using any technique as should be known to one skilled in the art, e.g. wedges and so forth.
  • one or more cavities may be provided between the window frame sub-assemblies and one or more of the lintel 1008 and the trimmer studs 1002, 1004. As a result, insulation materials may also be provided in the cavities (not indicated in the Figures).
  • the window assembly 100 may be positioned to abut one or more of the lintel 1008 and the trimmer studs 1002, 1004 and trimmer 1006.
  • the flashing portion 312 extends away from the trimmer 1006 and defines a gap 1010. Cladding (not shown in Figure 13 but indicated as 1012 in Figures 12A to 121) can extend into the gap 1010 and therefore this provides a desirable aesthetic finish to the building 1000.
  • the orientation of the flashing portion 312 minimises or prevents wind blowing towards the corner piece 500 and so can also assist to prevent ingress of moisture into the window assembly 100.
  • the flashing portion 312 protects the exposed ends of the cladding 1012 from moisture e.g. rain, preventing this being blown over top of the exposed edges whereby it could enter into the cavity space of the building.
  • FIG. 14 shows a building element in the form of an opening sash window 2000 according to an aspect of the present technology.
  • Components of the building element 2000 are similar to the components of the window assembly 100 and therefore like references refer to like components.
  • an opening frame member 2002 is provided which is mounted to a window frame sub-assembly 700 by a hinge (not illustrated in Figure 14).
  • the hinge (not illustrated) may be any known hinge arrangement as should be known to one skilled in the art.
  • the opening frame member 2002 engages with a glazing member 350 to support panes of glass 102,
  • a standard spaced 380 is provided between the panes of glass 102, 104 to keep those spaced apart from each other. This is as should be known to one skilled in the art.
  • a handle (not illustrated in Figure 14) can be provided to the opening frame member 2002.
  • a person can move the opening frame member 2002 to open and / or close the window.
  • the waterproofing system provides advantages as are described above with references to Figures 1 to 13.
  • FIG. 15 shows a cross-sectional view of a building element in the form of an opening hinged door 3000 according to an aspect of the present technology.
  • Components of the opening hinged door 3000 are similar to the components of the window assembly 100 and therefore like references refer to like components.
  • a door frame is provided e.g., by a first member 3002 and a second member 3004, and which is mounted to a window frame sub-assembly 700 by a hinge (not illustrated in Figure 14).
  • the hinge (not illustrated) may be any known hinge arrangement as should be known to one skilled in the art.
  • a glazing member 350 engages with first member 3002 to support panes of glass 102, 104. Seals and other features of the opening hinged door are as should be known to one skilled in the art and therefore are not described herein.
  • a handle (not illustrated in Figure 14) can be provided to the door frame. In use, a person can move the door frame to open and / or close the opening hinged door 3000.
  • the waterproofing system provides advantages as are described above with reference to Figures 1 to
  • FIG 16 shows an alternate embodiment of a building element in the form of a sliding window or door 4000.
  • Components of the sliding window or door 4000 are similar to the components of the window assembly 100 and therefore like references refer to like components.
  • Sliding mechanism is provided by a first member 4002 which is attached to the inner window frame member 200, and a second member 4004 which is attached to the outer window frame member 300.
  • a door or window frame is provided to support panes of glass 102, 104 e.g. by a first frame element 4006, a second frame element 4008 and a glazing member 350.
  • An articulation mechanism (indicated generally as 4010).
  • a track 4012 is provided e.g. mounted in a channel (not indicated) which is defined by the first member 4002 and the second member 4004.
  • the articulation mechanism 4010 facilitates moving the door or window frame along the length of the first member 4002 and the sconed member 4004. This enables a person to open and / or close the door or window provided by the sliding window or door 4000.
  • the waterproofing system provides the advantages as described herein with reference to Figures 1 to 13.
  • FIG 17 shows an alternate attachment arrangement to attach a window assembly 100 to a support structure e.g. a building (not shown).
  • a supplementary bracket 5000 is attached to the 306.
  • the bracket 500 and the outer window frame member 300 may have complementary fasteners halves which cooperate to attach the components together.
  • the bracket 5000 includes a first fastener half 5002 e.g. a cylindrically shaped portion, while the outer window frame member 3000 includes a second fastener half e.g. a receiver in the form of a channel 324 (as is perhaps best illustrated in Figures 7A and 7B.
  • the first fastener half 5002 is positioned relative to, and slid along the channel 324, or alternatively presented up to the channel and rotated into position.
  • the supplementary bracket 5000 also includes an arm 5004 which extends away from the first fastener half 5002. It can be seen that at least a portion of the arm 5004 extends distal to the drainage means 330 when the supplementary bracket 5000 is attached to the outer window frame member 300.
  • the arm 5004 therefore provides an extended surface through which a fastener (not illustrated in Figure 17) can extend to attach the supplementary bracket 5000 (and therefore the window assembly 100) to a
  • the use of the supplementary bracket 5000 can be particularly useful to install a building element according to the present invention in certain types of building e.g., those where a fastener must be set back from an edge of the building such as a concrete pad.
  • the bracket 5000 is structured and / or arranged to allow moisture to drain out of the window assembly 100. For instance, it may be formed in or cut to relatively short lengths. When installed the brackets 5000 are spaced apparat to create gaps which can act as drains. Alternatively, opening may be formed into the bracket 5000 e.g. by punching or cutting.
  • the waterproofing system provides the advantages discussed herein.
  • the invention may also be said broadly to consist in the parts, elements, characteristics and features referred to or indicated in the specification of the application, individually or collectively, in any or all combinations of two or more of said parts, elements, characteristics or features.

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  • Engineering & Computer Science (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Specific Sealing Or Ventilating Devices For Doors And Windows (AREA)

Abstract

The invention relates to improvements to building elements, and methods of manufacture and installation of building elements, with particular application to waterproofing window and / or door assemblies with glazing. The invention includes a waterproofing tray which is mounted to and spans the outer and inner frame members of a window assembly. Together with the use of corner pieces and an end cap, the waterproofing tray collects and directs any moisture out of the window assembly, away from the interior of the building to which the window assembly is fitted.

Description

IMPROVEMENTS TO BUILDING ELEMENTS, AND METHODS OF MANUFACTURE AND INSTALLATION OF BUILDING ELEMENTS
1. Field of Technology
The present technology relates to improvements to building elements, and methods of manufacture and installation of building elements. The invention has particular application to waterproofing window and / or door assemblies with glazing.
2. Background to the technology
There are a wide range of building elements which can be used to provide different parts of a building. Of these, some building elements are used to cover an opening in the external cladding of a building. For instance, a window can cover an opening in the cladding while allowing natural light into the building and people to look into or out from the building. Similarly, doors allow people to move through the opening while also closing the opening when required.
There has been significant investment in the design of building elements. As a result, there are a large range of different products available.
An important consideration in the design and manufacture of building elements is their ability to thermally insulate the inside of the building from the surrounding environmental. This can be influenced by various factors. For instance, the building elements have a barrier of some form that is mounted in a frame, and the frame is fixed to the building so that the barrier extends across the opening. In the case of a window, the barrier is glazing i.e., one or more panes of glass.
One approach to window design and manufacture is to provide window frames made from aluminium extrusions which support and retain one of more panes of glass e.g., one pane for a single-glazed window assembly, two panes for a double-glazed window assembly or three panes for a triple-glazed window assembly. These window assemblies are installed into a frame formed in a building.
A window disrupts the surrounding membrane, i.e. cladding, of the building in which it is installed. This can therefore create areas in the building membrane where moisture may enter the building or into the frame of the building. Over time, this penetration of moisture can cause significant damage to the building. This can arise for various reasons including improper installation of the window assembly due to poor workmanship or error, or inherent problems due to the design of the window assembly. As a result, windows are a key concern for weatherproofing of a building. In New Zealand at least, poor window installation can be a significant factor in moisture penetrating into the building. This may affect the components of the building, such as wood and fabrics, that are contacted by the moisture and also lead to the formation of mould on interior surfaces.
In addition, glass has a relatively low thermal insulation value. Therefore, construction techniques such as double-glazing aim to reduce heat loss through a window. That notwithstanding, the installation of a window in a building can introduce "thermal leaks" such as gaps between the window and components of the building it is installed e.g. the window frame or the cladding. Those gaps allow air flow and lead to loss of heat from the interior of the building to its exterior. In modern buildings, in New Zealand at least, the existence of building cavities can exacerbate this as these allow cold external air to circulate well into the wall space and compromise the performance of the building's insulation materials.
Another challenge for window design, construction and installation is optimising the overall aesthetics of the building in which they are installed. This requires balancing various considerations such as the size and shape of the frame and position of the glass pane(s) relative to the building's walls and cladding. However, the position of the glass pane(s) can create challenges for window design, construction and installation. Accordingly, to achieve desired aesthetics, there are number of problems that need to be overcome.
3. Object of the Technology
It is an object of the technology to provide a window assembly which may reduce the likelihood of damage to a building due to water ingress.
Alternatively, it is an object of the technology to provide a window assembly that can be manufactured and transported as a substantially complete unit.
Alternatively, it is an object of the technology to provide a window assembly, and methods of installation, which may improve thermal insulation.
Alternatively, it is an object of the technology to provide a window assembly, and methods of installation, which may improve weathertightness and waterproofing.
Alternatively, it is an object of the technology to provide a window assembly, and methods of installation, which may reduce weathertightness and waterproofing issues that can arise form damage to components of the window during transport, storage and installation.
Alternatively, it is an object of the technology to provide a window assembly, and methods of installation, which may facilitate achieving a desired aesthetic Alternatively, it is an object of the technology to provide a window assembly which maybe more cost effective to manufacture and assemble or install.
Alternatively, it is an object of the technology to at least provide the public with a useful choice.
4. Summary of the Invention
According to one aspect of the technology there is provided a building element, wherein the building element includes: a plurality of frame sub-assemblies that are attached to each other, and a waterproofing system.
According to one aspect of the technology there is provided a frame sub-assembly, wherein the frame sub-assembly includes: an inner frame member, an outer frame member, and a waterproofing system.
According to one aspect of the technology there is provided a building element, wherein the building element includes: an inner frame member, an outer frame member, and a waterproofing system, wherein the waterproofing system includes a drain, wherein the inner frame member and the outer frame member are attached to each other, and further wherein the waterproofing system is positioned and arranged to, in use, collect moisture and direct the moisture towards the drain.
According to one aspect of the technology there is provided a frame sub-assembly, wherein the frame sub-assembly includes: an inner frame member, an outer frame member, and a waterproofing system, wherein the waterproofing system includes a drain, wherein the inner frame member and the outer frame member are attached to each other, and further wherein the waterproofing system is positioned and arranged to, in use, collect moisture and direct the moisture towards the drain.
According to one aspect of the technology there is provided a building element configured to be secured to a support element of a building, wherein the building element includes: an inner frame member, an outer frame member, and wherein the outer frame member includes a fin that is orientated to be positioned relative to the support element of the building, and further wherein a fastener can extend through the fin and into the support element to secure the building element to the building.
According to one aspect of the technology there is provided a method of installing a building element to a building, including the steps of:
(a) positioning a building element as described above with respect to at least one support element of the building;
(b) using a fastener to attach a fin of the building element to an external surface of the support element.
In one embodiment, the technology may include one or more of the following steps in any order:
(c) applying tape to a fin of a window assembly and a lintel of the building to create a seal between the fin and the lintel.
(d) applying tape to one or more fins of a window assembly and a jamb of the building to create a seal between the fin(s) and the jamb(s).
The present specification describes technology relating to improvements to building elements. The technology may preferably find application in a building element in combination. Accordingly, reference will be made herein as such.
However, the aspects of technology may be applied separately of each other. As a result, description of the technology in combination should not be seen as liming on the scope of the present invention.
Reference throughout the present specification will be made to terms such as inner and outer. For instance, reference may be made to an inner frame member or outer surface of a component. These should be understood to be relative references, indicating the position of one component or surface relative to another component or surface, with respect to the middle or interior of a building. It should also be appreciated that any relative reference should not be seen as limiting on the scope of the present invention.
In a preferred embodiment, building elements according to the present technology may include at least one barrier arrangement.
In particularly preferred embodiments, the barrier arrangement may include glazing, i.e. includes at least one pane of glass, but even more preferably, two panes of glass to provide a double-glazed barrier arrangement or three panes of glass to provide a triple-glazed barrier arrangement.
Reference herein will be made to the barrier arrangement being the panes of glass. However, his should not be seen as limiting on the scope of the present invention. For example, the barrier arrangement may be panes of transparent plastics material.
In a particularly preferred embodiment, the building element may be a window assembly. For instance, it may be a non-opening window, a hinged window, or a sliding window such as a stacking window. However, the building element may also be a sliding or hinged door.
Reference throughout the present specification to the term "waterproofing system" should be understood as meaning one or more components which can collect moisture in a window assembly.
In a preferred embodiment, the waterproofing system may be configured to partially or completely collect failure water, e.g. water that seeps down through a window frame that has been damaged or incorrectly installed. The waterproofing system may partially or completely prevent failure water entering into a building cavity or damaging components of the building, e.g. stud, jambs etc.
In a preferred embodiment, the waterproofing system may be attached to at least one frame member forming the building element.
In a particularly preferred embodiment, the waterproofing system may be attached to both of an inner frame member and an outer frame member.
However, in alternative embodiments the waterproofing system may be at least partially formed integrally with one or both of an inner frame member and an outer frame member.
Throughout the present specification will be made to the building element including an inner frame member and an outer frame member. These should be understood are relative terms indicating the location of the members relative to each other and the middle of a building. For instance, the inner frame member is closer to the middle or interior of the building than the outer frame member.
In a preferred embodiment the inner frame member and outer frame member may be attached to each other. For instance, each of the members may include a channel configured to receive a portion of a connector. The channels may be shaped and dimensions to prevent the connector being pulled out laterally to thereby attach the members together. In addition, alternate attachment arrangements are envisaged within the scope of the present technology.
In a preferred embodiment, the outer frame member may include at least one fin.
The fin may be configured to provide one or more functional benefits. For instance, in one form the fin may be positioned and orientated to facilitate attachment of the outer frame member of the building element to a surface of another building element, for example, a support element of the frame of the building. In addition, the fin may be structured to provide structural support to the outer frame member, e.g. it facilitates supporting an upper portion of the frame member (and therefore hold the building element in position).
In yet further embodiments, the fin may be shaped and orientated to facilitate creation of a seal between the fin and the support element of the building to which it is attached. For instance, the fin may be provided with a seal, e.g. a foam tape, which can, for example, be positioned, and optionally compressed, by the fin and the support element. Alternatively, a seal such as a waterproof tape could be attached to the fin and support element to provide a barrier that seals the gaps therebetween.
In a preferred embodiment, the outer frame member may include a flashing portion.
In embodiments, attachment of the waterproofing system to the building element can occur during manufacture or assembly of the building element. Therefore, the building element can be shipped or transported to a building site at which it is to be installed into a building.
In a particularly preferred embodiment, the waterproofing system may be attached to at least one of the inner frame member and the outer frame member. The attachment may be a direct attachment, in which a component of the waterproofing system is attached directly to a component of the building element, e.g. by a fastener such as a screw, or inserting a portion of one component into a corresponding receiving portion such as a channel on the other component.
Alternatively, the attachment may be indirect e.g., there is one or more components between the waterproofing system and the building element.
In a preferred embodiment, the waterproofing system may comprise a waterproofing tray.
Preferably, the waterproofing tray may be shaped and dimensioned to span a region of the building element at which an inner frame member and an outer frame member are attached to each other.
Preferably, the waterproofing tray may be shaped and dimensioned to span a region of the building element in which the barrier arrangement is supported.
Preferably, the waterproofing tray may include a bearing surface for a frame component that receives the glazing of the barrier arrangement. Preferably, the waterproofing tray may have an inner portion and an outer portion. For instance, the inner portion may be the part of the waterproofing tray which is located closer to the inside of a building than the barrier arrangement. Further, in these embodiments, the outer portion may be the part of the waterproofing tray that is located closer to the outside of a building than the barrier arrangement.
Preferably, one or both of the inner frame member and outer frame member is configured to receive at least part of one or both of the inner portion and outer portion of the waterproofing tray.
In a preferred embodiment, the waterproofing system may include at least one corner piece.
In a preferred embodiment, the corner piece may be shaped and dimensioned to be extend through a corresponding opening in a frame sub-assembly of the building element, e.g., in an outer frame member.
In a preferred embodiment, the waterproofing system may include at least one end.
In a preferred embodiment, the building element may include at least one cavity. Even more preferably, the building element may include at least one cavity proximate the at least one end of the waterproofing system.
In a particularly preferred embodiment, the at least one cavity may include an opening to facilitate exit of moisture from the cavity.
In a particularly preferred embodiment, the opening may be one or more of a drainage opening through which moisture on the waterproofing tray can flow, or a slot configured to align with another component of the waterproofing system, e.g. a / the corner piece of the waterproofing system.
In a preferred embodiment, the at least one cavity may be defined by a surface of the waterproofing tray and a surface of at least one of the outer frame member and the inner frame member.
Further aspects of the technology, which should be considered in all its novel aspects, will become apparent to those skilled in the art upon reading of the following description which provides at least one example of a practical application of the invention.
5. Brief Description of the Drawings
One or more embodiments of the technology will be described below by way of example only, and without intending to be limiting, with reference to the following drawings, in which:
Figure 1A is a first perspective view of a building element according to one aspect of the technology in the form of a window assembly;
Figure IB is a second perspective view of the window assembly of Figure 1A; Figure 2A is a first perspective view of a waterproofing tray according to one aspect of the technology;
Figure 2B is a second perspective view of the waterproofing tray of Figure 2A; Figure 2C is an end view of the waterproofing tray of Figures 2A and 2B; Figure 3A is a first perspective view of a corner piece according to one aspect of the technology; Figure 3B is a second perspective view of the corner piece of Figure 3A; Figure 3C is a third perspective view of the corner piece of Figures 3A and 3B; Figure 4A is a first perspective view of an end cap according to one aspect of the technology; Figure 4B is a second perspective view of the end cap of Figure 4A; Figure 5A is a first perspective view of a corner piece and waterproofing tray relative to each other;
Figure 5B is a second perspective view of the corner piece and waterproofing tray of Figure 5A, together with an end cap;
Figure 5C is a third perspective view of the corner piece and waterproofing tray of Figures 5A and 5B, together with the end cap;
Figure 6A is a first end view of an inner frame member of the building element according to one aspect of the technology;
Figure 6B is a first perspective view of the inner frame member of Figure 6A; Figure 6C is a perspective view of a glazing member according to one aspect of the technology; Figure 6D is a first end view of the glazing member of Figure 6C; Figure 7A is a first end view of an outer frame member of the building element according to one aspect of the technology;
Figure 7B is a first perspective view of the outer frame member of Figure 7A;
Figure 8A is an end view of an outer frame member and an inner frame member attached to each other according to one aspect of the technology;
Figure 8B is a perspective view of Figure 8A; Figure 8C is an end view of a seal according to one aspect of the technology;
Figure 8D is a perspective view of the seal of Figure 8C; Figure 8E is an end view of a pair of connectors used to connect the outer frame member to the inner frame member according to one aspect of the technology;
Figure 8F is a perspective view of the connectors of Figure 8E;
Figure 8G is a cross-sectional view of a waterproofing system attached to an assembled frame sub- assembly of the building element;
Figure 8H is a first perspective view of Figure 8G; Figure 9A is first perspective view of a head flashing for the building element according to one aspect of the technology;
Figure 9B is a cross-sectional view of the head flashing of Figure 9A; Figure 10A is a first perspective view of a top end cap according to one aspect of the technology; Figure 10B is a side view of the top end cap of Figure 10A; Figure IOC is a second perspective view of the top end cap of Figures 10A and 10B; Figure 11A is a front perspective view of a window assembly according to one aspect of the present technology; Figure 11B is a first close-up front perspective view of area A shown in Figure 11A; Figure 11C is a further close-up front perspective view of area A shown in Figure 11A; Figure 11D is a second close-up rear perspective view of area A shown in Figure 11A; Figure 11E is a further close-up rear perspective view of section A shown in Figure 11A; Figure HF is a view of Figure HE with the end cap removed; Figure 11G is a bottom perspective view through cross-section A-A shown in Figure 11A; Figure HH is a second bottom perspective view through cross-section A-A shown in Figure 11A; Figure HI is an end view through of cross-section A-A shown in Figure 11A; Figure HJ is a first close-up perspective view of area B shown in Figure 11A; Figure HK is a second close-up perspective view of area B shown in Figure 11A; Figure Ill- is a first rear close-up perspective view of area B shown in Figure 11A; Figure HM is a first perspective view of a cross-section through B-B shown in Figure 11A;
Figure 12A is a first perspective view of a building with a window assembly according to an aspect of the technology; Figure 12B is a cross-sectional view through section C-C shown in Figure 12A; Figure 12C is a close-up view of section D-D shown in Figure 12A from a first perspective view; Figure 12D is a second close-up of section D-D shown in Figure 12A from a second perspective view; Figure 12E is a end view of section D-D shown in Figure 12A; Figure 12F is a first close-up view of section E-E shown in Figure 12A from a first perspective view; Figure 12G is a side on view of section E-E shown in Figure 12A; Figure 12H is a cross-sectional view through section F-F shown in Figure 12A; Figure 121 is a close-up view of a portion of section F-F shown in Figure 12H; Figure 13 is a cross-sectional view of a portion of a window frame sub-assembly according to the technology installed in a building;
Figure 14 is a cross-sectional view of another embodiment of a building element according to another aspect of the present technology in the form of an opening sash window;
Figure 15 is a cross-sectional view of another embodiment of a building element according to another aspect of the present technology in the form of an opening hinged door ;
Figure 16 is a cross-sectional view of another embodiment of a building element according to another aspect of the present technology in the form of sliding window or door;
Figure 17 is a cross-sectional view of another embodiment of a building element according to another aspect of the present technology illustrating an alternative attachment arrangement. 6. Description of Preferred Embodiments of the Invention
Throughout the Figures like references refer to like components. It should be noted that in various Figures certain components may not be shown to simplify the Figures and to better emphasise certain features of the present technology. This should not be seen as limiting on the scope of the technology and the disclosure herein should be considered in its entirety. 6.1. Window Assembly
Referring first to Figures 1A and IB which show a building element according to an aspect of the invention in the form of a window assembly 100. Reference herein to the building element as a window assembly should not be seen as limiting on the scope of the present technology. The window assembly 100 is designed and configured to be completely or substantially assembled including one or more of the components described herein. It can then be shipped as a complete or substantially complete unit to the location at which it is to be installed in a building (not shown in Figures 1A or IB).
The window assembly 100 includes an integrated waterproofing system as will be described in more detail below.
The window assembly 100 has an outer side (being the closest side of the window assembly in Figure 1) and an inner side (being the closest side of the window assembly in Figure 2).
The window assembly 100 generally comprises a plurality of inner frame members 200, a plurality of outer frame members 300, and one or more panes of glass e.g., two panes of 102, 104 as illustrated in the Figures. The inner frame members 200 and the outer frame members 300 are attached to each other to create a frame sub-assembly which can receive and support the panes of glass 102, 104.
In the illustrated embodiment, the inner frame members 200 and outer frame members 300 are each formed as extrusions from an extrudable material e.g., aluminium, as standard lengths. Flowever, it should also be appreciated that the inner frame member 200 and the outer frame member 300 could be formed from other materials such as plastics, fibreglass, composites, or steel. Therefore, the discussion herein should not be seen as limiting on the scope of the present invention.
After being formed, the members 200, 300 are cut to length according to the required dimensions for the window assembly 100. In addition, the ends to the frame members 200, 300 can be angle cut e.g., to create an angle corresponding to an angle created on another frame member 200, 300 respectively. In preferred forms, the angle may be substantially 45° which allows two frame sub-assemblies according to the present technology to be joined together to form a corner with an angle of substantially 90°.
When the inner frame members 200 and the outer frame members 300 are assembled together, the angle cut ends form a joint between two sides e.g. between the top side and a lateral side, and between the bottom and a lateral side.
It should be appreciated that the shape of the frame members 200, 300 is chosen so that they may form either at top, bottom or lateral side edge of the window assembly 100 when assembled together.
6.1.1. Waterproofing System
Referring now to Figures 2A to 2C which show views of a waterproofing tray 400 according to an aspect of the present technology. The waterproofing tray 400 is a moulding of plastics material, such as uPVC, which is attached to the window frame to help form the window assembly 100. It should be appreciated that, as when installed the waterproofing tray contacts both the inner frame member and the outer frame member, the use of plastics material or similarly thermally inert material at least minimises, if not eliminates, thermal transfer between the respective frame members.
The waterproofing tray 400 has a body having a first arm 402 and a second arm 404 which are orientated substantially perpendicularly to each other. The first arm 402 includes a top surface 406, an under surface 408, and an edge portion 410 which is distal to the second arm 404. The first arm 402 has a lip 412 located at the edge portion 410, and which is defined by a curved portion of the first arm 402 which wraps around and back over the first arm 402 to define a channel 413 between the top surface 406 and the lip 412. The under surface 408 is substantially flat, such that in use, it better transfers any loading through to the building element or support beneath.
The waterproofing 400 tray includes a plastic portion 416 which is similarly formed from a material which is substantially or completely thermally insulating e.g. a plastics material such as uPVC. The plastic profile 416 provides a broad flat surface area that, in use, bears the weight of the aluminium frame and glazing above. The extent of the flat surface is such that it can be used with aluminium frames of a variety of sizes. The plastic profile 416 is configured with a plurality of stems e.g. three stems as indicated as 416A, 416B and 416C, that contact the top surface 406 of the waterproofing tray 400. One stem 416C tucks under detail fold 411 of the tray 400.
In the illustrated example, the plastic portion is a separate component, formed separately from the waterproofing tray 400 for ease of manufacture. However, in alternative embodiments not shown here, this may be formed as an integral structure to the waterproofing tray. In these embodiments, the extrusion may only include the equivalent of the stem structures, not the broad flat surface of the plastic portion.
In some examples, not shown here, the second surface 410 may be orientated to provide a slight downward slope from the inner to the outer directions e.g., in the direction towards the outside of a building in which the window assembly is installed. This may assist in ensuring moisture collected by the waterproofing tray 400 is directed out of the window assembly (by other features as are discussed in more detail below).
In preferred forms as illustrated, the plastic profile 416 does not extend along the entire length of the waterproofing tray 400. For instance, and as best shown in Figure 2A, it may be spaced from at least one end 428 of the waterproofing tray 400 to define a gap Z. It should be appreciated that the gap Z could be provided at both end 428 and the distal end (not illustrated in Figures 2A to 2C) of the waterproofing tray 400.
A reclined flange 430 is provided on the second surface 410 of the arm 402, close to the edge 410. Together, the flange 430 and the lip 412 define a gap indicated generally as 422. A further gap between the flange and the plastic profile 416 is indicated by line R. The angle of the reclined flange 430 better facilitates the insertion of the waterproofing tray 400 to the sill frame. The reclined flange 430 includes a line of weakness 431 along which a portion may be removed, if necessary, to provide clearance to the corner piece that is shown in Figures 3A to 3C or other features of the window assembly.
The second arm 404 has an edge 424 which is distal to the first arm 402. The edge 424 is shaped as a step.
Further aspects of the waterproofing tray 400 including its structure and function should become clearer from further discussion later in the present specification.
Referring now to Figures 3A, 3B and 3C which show views of a corner piece 500 according to an aspect of the present technology. The corner piece 500 is designed and configured to facilitate attaching components of the window assembly 100 together. The illustrated example is handed, i.e. provided in left and right forms but it should be appreciated that in some instances, it may be non-handed although in such a scenario may require additional connecting fittings.
The corner piece 500 has a first arm 502 and a second arm 504 which are substantially perpendicular to each other. Each of the first arm 502 and the second arm 504 has an inner surface 506, 508 respectively, and an outer surface 510, 512 respectively. The inner surfaces 506, 508 are shaped to lie against the edge surface 410 of the waterproofing tray 400.
Each of the first arm 502 and the second arm 504 has flanges 514, 516 respectively. The flanges 514, 516 are configured to wrap around the edges (not illustrated in Figures 3A, 3B and 3C) formed in the outer frame member 300. Excess water is allowed to exit the window assembly via flange 514. This aspect of the technology will be discussed in more detail below.
An edge 518 of the arm 502 is shaped to define a flange which corresponds to a profile of the outer frame member 300. A toothed feature 522 may be formed into the edge 518, this engaging with the profile of the outer frame member. The opposing edge of the other arm 504 may be similarly configured. Bosses 520 and 520a containing fittings for a screw may be provided to the corner piece 500 to allow it to be secured to the window frame. In use, this would be orientated such that the screw passes through boss 520 from the underside 512 of the corner piece 500. Boss 520a is positioned such that a screw being inserted through this passes through the inner frame member (refer to Figures 6A and 6B).
Referring now to Figures 4A and 4B which show views of an end cap 600 according to an aspect of the present technology. The end cap 600 has a first portion formed by a first arm 602 and a second arm 604 that are substantially perpendicular to each other, and a third arm 606 and fourth arm 608 that are substantially perpendicular to each other.
Referring now to Figures 5A to 5C which illustrate how a corner piece 500 and a cap 600 attached to one end of a waterproofing tray 400 and a plastic profile 416. To better show the relationship of the waterproofing tray 400 and the corner piece 500 the cap is not shown in Figure 5A.
The components of Figures 5A to 5C may be attached or otherwise secured to the respective parts of the window frame using mechanical fasteners, such as screws, or with an adhesive or sealant which is applied to one or more of the components. The adhesive or sealant attaches the components together and may also create a seal to prevent passage of moisture through the gaps between the components. It should be noted that the attachment of components 400, 500, and 600 may not occur all at the same time. For example, the corner piece 500 may be joined to the window frame at the time of constructing the corner. The waterproofing tray 400 is then rotated or pivoted into place against the outer frame member. The end cap 600 is then sealed to the corner to make a waterproof corner.
It should also be appreciated that a corner piece 500 and cap 600 are also attached to the distal end of the waterproofing tray 400 but have not been shown in Figures 5A, 5B and 5C for sake of clarity.
The waterproofing system of the present technology may provide a number of advantages. For instance, having a waterproofing tray 400 with at least one corner piece 500 attached thereto allows the components to be formed as individual components and then cut to a desired length. This facilitates, inter alia, providing a relatively wider range of lengths for a building element while minimising the number of components that must be manufactured and held in stock.
These advantages and other features should become clearer from the following description.
6.1.2. Frame Sub-Assembly
As noted above, the window assembly 100 includes at least one frame sub-assembly 700 formed from a plurality of inner frame members 200, a plurality of outer frame members 300, and panes of glass 102, 104. Multiple of the frame sub-assemblies 700 can be secured together to form at least a portion of the window assembly 100. For instance:
• A first frame sub-assembly 700 will provide a bottom window frame jamb and therefore will be substantially horizontal when the window assembly 100 is installed.
• A window frame sub-assembly 700 will provide a head jamb and therefore be orientated substantially horizontal when the window assembly 100 is installed. • A third frame sub-assembly 700 will provide a left frame jamb and therefore will be substantially vertical when the window assembly 100 is installed.
• A fourth frame sub-assembly 700 will provide a right jamb and therefore will be substantially vertical when the window assembly 100 is installed.
Reference herein will be made to the first frame sub-assembly, the second frame sub-assembly, the third frame sub-assembly and the fourth frame sub-assembly.
6.1.2.1 Inner Frame Member
Referring now to Figures 6A and 6B which show views of an inner frame member 200 according to an aspect of the technology.
The inner frame member 200 includes at least one connection channel, e.g. a first connection channel 202A and a second connection channel 202B, and a frame portion 204. The first connection channel 202A and the second connection channel 202B are each configured to receive a connector (not shown in Figures 6A and 6B) to facilitate attaching the inner frame member 200 to the outer frame member 300.
At least one seal connector, e.g. a channel 206, is provided to receive a seal (not shown in Figures 6A and 6B).
A reveal connector is provided to facilitate attaching a reveal (not shown in Figures 6A and 6B) to the inner frame member 200. The reveal connector is preferably provided in the form of a channel 208 defined by a flange 210 and a leg 212. The channel 208 is shaped and dimensioned to receive a portion of the reveal (not shown in Figures 6A and 6B).
The leg 212 is shaped and dimensioned to facilitate it being inserted into the channel 413 of the waterproofing tray 400. As can be seen in Figure 6A, at least a portion of the leg 212 can be formed to be relatively thin compared to other portions of the leg 212. This may make it easier for fasteners (not shown in Figure 6A) to extend through the leg 212 and into a reveal (not shown in Figure 6A) disposed in the channel 208.
A receiver 214 can be optionally provided. The receiver 214 is located and orientated to align with boss 520a when the frame sub-assembly 700 is assembled. This may facilitate a fastener extending through the boss 520a of the corner piece 500. In the illustrated embodiments, the receiver 214 is provided in the form of a screw pipe formed in the inner frame member 200. Flowever, the receiver 214 could take other forms, e.g. a threaded aperture or flange through which a fastener can extend.
6.1.2.2 Outer Window Frame Member Referring now to Figures 7A and 7B which show views of an outer frame member 300 according to an aspect of the present technology.
The outer frame member 300 includes at least one connection channel e.g., a first connection channel 304A and a second connection channel 304B. The first connection channel 304A and the second connection channel 304B are each configured to receive a connector (not shown in Figures 7A and 7B) to facilitate attaching the outer frame member 300 to the inner frame member 200. This aspect of the technology will be discussed in more detail below.
A fin 306 is provided which has a lip 308. The lip 308 is shaped to create a ledge when the outer frame member 300 is orientated substantially horizontally e.g., used as a sill in a window assembly 100 (as is discussed in more detail below). As can be seen in at least Figures 7A and 8A the lip 308 and the fin 306 define a channel 308A. In use, this channel 308a receives the edge 424 of the waterproofing tray 400.
In addition, the fin 306 is a structure that is orientated and dimensioned to provide other functions for the window assembly 100. For instance, fasteners (not illustrated in Figures 7A and 7B) can extend through the fin 306 and into a support frame in a building to mount the window assembly 100 in position.
Alternatively, or in addition, a sealant e.g., tape can be applied to the fin 306 on one or more sides of the window assembly 100 and a support frame in a building. For instance, in preferred embodiments, tape can be applied to at least one, and preferably two or three, of the fins 306 forming the window assembly 100. This can attach fins 306 to an appropriate part of a building in which the window assembly is installed, e.g. a lintel and trimmer stud (neither shown in Figures 7A and 7B) to which they are adjacent when installed.
The lip 308 may include at least one drainage means(not shown) formed after extrusion of the outer frame member 300 e.g., by drilling, cutting or punching. Flowever, alternate ways of allowing moisture to exit the window assembly 100 are described in Figure 8G.
A flashing portion 312 extends away from the channel 304 so as to be outward of a building when the window assembly 100 is installed.
In preferred forms the flashing portion 312 is formed integrally to other parts of the outer frame element 200, e.g. during extrusion of the outer frame element 300. This may be particularly beneficial as it enables a window assembly 100 to be assembled in a factory and transported to the construction site for installation into the building. As a result, that embodiment reduces the chances that a window may be improperly installed. Alternatively, it can reduce "on site" labour and installation costs or speed up installation of a window. However, the flashing portion 312 may also be formed separately and attached to the outer frame member 300. In the embodiments where the flashing portion 312 is formed separately from the outer frame member 300, it can be permanently attached to the outer frame member 300 prior to the window assembly 100 leaving a factory. As a result, these embodiments may still provide the advantages of a flashing portion 312 which is integrally formed with the outer frame member 300.
A channel 314 is defined by a first lip 316 and a second lip 318. The channel 314 is shaped and dimensioned to receive corresponding parts of a glazing member (not illustrated in Figures 7A and 7B but examples shown in Figures 6C and 6D) and attach the glazing member to the outer frame member 300.
At least one receiver e.g., two receivers 320, 322 can be optionally provided to the outer frame member 300. The receiver 320 is located and orientated to align with the boss 520 of the corner piece when a frame sub-assembly 700 is assembled. This may facilitate a fastener extending through the boss 520 and attaching to the outer frame member 300. In the illustrated embodiments, the receiver 320 for the corner piece is provided in the form of screw pipes formed into the outer frame member 300. However, the receiver 320 (and also 322) could take other forms e.g., a threaded aperture or flange through which a fastener can extend. Alternatively, other attachment mechanisms may be used such as adhesive or welding.
The outer frame member 300 may also be provided with supplementary receivers e.g., 324, 326. The receivers 324, 326 facilitate attaching additional components to the outer frame member 300, for example flashings to improve aesthetic appearances.
Referring now to Figure 8H, the slot(s) 328 are located and orientated to receive a portion of a corner piece 500 and allow that component to extend from an inner side of the arm 306 to an outer side of the arm 306.
As previously noted, the arm (306) may be formed with drainage means for moisture. When assembled, this may enable moisture on an upper surface of the waterproofing tray 400 to exit from the window assembly 100.
6.1.2.3 Glazing Member
Referring now to Figures 6C and 6D, these show views of a glazing member 350 according to an aspect of the technology. The glazing member 350 is configured to attach to at least one of the outer frame member 300 and the inner frame member 200.
The glazing member 350 has a first arm 352 and a second arm 354. The first arm 352 and the second arm 354 meet in a region 358. The first arm 352 has a distal end 356 which is shaped to define a retention part 360. The retention part 360 can take various shapes, however as illustrated in the Figures it is a leg shape.
The second arm 354 is shaped to define a bearing surface 364.
The region 358 is shaped to define a step 362. In use and when assembled, the step 362 and the retention part 360 engage corresponding features of at least one of the outer frame member 300 and the inner frame member 200. This attaches the components together.
In addition, the bearing surface 364 and a corresponding feature on at least one of the outer frame member 300 and the inner frame member 200 define a channel (not indicated in Figures 6C and 6D).
The channel (not shown in Figures 6C and 6D) can receive a barrier arrangement e.g. the panes of glass 102, 104.
6.1.2.4 Assembled Frame Sub-Assembly
Referring now to Figures 8A and 8B which show a frame sub-assembly 700, formed by attaching an inner frame member 200 and an outer frame member 300 together.
A connector 702 is shaped and dimensioned to be received in each of the connection channel 202 and the connection channel 304. In the illustrated embodiment the window frame sub-assembly 700 includes two connectors 702 such as shown in Figures 8E and 8F. The use of these connectors 702 attaches the inner frame member 200 and an outer frame member 300 together.
In the illustrated embodiment, the lateral edges of the connector 702 have a substantially triangular or dovetail shape which facilitates them sliding along the length of the channels 202, 304 respectively. The respective shapes of the connector 702 and the channels 202, 304 assists in preventing the connector being pulled out of the channels 202, 304 in the directions indicated by arrows X and Y in Figure 8A.
In addition, a seal 704 is provided in the seal connector 206.
The frame sub-assembly 700 illustrated in Figures 8A, 8B, 8G and 8H can be used to form the sill, head or jambs of the window assembly 100. This should become clearer from the following description.
6.1.3 Waterproofing System Fitted to Frame Sub-Assembly
Referring now to Figure 8G which is a cross-sectional view of the waterproofing system attached to the frame sub-assembly 700.
The waterproofing tray 400 is attached to both of the inner frame member 200 and the outer frame member 300. For instance, as is illustrated, the step 426 is inserted into the channel 308A while the leg 212 is inserted into the channel 413. This may be achieved by aligning the step 426 and the channel 308A, and the leg 212 and the channel 413, and then sliding the components relative to each other. Alternatively, the waterproofing tray 400 may be bent or otherwise deformed to push the step 426 into the channel 308A and the leg 212 into the channel 413.
The leg 212 and the channel 413 are shaped and dimensioned to have a tight fit with each other. This creates a substantial or complete air seal between the two components. As a result, when a window assembly 100 including the frame sub-assembly 700 with the waterproofing tray 400 fitted thereto, is installed in a building there is a barrier to air movement. As a result, the present technology may assist in providing a more thermally efficient window.
A portion of the plastic profile 416 is in contact with a bearing surface 216 on the inner frame member 200, while another portion of the plastic profile 416 is in contact with a bearing surface 332 on the outer frame member 300. The plastic profile 416 is also in contact with the connector 702.
The edge 424 is positioned in the lip 308 while the step 426 sits over the lip 426. The fit between these parts, while still snug, permits egress of moisture. As preferred embodiments of the waterproofing tray is made from plastics material, there will some natural deformation and undulations which will form gaps through which moisture will be able to pass.
While not illustrated in Figure 8G, caps 600 are attached to the distal ends of the frame sub-assembly 700 e.g., in the configuration discussed above with respect to Figures 5A to 5C. For instance, a surface of the second arm 604 is in contact with the stems 416A, 416, B and 416C of the plastic profile 416 while a surface of the fourth arm 608 is in contact with a surface 425 of the second arm 404.
A seal 334 is provided to an inner surface 336 of the fin 306. In use, and when installed in a building, the seal 334 can be compressed against a surface of a building component e.g., an outer surface of wall framing members, a floor member, a concrete floor pad (footing), or some other structural component. The seal 334 prevents moisture passing from the outside of the fin 306 to the inside. This can assist to limit moisture passing into a building in which the window assembly is installed. Moisture is instead able to exit via gravity through the drainage means 330, which is a space between the step 426, receivers 326 and the arm 306.
In addition, the seal 334 provides an insulating barrier to prevent heat loss through a gap between the surface and a surface of the building. The seal 334 forms the air seal along the lower edge of the exterior side of the window assembly. Similarly, an air seal is formed between the channel 413 and leg 212 of the inner frame member on the interior side of the window assembly
The seal 334 is preferably an adhesive foam tape e.g. a closed cell foam tape such as that sold under the brand name Inseal™. The use of foam allows the seal 334 to be compressed to improve its ability to prevent ingress of moisture into the building or heat loss. In addition, the foam expands against a fastener(s) that extends through the seal 334. However, this should not be seen as limiting as the seal 334 can take other forms such as a wet sealant applied as a strip or bead to the fin 306.
Alternatively, or in addition, the seal 334 may be applied as a wet sealant to the fin 306 as part of install of the window assembly 100 after it has been positioned in building. In these embodiments, the seal 334 may be an expanding foam as should be known to one skilled in the art.
A reveal 360 is attached to the inner frame member 200, e.g. a portion of the reveal 360 is inserted into the channel 208 and secured in place such as by a fastener (like the staple 362 illustrated in Figure 8A) or an adhesive.
6.1.3.1 Head Flashing
Referring now to Figures 9A and 9B which illustrate views of a head flashing 800 according to an aspect of the technology.
The head flashing 800 includes a flashing portion 802 which has a leg 804 and a turned out lip 806, directing any water outwards, located at the distal end of the leg 804.
An upstand 808 is orientated to extend away from the flashing portion 802, and to be substantially vertical when installed in a building (not shown in Figures 9A and 9B).
A declined or otherwise angled ledge 810 extends from the upstand 808. The ledge 810 is orientated to extend outwardly, and away from the inside of a building in which the window assembly 100 is installed. The decline is sufficient to allow water to directed outwards, away from the window assembly. It also includes a flange 811 which helps when presenting the head flashing to wall cladding (not shown).
As can be seen in Figures 9A and 9B, the ledge 810 has a series of perforations 809 which provides a plurality of ventilation apertures. The ventilation apertures 809 allow moisture to drain from the building in which the window assembly 100 is installed, and air circulation into the building cavity. However, the ventilation apertures 809 are not so large as to allow vermin such as spiders to pass.
In an example not illustrated here, the ledge 810 may alternatively have a serrated edge, the gaps between adjacent serrations forming the ventilation apertures. The dimensions and size of the ventilation apertures 809, as should be understood by one skilled in the art, be as is necessary to comply with the relevant building codes.
The structure of the ledge 810 allows it to perform the same function as a cavity closer component. As a result, the present technology further reduces the components that are required when installing a window assembly 100 compared to the prior art. In addition, this may assist with simplifying installation of the window assembly 100, reducing installation time and costs, and reduction instances of improper installation. A receiver 812 is formed into the head flashing 800 and is positioned and orientated to receive a fastener (not illustrated in Figures 9A and 9B).
It should be understood that the head flashing 800 is preferably fitted to the window assembly 100 after that has been at least partially installed in a building. However, in some embodiments, the head flashing 800 may be fitted to a window assembly 100 at a factory or otherwise during assembly of the window assembly 100.
6.1.3.2 Head Flashing Bracket
Referring now to Figures 10A, 10B and IOC which show views of a head flashing bracket 900 according to an aspect of the technology.
The head flashing bracket 900, moulded from plastics material, is configured to facilitate attaching the head flashing 800 to a window frame sub-assembly 700 and holding the head flashing in the required position.
The head flashing bracket includes a body 902, which has a slot formed therein. The slot 902 is dimensioned and orientated to facilitate the body receiving part of the flashing portion 802.
An alignment arm 904 extends away from the body 902 and includes a channel 906. The channel 906 is aligned with the slot 902 and can also receive a side edge of the flashing portion 802.
The arm 904 provides a raised barrier which can in use prevent or limit water on top of the flashing portion 902 running off the lateral sides where it could enter into the building around the window assembly 100. Instead, water is directed to run of the head flashing distal to the upstand 808.
A receiver 908 is positioned and orientated to align with the receiver 812 which the head flashing cap 900 and the head flashing 800 are assembled together. A fastener (not illustrated in Figures 10A to IOC) can extend through the receiver 908 and into the receiver 812 to secure the two components together. Note that ejector pin marks, some of which are indicated by 910, from the plastic moulding used to form the head flashing bracket, are visible.
6.1.4 Complete Window Assembly
Figures 11A to 11M show various views of a substantially assembled window assembly 100 according to the technology. They show how frame sub-assemblies 700 can be used together to form the window assembly 100.
Panes of glass 102, 104 and seals 704 are attached.
The corner piece 500 provides a joint between the different frame sub-assemblies forming the window assembly 100 e.g. a substantially 90° joint between a window jamb and a sill, the area of the window assembly most prone to moisture penetration.. In a simpler form, for example without the flange 514 that serves as an exit point for moisture, the corner piece 500 may also be used as a jointer between a window head and a window jamb (this area does not suffer moisture penetration problems to the same extent as the lower corners of the window assembly 100). In addition, the corner piece 500 attaches two frame sub-assemblies e.g., fasteners such as screws (not illustrated in Figure 11F) extend through apertures 508 and into the corresponding receivers 214, 320.
As can be seen in Figure 11G, the corner piece 500 extends through the slot 328 and sits over an edge of the fin 306.
6.1.5 Installed Window Assembly
Referring now to Figures 12A to 121 and 13, which show various views of a window assembly 100 installed in a building 1000. For sake of clarity, only a portion of the building 1000 is shown in the Figures.
The building 1000 includes a support frame having a plurality of support elements (not shown in Figure 12A) that define an opening in the support frame. The opening (not indicated in the Figures) is the space which the window assembly 100 will fill and cover.
The support frame and the support elements are as should be known to one skilled in the art and constructed accordingly. Flowever, in the illustrated embodiment, the opening (not indicated in the Figures) is defined by a first trimmer stud 1002, a second trimmer stud 1004, a trimmer 1006 and a lintel 1008.
During construction of the building 1000, a moisture impermeable layer (such as building wrap 1010 indicated in the Figures) is attached to the building 1000 and cut to create an opening (not marked in the Figures). The building wrap 1010 may be folded over trimmer studs 1002, 1004, the trimmer 1006 and the lintel 1008 and secured in place.
A waterproofing material e.g., a bituminous adhesive tape (not shown in the Figures) as known to one skilled in the art may be attached to one or more of the trimmer studs 1002, 1004, the trimmer 1006 and the lintel 1008. Flowever, in the preferred forms of the present technology, the waterproofing system avoids the need to attach waterproofing materials directly to the structural components of the building 100.
The window assembly 100 is positioned in the opening (not indicated in the Figures) in the building 1000. In doing so, the first frame sub-assembly is located above and substantially parallel to the trimmer 1006, the second frame sub-assembly is substantially parallel to the lintel 1008, the third frame sub- assembly is substantially parallel to the trimmer stud 1002, and the fourth frame sub-assembly is located below and substantially parallel to the trimmer stud 1004.
The window assembly 100 is secured to the trimmer studs 1002, 1004, the trimmer 1006 and the lintel 1008 by fasteners (not shown in Figures 12A to 121). The fasteners may be screws, nails of other suitable fasteners that extend through the arm 306 and the seal 334 of each of the window frame sub- assemblies, and into the corresponding trimmer stud 1002, 1004 the trimmer 1006 and the lintel 1008.
Similarly, fasteners (not illustrated in the Figures) can be used to attach the frame sub-assemblies forming the jamb and head of the window assembly 100 to the respective fins 306. Flowever, for these frame subassemblies 700, a seal 334 is not provided between the fin 306 and the respective trimmer stud 1002, 1004 and lintel 1008. Instead, tape (not illustrated in the Figures) may be attached to cover a gap between a respective one of the trimmer studs 1002, 1004, and the lintel 1008 and the respective fin 306. In these embodiments, the tape creates a seal to prevent passage of moisture and air through the gap. In addition, the tape (not illustrated) provides at least one of an air and a moisture seal.
The seal 334 is resilient and expands to press against the fastener(s). This may substantially limit or prevent ingress of moisture into the building 1000 around the fastener. Flowever, in some instances, the fastener(s) may pass through the fin 306 beneath the seal 334.
As can be seen, the panes of glass 102, 104 are positioned to be substantially inline with a plane (not marked) on which the trimmer studs 1002, 1004, the trimmer 1006 and the lintel 1008 lie. As a result, the panes of glass 102, 104 are in-line with the frame of the building 1000. Accordingly, the location of the panes of glass 102, 104 which provide a thermal insulation for the building 1000 is located in line with the frame of the building 1000. This may improve the thermal performance of the window assembly 100 compared to other windows e.g., those in which the glass is located in line with, or on the outside of, the cladding.
It should be appreciated that the weight of the panes of glass 102, 104 is not cantilevered outside of the trimmer 1006 and lintel 1008. As a result, the present technology may simplify installation of the window assembly 100 in the building 100. For instance, it may remove the need to use components such as a WANZ (Window Association of New Zealand) bar to support the weight of a window inside a building as is currently required by many prior art windows.
In addition, the waterproofing tray 400 extends from an inner side of the window assembly 100 past an outer surface of a support to which the window assembly 100 is attached. For instance, as can be seen in the Figures, the waterproofing tray 400 extends from an inner side of the window assembly 100, underneath the panes of glass 102, 104 to an outer side of the trimmer 1006. The waterproofing tray 400 can therefore collect moisture which may seep downwards for any of various reasons. In the preferred forms, the waterproofing tray 400 extends from an inner most edge of the inner frame member 200 and to the fin 306 so as to span substantially the entire width of the support element. This can enable the waterproofing system to direct moisture out through the drainage means 330. Alternatively, if moisture is collected on the corner piece 500 it can flow of the portion of the corner piece 500 which extends through the slot 328. This is a way to prevent or eliminate moisture coming into contact with the walls and frame of the building 1000.
It can also be seen that there are several cavities formed between the components of the window assembly 100. The cavities may be important for thermal performance of the window assembly.
An outer cavity 1100 is defined by an upper surface the waterproofing tray 400 and an inner surface of the outer frame member 300. In the illustrated embodiments, the outer cavity 110 can be considered to be bordered at its inner side by the plastic profile 416. The cavity 1100 is "open" to atmospheric pressure due to one or more of the slots 328 and drainage means 330. This allows the outer cavity 1100 to be pressure equalised to atmospheric pressure. However, the slots 328 and drainage means 330 still provides outlets through which moisture collected by the waterproofing tray 400 can exit the window frame assembly 100.
However, the slots 328 are relatively small compared to the outer frame member 300. As a result, the slots 328 and the drainage means 330 provide minimal to no adverse effect on the thermal performance of the window assembly.
An inner cavity 1200 is defined by an upper surface of the waterproofing tray 400 and the inner frame member 200. In the illustrated embodiment, the inner cavity 1200 is bounded on its outer side by the stem of the plastic profile 416.
It should be noted that the plastic profile 416 does not extend the full length of the inner frame, thus creating the gap Z. The gap Z provides an opening through which moisture can pass. This can allow moisture to flow from the cavity 1200. This is therefore a failsafe to collect water that seeps down onto the waterproofing tray and direct that out through the drainage means 330 or the slot 328.
However, the gap Z is sized and dimensioned to allow moisture which can find its way between waterproofing tray 400 and the ledge 430 to drain out of that region of the window assembly 100. However, the gap Z is not so large as to allow significant thermal convection from cavity 110 to cavity 1200. It therefore does not significantly affect thermal performance of the window assembly 100.
As a result, the waterproofing system may provide several benefits. For instance, it could act as both a failsafe to collect failure moisture in the window assembly and direct this out of the window assembly 100, while improving thermal performance of the building in which the window assembly 100 is installed. In addition, it can be seen that the plastic profile 416, when located atop the waterproofing tray 400, provides a bearing surface on which another component of the window assembly 100 can bear or touch. For instance, as is shown in Figure 13, the plastic profile 416 provides a bearing surface on which an underside of the structure that forms the channel 202A can bear. This may assist the waterproofing system to thermally insulating the inner region of the window assembly 100 from the outer region of the window assembly 100.
Figure 13 shows how a fastener (not shown) would be able to pass through the fin 306 and into the trimmer 1006. The seal 334 wraps around and conforms to the fastener and therefore prevents or eliminates moisture moving from the waterproofing tray 400 back towards the trimmer 1006.
The window assembly 100 can be installed in the building 1000 to define a trim gap 1300 as should be known to one skilled in the art. The trim gap 1300 is defined by a lower surface (the first surface 408) of the waterproofing tray 400 and an upper surface of the trimmer 1006. The trim gap 1300 can be filled with insulation materials (not indicated in the figures). This is possible because the waterproofing system of the present technology is separate from, and not dependent on, the structure components of the building 1000, e.g. the trimmer 1006. The ability to provide insultation materials in the trim gap 1300 may improve the thermal performance of the window assembly 100 when mounted in a building 1000.
Creation of the trim gap 1300 may be achieved using any technique as should be known to one skilled in the art, e.g. wedges and so forth.
It should also be understood that one or more cavities (not indicated in the Figures) may be provided between the window frame sub-assemblies and one or more of the lintel 1008 and the trimmer studs 1002, 1004. As a result, insulation materials may also be provided in the cavities (not indicated in the Figures). Alternatively, the window assembly 100 may be positioned to abut one or more of the lintel 1008 and the trimmer studs 1002, 1004 and trimmer 1006.
The flashing portion 312 extends away from the trimmer 1006 and defines a gap 1010. Cladding (not shown in Figure 13 but indicated as 1012 in Figures 12A to 121) can extend into the gap 1010 and therefore this provides a desirable aesthetic finish to the building 1000. The orientation of the flashing portion 312 minimises or prevents wind blowing towards the corner piece 500 and so can also assist to prevent ingress of moisture into the window assembly 100.
In addition, the flashing portion 312 protects the exposed ends of the cladding 1012 from moisture e.g. rain, preventing this being blown over top of the exposed edges whereby it could enter into the cavity space of the building. 6.2 Opening Sash Window
Referring now to Figure 14 which shows a building element in the form of an opening sash window 2000 according to an aspect of the present technology. Components of the building element 2000 are similar to the components of the window assembly 100 and therefore like references refer to like components.
As can be seen in Figure 14, an opening frame member 2002 is provided which is mounted to a window frame sub-assembly 700 by a hinge (not illustrated in Figure 14). The hinge (not illustrated) may be any known hinge arrangement as should be known to one skilled in the art.
The opening frame member 2002 engages with a glazing member 350 to support panes of glass 102,
104. In addition, a standard spaced 380 is provided between the panes of glass 102, 104 to keep those spaced apart from each other. This is as should be known to one skilled in the art.
Seals and other features of the opening hinged door are as should be known to one skilled in the art and therefore are not described herein.
In addition, a handle (not illustrated in Figure 14) can be provided to the opening frame member 2002.
In use, a person can move the opening frame member 2002 to open and / or close the window.
The waterproofing system provides advantages as are described above with references to Figures 1 to 13.
6.3 Opening Hinged Door
Referring now to Figure 15 which shows a cross-sectional view of a building element in the form of an opening hinged door 3000 according to an aspect of the present technology. Components of the opening hinged door 3000 are similar to the components of the window assembly 100 and therefore like references refer to like components.
A door frame is provided e.g., by a first member 3002 and a second member 3004, and which is mounted to a window frame sub-assembly 700 by a hinge (not illustrated in Figure 14). The hinge (not illustrated) may be any known hinge arrangement as should be known to one skilled in the art.
A glazing member 350 engages with first member 3002 to support panes of glass 102, 104. Seals and other features of the opening hinged door are as should be known to one skilled in the art and therefore are not described herein.
In addition, a handle (not illustrated in Figure 14) can be provided to the door frame. In use, a person can move the door frame to open and / or close the opening hinged door 3000.
The waterproofing system provides advantages as are described above with reference to Figures 1 to
13. 6.4 Sliding Window / Door
Referring now to Figure 16, which shows an alternate embodiment of a building element in the form of a sliding window or door 4000. Components of the sliding window or door 4000 are similar to the components of the window assembly 100 and therefore like references refer to like components.
Sliding mechanism is provided by a first member 4002 which is attached to the inner window frame member 200, and a second member 4004 which is attached to the outer window frame member 300.
A door or window frame is provided to support panes of glass 102, 104 e.g. by a first frame element 4006, a second frame element 4008 and a glazing member 350. An articulation mechanism (indicated generally as 4010).
A track 4012 is provided e.g. mounted in a channel (not indicated) which is defined by the first member 4002 and the second member 4004.
In use, the articulation mechanism 4010 facilitates moving the door or window frame along the length of the first member 4002 and the sconed member 4004. This enables a person to open and / or close the door or window provided by the sliding window or door 4000.
The waterproofing system provides the advantages as described herein with reference to Figures 1 to 13.
6.5 Alternate Attachment Arrangement
Referring now to Figure 17 which shows an alternate attachment arrangement to attach a window assembly 100 to a support structure e.g. a building (not shown).
In the embodiment of Figure 17, a supplementary bracket 5000 is attached to the 306. For instance, the bracket 500 and the outer window frame member 300 may have complementary fasteners halves which cooperate to attach the components together. In the illustrated embodiment, the bracket 5000 includes a first fastener half 5002 e.g. a cylindrically shaped portion, while the outer window frame member 3000 includes a second fastener half e.g. a receiver in the form of a channel 324 (as is perhaps best illustrated in Figures 7A and 7B.
To attach the supplementary bracket 5000 to the outer window frame member 300, the first fastener half 5002 is positioned relative to, and slid along the channel 324, or alternatively presented up to the channel and rotated into position.
The supplementary bracket 5000 also includes an arm 5004 which extends away from the first fastener half 5002. It can be seen that at least a portion of the arm 5004 extends distal to the drainage means 330 when the supplementary bracket 5000 is attached to the outer window frame member 300. The arm 5004 therefore provides an extended surface through which a fastener (not illustrated in Figure 17) can extend to attach the supplementary bracket 5000 (and therefore the window assembly 100) to a
The use of the supplementary bracket 5000 can be particularly useful to install a building element according to the present invention in certain types of building e.g., those where a fastener must be set back from an edge of the building such as a concrete pad. The bracket 5000 is structured and / or arranged to allow moisture to drain out of the window assembly 100. For instance, it may be formed in or cut to relatively short lengths. When installed the brackets 5000 are spaced apparat to create gaps which can act as drains. Alternatively, opening may be formed into the bracket 5000 e.g. by punching or cutting.
The waterproofing system provides the advantages discussed herein.
Unless the context clearly requires otherwise, throughout the description and the claims, the words "comprise", "comprising", and the like, are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense, that is to say, in the sense of "including, but not limited to".
The entire disclosures of all applications, patents and publications cited above and below, if any, are herein incorporated by reference.
Reference to any prior art in this specification is not, and should not be taken as, an acknowledgement or any form of suggestion that that prior art forms part of the common general knowledge in the field of endeavour in any country in the world.
The invention may also be said broadly to consist in the parts, elements, characteristics and features referred to or indicated in the specification of the application, individually or collectively, in any or all combinations of two or more of said parts, elements, characteristics or features.
Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof as defined herein.
Where in the foregoing description reference has been made to integers or components having known equivalents thereof, those integers are herein incorporated as if individually set forth.
It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the invention as claimed herein and without diminishing its attendant advantages. It is therefore intended that such changes and modifications be included within the present invention.

Claims

7. Claims
1. A building element for a building, wherein the building element includes: an inner frame member, an outer frame member, and a waterproofing system, wherein the waterproofing system includes a drain, wherein the inner frame member and the outer frame member are attached to each other, and further wherein the waterproofing system is positioned and arranged to, in use, collect moisture and direct the moisture towards the drain.
2. A building element as claimed in either claim 1 or claim 2, wherein the building element incudes at least one barrier arrangement.
3. A building element as claimed in claim 2, wherein the barrier arrangement is one or more panes of glass.
4. A building element as claimed in any one of claims 1 to 3, wherein the building element is a:
• window assembly; or
• sliding door;
• or hinged door.
5. A building element as claimed in any one of claims 1 to 4, wherein each of the inner frame member and the outer frame member is configured with a channel that receives a portion of a connector to attach the inner frame member to the outer frame member.
6. A building element as claimed in any one of claims 1 to 5, wherein the waterproofing system is attached to one or both of the inner frame member and the outer frame member.
7. A building element as claimed in any one of claims 1 to 6, wherein the waterproofing system includes a waterproofing tray.
8. A building element as claimed in claim 7, wherein the waterproofing tray is shaped and dimensioned to span a region of the building element at which the inner frame member and the outer frame member are attached to each other.
9. A building element as claimed in either claim 7 or claim 8, wherein the waterproofing tray is configured with an inner portion and an outer portion.
10. A building element as claimed in claim 9, wherein the inner portion of the water proofing tray is located closer to an interior of the building than the outer portion of the water proofing tray.
11. A building element as claimed in any one of claims 1 to 10, wherein the waterproofing system includes at least one corner piece.
12. A building element as claimed in claim 11, wherein the corner piece is shaped and dimensioned to extend through a complementary opening in one or both of the inner frame member or the outer frame member.
13. A building element as claimed in any one of claims 1 to 12, wherein the building element includes at least one cavity.
14. A building element as claimed in claim 13, wherein the at least one cavity is configured with an opening to facilitate exit of moisture from the cavity.
15. A building element as claimed in claim 14, wherein the opening may be one or more of:
• a drainage opening through which moisture on the waterproofing tray can flow; or
• a slot configured to align with another component of the waterproofing system.
16. A building element as claimed in any one of claims 13 to 15, wherein the at least one cavity is defined by a surface of the waterproofing tray and a surface of at least one of the inner frame member and the outer frame member.
17. A building element as claimed in any one of claims 1 to 16, wherein the outer frame member includes at least one fin.
18. A building element as claimed in claim 17, wherein the fin is configured to facilitate attachment of the outer frame member to a support element.
19. A building element as claimed in claim 18, wherein the fin is provided with a sealing surface for the support element.
20. A building element as claimed in any one of claims 1 to 19, wherein the outer frame member includes a flashing portion.
21. A method of installing a building element, including the steps of: a) positioning a building element as claimed in any one of claims 1 to 20 with respect to at least one support element of a building; b) using a fastener to attach a fin of the building element to an external surface of the support element.
PCT/NZ2022/050051 2021-05-06 2022-05-06 Improvements to building elements, and methods of manufacture and installation of building elements WO2022235171A1 (en)

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NZ775725 2021-05-06

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11933098B1 (en) 2023-03-20 2024-03-19 Pella Corporation Fenestration unit with interior installation features and associated systems and methods

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Publication number Priority date Publication date Assignee Title
WO1995008041A1 (en) * 1993-09-15 1995-03-23 Skandinaviska Aluminium Profiler Ab Corner joint assembly
EP1726765A1 (en) * 2005-05-10 2006-11-29 Reynaers Aluminium, naamloze vennootschap Sliding door or sliding window with an improved drain
ES2351267A1 (en) * 2008-10-20 2011-02-02 S.L Grifell Pons Frame for sliding leaf closures. (Machine-translation by Google Translate, not legally binding)
WO2019123436A1 (en) * 2017-12-22 2019-06-27 Intelli Group Limited A frame, assembly and components thereof
CN210918802U (en) * 2019-09-09 2020-07-03 佛山市禅城广宇铝业有限公司 Wind-proof water-draining aluminium alloy window
CN211776869U (en) * 2019-10-28 2020-10-27 广东贝克洛幕墙门窗系统有限公司 Sliding door lower frame and sliding door

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1995008041A1 (en) * 1993-09-15 1995-03-23 Skandinaviska Aluminium Profiler Ab Corner joint assembly
EP1726765A1 (en) * 2005-05-10 2006-11-29 Reynaers Aluminium, naamloze vennootschap Sliding door or sliding window with an improved drain
ES2351267A1 (en) * 2008-10-20 2011-02-02 S.L Grifell Pons Frame for sliding leaf closures. (Machine-translation by Google Translate, not legally binding)
WO2019123436A1 (en) * 2017-12-22 2019-06-27 Intelli Group Limited A frame, assembly and components thereof
CN210918802U (en) * 2019-09-09 2020-07-03 佛山市禅城广宇铝业有限公司 Wind-proof water-draining aluminium alloy window
CN211776869U (en) * 2019-10-28 2020-10-27 广东贝克洛幕墙门窗系统有限公司 Sliding door lower frame and sliding door

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11933098B1 (en) 2023-03-20 2024-03-19 Pella Corporation Fenestration unit with interior installation features and associated systems and methods

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