U.S. patent application number 10/501460 was filed with the patent office on 2005-06-02 for corner key for connecting profiles together and frame work assembly.
Invention is credited to Schmidt, Helmut.
Application Number | 20050115178 10/501460 |
Document ID | / |
Family ID | 4143195 |
Filed Date | 2005-06-02 |
United States Patent
Application |
20050115178 |
Kind Code |
A1 |
Schmidt, Helmut |
June 2, 2005 |
Corner key for connecting profiles together and frame work
assembly
Abstract
A corner key (10) for connecting profiles (12, 14) together and
a frame work assembly formed of such corner keys (10) and (profiles
(12, 14). Each profile (12, 14) has an anchoring channel (16, 18),
a drainage and venting passage (20, 22) and a securing bore (24,
26). The corner key (10) has two adjacent inner corner faces (28,
30), two adjacent outer corner faces (32, 34), and opposite inner
and outer side corner faces (36, 38). Tabs (40, 42) on the inner
corner faces (28, 30) guide the coupling of the profiles (12, 14).
Fasteners (48, 50) are inserted through the outer corner faces (32,
34) in corner key bores (44, 46) and in the bores (24, 26) of the
profiles (12, 14). A drainage and venting passage (52) in the
corner key (10) communicates with the drainage and venting passages
(20, 22) of the profiles (12, 14).
Inventors: |
Schmidt, Helmut;
(Unionville, CA) |
Correspondence
Address: |
Centre CDP Capital
1001 Victoria Square
Bloc E - 8th Floor
Montreal, Quebec
H2Z 2B7
CA
|
Family ID: |
4143195 |
Appl. No.: |
10/501460 |
Filed: |
July 14, 2004 |
PCT Filed: |
January 14, 2002 |
PCT NO: |
PCT/CA02/00041 |
Current U.S.
Class: |
52/272 |
Current CPC
Class: |
E06B 3/9616 20130101;
E06B 3/9636 20130101; E06B 3/9641 20130101 |
Class at
Publication: |
052/272 |
International
Class: |
E04B 001/00 |
Claims
What is claimed is:
1. A corner key for connecting two or more profiles together, each
profile having an end face, a longitudinal drainage and venting
passage and a longitudinal securing bore, the corner key
comprising: first and second adjacent inner corner faces, first and
second adjacent outer corner faces opposite to the inner corner
faces, and opposite inner and outer side corner faces extending
between the inner and outer corner faces, the inner corner faces
being shaped for respective coupling with the profiles; first and
second guide arrangements having a tab projecting on one of the
inner corner faces and the end faces of the profiles, and an
accommodating anchoring channel in the other one of the end faces
of the profiles and the inner corner faces, the tab being shaped
for fit engagement into the accommodating anchoring channel; first
and second bores each extending between a different one of the
outer corner faces and one of the inner corner faces opposite to
the one of the outer corner faces, the bores being in registration
with the securing bores of the profiles when the profiles are
coupled with the corner key; first and second fasteners
respectively insertable in the bores of the corner key and the
profiles in a locking arrangement in which the corner key and the
profiles are connected together; and a drainage and venting passage
extending between the first and second inner corner faces, the
drainage and venting passage having opposite end openings in
registration with the drainage and venting passages of the profiles
when the profiles are coupled with the corner key.
2. The corner key according to claim 1, wherein the tabs project
respectively from the first and second inner corner faces of the
corner key for fit engagement into the accommodating anchoring
channels in the end faces of the profiles.
3. The corner key according to claim 2, wherein the tabs form a
right angle with each other.
4. The corner key according to claim 2, wherein the tabs form acute
or obtuse angles with each other.
5. The corner key according to claim 1, wherein the outer side
corner face has a water evacuation and pressure equalization vent
in communication with the drainage and venting passage of the
corner key and the drainage and venting passage of each
profile.
6. The corner key according to claim 5, wherein the vent and the
drainage and venting passage of the corner key have substantially
flush bottom surfaces declining toward the outer side corner
face.
7. The corner key according to claim 2, wherein the bores of the
corner key are located adjacent to the tabs of the corner key.
8. The corner key according to claim 2, wherein the tabs have
tapered ends facilitating fit engagement into the anchoring
channels.
9. The corner key according to claim 8, wherein the tabs and the
anchoring channels have matching shapes further facilitating fit
engagement of the tabs into the anchoring channels, and wherein
each of the tabs has a continuous shape.
10. The corner key according to claim 2, wherein the first and
second inner corner faces form a right angle with each other and
the first and second outer corner faces form a right angle with
each other.
11. The corner key according to claim 1, wherein the first and
second inner corner faces are provided with a sealing element
sealing the corner key with the profiles when the profiles are
coupled to the corner key.
12. The corner key according to claim 2, wherein the first and
second inner corner faces respectively comprise first and second
sealing recesses located adjacent to the tabs, the sealing recesses
receiving a sealing element sealing the corner key with the
profiles when the profiles are coupled to the corner key.
13. The corner key according to claim 12, wherein the inner and/or
outer side corner faces comprise extension fins for masking joints
created between the inner and/or outer side corner faces and the
profiles when the profiles are coupled to the corner key.
14. The corner key according to claim 2, wherein the fasteners
comprise screws or rivets.
15. The corner key according to claim 2, wherein the fasteners
comprise an adhesive matter or an ultrasound weld.
16. The corner key according to claim 12, wherein the first and
second inner corner faces have substantially flat surface portions,
and the sealing recesses have sloped wall surface portions.
17. The corner key according to claim 2, wherein the corner key is
made of thermoplastic material or metal.
18. The corner key according to claim 2, wherein the inner and/or
outer side corner face has a chamfered and rounded corner extending
between the inner corner faces.
19. The corner key according to claim 2, wherein the drainage and
venting passage of the corner key has an opening in one of the
inner corner faces above the end opening of the drainage and
venting passage of the corner key in said one of the inner corner
faces.
20. The corner key according to claim 2, wherein the outer side
corner face has a water evacuation and pressure equalization vent
in communication with the drainage and venting passage of the
corner key and the drainage and venting passage of each
profile.
21. The corner key according to claim 20, wherein the first and
second inner corner faces respectively comprise first and second
sealing recesses located adjacent to the tabs, the sealing recesses
receiving a sealing element sealing the corner key with the
profiles when the profiles are coupled to the corner key.
22. The corner key according to claim 21, wherein the inner and/or
outer side corner faces comprise extension fins for masking joints
created between the inner and/or outer side corner faces and the
profiles when the profiles are coupled to the corner key.
23. The corner key according to claim 20, wherein the fasteners
comprise screws or rivets.
24. The corner key according to claim 20, wherein the drainage and
venting passage of the corner key has an opening in one of the
inner corner faces above the end opening of the drainage and
venting passage of the corner key in said one of the inner corner
faces.
25. The corner key according to claim 1, wherein the inner or outer
side corner faces bear logos, trademarks, information or
decorations.
26. A frame work assembly comprising: a) two or more lineal
profiles, each having an end face, a longitudinal drainage and
venting passage and a longitudinal securing bore; and b) one or
more corner keys, each corner key for connecting the two or more
profiles together, each corner key having: first and second
adjacent inner corner faces, first and second adjacent outer corner
faces opposite to the inner corner faces, and opposite inner and
outer side corner faces extending between the inner and outer
corner faces, the inner corner faces being shaped for respective
coupling with the profiles; first and second guide arrangements
having a tab projecting on one of the inner corner faces and the
end faces of the profiles, and an accommodating anchoring channel
in the other one of the end faces of the profiles and the inner
corner faces, the tab being shaped for fit engagement into the
accommodating anchoring channel; first and second bores each
extending between a different one of the outer corner faces and one
of the inner corner faces opposite to the one of the outer corner
faces, the bores being in registration with the securing bores of
the profiles when the profiles are coupled with the corner key;
first and second fasteners respectively insertable in the bores of
the corner key and the profiles in a locking arrangement in which
the corner key and the profiles are connected together; and a
drainage and venting passage extending between the first and second
inner corner faces, the drainage and venting passage having
opposite end openings in registration with the drainage and venting
passages of the profiles when the profiles are coupled with the
corner key.
27. The frame work assembly according to claim 26, wherein the tabs
project respectively from the first and second inner corner faces
of the corner key for fit engagement into the accommodating
anchoring channels in the end faces of the profiles.
28. The frame work assembly according to claim 27, wherein the tabs
form a right angle with each other.
29. The frame work assembly according to claim 27, wherein the tabs
form acute or obtuse angles with each other.
30. The frame work assembly according to claim 26, wherein the
outer side corner face has a water evacuation and pressure
equalization vent in communication with the drainage and venting
passage of the corner key and the drainage and venting passage of
each profile.
31. The frame work assembly according to claim 30, wherein the vent
and the drainage and venting passage of the corner key have
substantially flush bottom surfaces declining toward the outer side
corner face.
32. The frame work assembly according to claim 27, wherein the
bores of the corner key are located adjacent to the tabs of the
corner key.
33. The frame work assembly according to claim 27, wherein the tabs
have tapered ends facilitating fit engagement into the anchoring
channels.
34. The frame work assembly according to claim 33, wherein the tabs
and the anchoring channels have matching shapes further
facilitating fit engagement of the tabs into the anchoring
channels, and wherein each of the tabs has a continuous shape.
35. The frame work assembly according to claim 27, wherein the
first and second inner corner faces form a right angle with each
other and the first and second outer corner faces form a right
angle with each other.
36. The frame work assembly according to claim 27, wherein the
first and second inner corner faces are provided with a sealing
element sealing the corner key with the profiles when the profiles
are coupled to the corner key.
37. The frame work assembly according to claim 27, wherein the
first and second inner corner faces respectively comprise first and
second sealing recesses located adjacent to the tabs, the sealing
recesses receiving a sealing element sealing the corner key with
the profiles when the profiles are coupled to the corner key.
38. The frame work assembly according to claim 37, wherein the
inner and/or outer side corner faces comprise extension fins for
masking joints created between the inner and/or outer side corner
faces and the profiles when the profiles are coupled to the corner
key.
39. The frame work assembly according to claim 27, wherein the
fasteners comprise screws or rivets.
40. The frame work assembly according to claim 27, wherein the
fasteners comprise an adhesive matter or an ultrasound weld.
41. The frame work assembly according to claim 37, wherein the
first and second inner corner faces have substantially flat surface
portions, and the sealing recesses have sloped wall surface
portions.
42. The frame work assembly according to claim 27, wherein the
corner key is made of thermoplastic material or metal.
43. The frame work assembly according to claim 27, wherein the
inner and/or outer side corner face has a chamfered and rounded
corner extending between the inner corner faces.
44. The frame work assembly according to claim 27, wherein the
drainage and venting passage of the corner key has an opening in
one of the inner corner faces above the end opening of the drainage
and venting passage of the corner key in said one of the inner
corner faces.
45. The frame work assembly according to claim 27, wherein the
outer side corner face has a water evacuation and pressure
equalization vent in communication with the drainage and venting
passage of the corner key and the drainage and venting passage of
each profile.
46. The frame work assembly according to claim 45, wherein the
first and second inner corner faces respectively comprise first and
second sealing recesses located adjacent to the tabs, the sealing
recesses receiving a sealing element sealing the corner key with
the profiles when the profiles are coupled to the corner key.
47. The frame work assembly according to claim 46, wherein the
inner and/or outer side corner faces comprise extension fins for
masking joints created between the inner and/or outer side corner
faces and the profiles when the profiles are coupled to the corner
key.
48. The frame work assembly according to claim 45, wherein the
fasteners comprise screws or rivets.
49. The frame work assembly according to claim 45, wherein the
drainage and venting passage of the corner key has an opening in
one of the inner corner faces above the end opening of the drainage
and venting passage of the corner key in said one of the inner
corner faces.
50. The frame work assembly according to claim 26, wherein the
inner or outer side corner faces bear logos, trademarks,
information or decorations.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a corner key for connecting
profiles together and also to a frame work assembly that includes
such corner keys and profiles.
BACKGROUND OF THE INVENTION
[0002] Corner keys and lineal profiles are well known in the art,
particularly in the context of windows and doors. A lineal profile
in this context designates either a sash profile or a frame
profile. A corner key is used to connect the sash or frame profiles
together.
[0003] As it is known in the art, a sash element in the context of
windows forms the mobile and working portion of a window. The sash
element forms a perimeter called a sash frame that holds the
necessary working hardware to allow the sash to slide, pivot, tilt,
lock, etc. The sash element also includes the assembly of glazing
and the edge-surrounding sash profiles. Sash profiles include top
and bottom horizontal rails, and vertical stiles. A sash in the
context of doors is most commonly referred to as a panel.
[0004] In the manufacture of a conventional sash or frame assembly,
one typically starts with lineal profiles. These profiles are
designed to incorporate specific functional features and to show a
certain aesthetic.
[0005] Furthermore, although many materials of construction are
conventionally utilized for the manufacturing of sash elements,
such as wood and aluminum, presently available insulating window
units that utilize a sash element formed of polyvinyl chloride
polymers (PVC) are known to provide superior insulating
properties.
[0006] A frame in the context of both windows and doors designates
the fixed structural assembly portion of a window or a door. The
frame in this context is used for example as a means of anchoring a
window to a building. The frames contain mobile sashes and hold
fixed glazing. Similarly as for sash elements, frame elements are
typically made of PVC, but other materials, such as wood or
aluminum, may be used as well.
[0007] Window frames and doorframes, are commonly made of four
mainframe profiles. In a typical window frame, the top frame
profile is usually identified as the header, the bottom one as the
sill and the remaining two as the side jambs.
[0008] PVC window fabrication primarily involves the use of
mitre-jointed corners. Accordingly, sash or frame profiles have
their ends cut at an angle in order to form such mitre joints.
Producing mitre joints requires great consistency in maintaining
the shape of the profiles and a high degree of precision in cutting
at the correct angle. Thus, very precise cutting equipment must be
used to this effect. Once cut, the mating ends of the profiles are
joined together and a corner key can be used to align and reinforce
the mitre joint.
[0009] The following documents disclose mitre cut profiles that are
connected with a corner key:
1 Inventors U.S. Pat. No. 4,240,765 OFFTERDINGER 4,453,855 RICHTER
et al. 6,047,514 VERCH 6,073,412 VERCH 6,108,997 BLAIS et al.
Foreign Patent EP-0,611,871 BLANPIED
[0010] A disadvantage of producing mitre joints is that they
require relatively expensive cutting equipment to make them. Such
equipment also requires a larger working area and also more highly
skilled labour.
[0011] It is also known in the art to use frame profiles that are
straight cut. Most wood and aluminum profile assemblies commonly
use butt-jointed corners, usually without corner keys. However,
these assemblies require very complex machining preparation.
[0012] The following documents disclose butt-jointed profiles that
also use a corner key to create the joint:
2 U.S. Pat. No. Inventors 4,296,587 BERDAN 4,502,260 MACHLER
4,570,406 DIFAZIO 4,856,230 SLOCOMB 5,431,211 GUILLEMET 5,473,853
GUILLEMET et al. 5,485,705 GUILLEMET 5,547,011 DOTSON et al.
5,921,051 HOPE 5,960,605 HOPE 6,067,760 NOWELL 6,134,857 HOPE
[0013] Typically, as disclosed in U.S. Pat. No. 6,067,760 (NOWELL)
for example, one end of the corner key is inserted inside a
profile. A screw is then driven in an outer face of the profile and
through the corner key to prevent them from disengaging from each
other.
[0014] This technique of using perpendicular fastener insertion for
joining together a profile to its corner key is satisfactory only
when using certain types of materials, such as aluminum or
pultrusion profiles. However, perpendicular fastener insertion
through thermoplastic (PVC) profiles is not satisfactory because of
the low tear resistance of such materials.
[0015] U.S. Pat. No. 5,105,581 (SLOCOMB, Jr.) discloses a corner
key that is only temporarily connected to a header by means of
screws inserted longitudinally in a screw boss of the header. No
screw is longitudinally or axially inserted along the jambs. These
screws temporarily hold the header to the corner key before an
ultra-sound welding operation permanently secures the frame
profiles to the corner key. This technique is disadvantageous in
that the frame profiles are to be secured to the corner key in two
steps, thus increasing manufacturing time. Furthermore, there is no
compression at all the interfaces of the profiles and the corner
key that ensures a tight contact between them.
[0016] Korean utility model 1996-0068593U (LEE) discloses a corner
key that is exclusively connected to profiles by means of axial
screws. The corner key has openings that allow the insertion from
the outside of reinforcement metals through the corner key and the
profiles, after these are connected together, so as to prevent the
phenomenon of bending of plastic frames.
[0017] None of the above mentioned documents address the problem of
the possibility of water and air leakage through the joints between
the profiles and the corner keys, nor any description of preventive
measures to preclude such leakages. Furthermore, none of the above
listed documents mention the use of corner keys, profiles and frame
work assemblies in a context besides windows and doors.
[0018] Accordingly, there exists a need in the market for a
relatively inexpensive frame work assembly having corner keys and
profiles that can be tightly fitted to each other, with their
joints being well sealed to avoid leakage problems.
[0019] Besides tight fitting and well sealed joints, it is known in
the art to use a barrier system in the design, which is named the
"Pressure-Equalized Rain-Screen Principle". This known principle is
based on an outer "water-shed" barrier, in combination with a
continuous, inner air barrier, whilst the air chamber between these
two barriers has to be in communication with the outside ambient
air pressure. To achieve the latter condition, openings to the
outside have to be created in the sill profiles of sashes and
frames. Furthermore, any accumulation of water within the sash and
frame profile cavities has to be evacuated through such openings as
well. The preparation of such openings requires special equipment
and affords extra labour.
[0020] There is therefore also a need in the market for a
relatively inexpensive frame work assembly that could incorporate
the pressure equalization and rain screen principle.
SUMMARY OF THE INVENTION
[0021] It is an object of the present invention to provide a corner
key and a frame work assembly that can overcome the prior art
deficiencies and shortcomings.
[0022] It is another object of the present invention to provide a
corner key for connecting two or more profiles together and forming
a frame work assembly in a simple, yet reliable manner with a
minimal effort and low manufacturing costs.
[0023] According to the present invention, there is provided a
corner key for connecting two or more profiles together, each
profile having an end face, a longitudinal drainage and venting
passage and a longitudinal securing bore, the corner key
comprising:
[0024] first and second adjacent inner corner faces, first and
second adjacent outer corner faces opposite to the inner corner
faces, and opposite inner and outer side corner faces extending
between the inner and outer corner faces, the inner corner faces
being shaped for respective coupling with the profiles;
[0025] first and second guide arrangements having a tab projecting
on one of the inner corner faces and the end faces of the profiles,
and an accommodating anchoring channel in the other one of the end
faces of the profiles and the inner corner faces, the tab being
shaped for fit engagement into the accommodating anchoring
channel;
[0026] first and second bores each extending between a different
one of the outer corner faces and one of the inner corner faces
opposite to the one of the outer corner faces, the bores being in
registration with the securing bores of the profiles when the
profiles are coupled with the corner key;
[0027] first and second fasteners respectively insertable in the
bores of the corner key and the profiles in a locking arrangement
in which the corner key and the profiles are connected together;
and
[0028] a drainage and venting passage extending between the first
and second inner corner faces, the drainage and venting passage
having opposite end openings in registration with the drainage and
venting passages of the profiles when the profiles are coupled with
the corner key.
[0029] According to another aspect of the present invention, there
is also provided a frame work assembly comprising:
[0030] a) two or more lineal profiles, each having an end face, a
longitudinal drainage and venting passage and a longitudinal
securing bore; and
[0031] b) one or more corner keys, each corner key for connecting
the two or more profiles together, each corner key having:
[0032] first and second adjacent inner corner faces, first and
second adjacent outer corner faces opposite to the inner corner
faces, and opposite inner and outer side corner faces extending
between the inner and outer corner faces, the inner corner faces
being shaped for respective coupling with the profiles;
[0033] first and second guide arrangements having a tab projecting
on one of the inner corner faces and the end faces of the profiles,
and an accommodating anchoring channel in the other one of the end
faces of the profiles and the inner corner faces, the tab being
shaped for fit engagement into the accommodating anchoring
channel;
[0034] first and second bores each extending between a different
one of the outer corner faces and one of the inner corner faces
opposite to the one of the outer corner faces, the bores being in
registration with the securing bores of the profiles when the
profiles are coupled with the corner key;
[0035] first and second fasteners respectively insertable in the
bores of the corner key and the profiles in a locking arrangement
in which the corner key and the profiles are connected together;
and
[0036] a drainage and venting passage extending between the first
and second inner corner faces, the drainage and venting passage
having opposite end openings in registration with the drainage and
venting passages of the profiles when the profiles are coupled with
the corner key.
[0037] Preferably, the tabs project respectively from the first and
second inner corner faces of the corner key for fit engagement into
the accommodating anchoring channels in the end faces of the
profiles, and the bores of the corner key are located adjacent to
the tabs of the corner key.
[0038] Preferably, the outer side corner face has a water
evacuation and pressure equalization vent in communication with the
drainage and venting passage of the corner key and the drainage and
venting passage of each profile.
[0039] Preferably, the corner key and profiles are made of
polyvinyl chloride polymers (PVC).
[0040] Preferably, the first and second inner corner faces
respectively comprise first and second recesses located adjacent to
the tabs, and the recesses are provided with a sealing element
sealing the corner key with the profiles when the profiles are
coupled to the corner key.
[0041] Preferably, the inner and outer side corner faces comprise
extension fins for masking joints between the side corner faces and
the profiles when the profiles are coupled to the corner key.
[0042] The invention as well as its numerous advantages will be
better understood by reading of the following non-restrictive
description of a preferred embodiment made in reference to the
appending drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] FIG. 1 is a perspective exploded view of a corner key and
profiles according to a preferred embodiment of the present
invention;
[0044] FIG. 2A is a cross sectional partial view at line II-II of
FIG. 1 showing a screw, corner key and profile before assembly, and
wherein the corner key is provided with a recess without its
sealing bead, according to a preferred embodiment of the present
invention;
[0045] FIGS. 2B is a cross sectional partial view of the screw,
corner key and profile of FIG. 2A after assembly, according to a
preferred embodiment of the present invention;
[0046] FIG. 3A is a cross sectional partial view at line II-II of
FIG. 1 showing a screw, corner key and profile before assembly, and
wherein the corner key is provided with a sealing bead in a recess,
according to a preferred embodiment of the present invention;
[0047] FIG. 3B is a cross sectional partial view of the screw,
corner key and profile of FIG. 3A after assembly, according to a
preferred embodiment of the present invention;
[0048] FIG. 4 is a perspective view of a corner key with an arrow
showing water evacuation, according to a preferred embodiment of
the present invention; and
[0049] FIG. 5 is a perspective view of a corner key with arrows
showing air pressure equalization, according to a preferred
embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0050] Referring to FIG. 1, there is shown a corner key 10
according to a preferred embodiment of the present invention. Also
shown are portions of two profiles, one corresponding to a sill 12
and the other to a jamb 14 that are to be connected together by
means of the corner key 10 to form part of a window frame
assembly.
[0051] Those skilled in the art will understand that although only
two window frame profiles 12, 14 are illustrated, the teachings
according to the present invention are also applicable to any
number of profiles or to any other general purpose profiles that
are to be jointed with a corner key. In particular, it will be
understood that the present teachings apply not only to window
frames, but also to door frames, and to other similar structural
assemblies as well.
[0052] The corner key 10 that is illustrated is preferably used as
a right side lower corner key, but those skilled in the art will
also understand that this corner key 10 can be modified so that it
can also be used in another position of the frame, as will be
described below.
[0053] The profiles 12, 14 that are to be used with the corner key
10 can be made from various materials and by means of different
techniques. For example, the profiles 12, 14 can be made of
extruded aluminum, steel, brass or other metals. Alternatively, the
profiles 12, 14 can be formed by means of pultruded plastics,
thermoplastics, such as PVC, or thermoset plastics. It is to be
understood, however, that other suitable materials and techniques
may be used to make these profiles as is well known in the art.
[0054] As shown, each profile 12, 14 that is to be connected to the
corner key 10 preferably has three types of apertures that are
apparent on the end faces 13, 15 of each profile 12, 14. These
apertures include a longitudinal anchoring channel 16, 18, a
longitudinal drainage and venting passage 20, 22 and one or more
longitudinal securing bores 24, 26. It is advantageous to form
these apertures during the fabrication of these profiles 12, 14 so
as to diminish the costs of production. In the case of, for
example, a lineal extrusion process, these apertures are easily
created when forming each profile 12,14. One could also create
these apertures later on, but this would increase manufacturing
processing times and ensuing costs.
[0055] The longitudinal anchoring channels 16, 18 do not need to
extend all the way across each profile 12, 14, but rather can take
the shape of a recess with a predetermined depth as will be
described below. Furthermore, the anchoring channels 16, 18 could
also be replaced with tabs as will be described below.
[0056] Preferably, the corner key 10 has a generally
three-dimensional rectangular shape with two adjacent inner corner
faces 28, 30, two adjacent outer corner faces 32, 34, and opposite
inner and outer side corner faces 36, 38 extending between the
inner and outer corner faces 28, 30, 32, 34. Similarly as explained
in relation with the profiles 12, 14, the corner key 10 may be made
according to different techniques and from different materials. For
example, it can be formed, cast or molded by using metals,
thermoplastics or thermoset plastics.
[0057] The inner corner faces 28, 30 are shaped for respective
coupling with the profiles 12, 14, preferably with flat portions
thereof matching those of the straight cut profiles 12, 14. Of
course, it will be understood that the corner key 10 may have
shapes other than a generally rectangular one, depending on the
particular application or preferred design. For example, the corner
key could be polygonal, such as hexagonal, or have any suitable
shape, such as curvilinear, as long as it can be properly connected
to appropriately shaped profiles. Furthermore, the corner key 10 of
the present invention may be modified so as to be able to connect
more than two profiles together as it will be apparent to those
skilled in the art.
[0058] In the illustrated embodiment, the corner key 10 has two
tabs 40, 42 that project respectively from the inner corner faces
28, 30. These tabs 40, 42 are shaped for fit engagement into the
anchoring channels 16, 18 of the profiles 12, 14. It is preferable
that the longitudinal anchoring channel 16, 18 of each profile 12,
14 and respective tabs 40, 42 have matching shapes in order to
facilitate fit engagement of the tabs 40, 42 into the anchoring
channels 16, 18. As illustrated, the tabs 40, 42 and the anchoring
channels 16, 18 may have matching L or S shapes. It is also
preferable that the tabs 40, 42 be tapered so as to further
facilitate their fitting into the anchoring channels 16, 18. The
tabs 40, 42 are preferably continuous in shape and extend along the
inner corner faces 28, 30 starting from close to the edge of the
inner side corner face 36 towards the outer side corner face 38, as
illustrated. Additional tabs (not shown) may also project from the
inner corner faces 28, 30 if more than two profiles are to be used
with a single corner key. Of course, the tabs may have different
designs than those illustrated herein, if desired. Preferably, the
tabs 40, 42 have a continuous shape extending lengthwise between
the inner and outer side corner faces 36, 38.
[0059] It should also be understood that the guide arrangement
formed of the tabs 40, 42 and channels 16, 18 as described above
can be modified according to design preferences. For example,
profile tabs may project from the end faces 13, 15 of the profiles
12, 14 in replacement of the anchoring channels 16, 18, while the
inner corner faces 28, 30 may be provided with channels or recesses
that receive these profile tabs. It is also contemplated that the
tabs may be removable, thus consisting in separate pieces from both
the corner key 10 and profiles 12, 14. Indeed, in such a
configuration both the end faces 13, 15 of the profiles 12, 14 and
the inner corner faces 28, 30 could then be provided with channels
or recesses for receiving portions of these removable tabs.
[0060] Furthermore, even though the tabs 40, 42 are shown to be at
a right angle from each other, this does not necessarily have to be
the case for all designs. Indeed, the tabs 40,42 may also form
acute or obtuse angles with each other.
[0061] The corner key 10 that is illustrated may be used in
rectangular frame work assemblies, however a modification of the
angles between the inner and outer corner faces 28, 30, 32, 34
and/or tabs 40, 42 can be made so as to obtain differently shaped
frames works, such as triangular shapes or rhomboid shapes with
acute and obtuse angles.
[0062] The corner key 10 illustrated has multiple bores 44, 46,
each extending between a different one of the outer corner faces
32, 34 and one of the inner corner faces 28, 30 opposite to the one
of the outer corner faces 32, 34. In the corner key 10 that is
illustrated, the bores 44, 46 are non-intersecting because of the
kind of fastener (a screw) that is used, but this need not be the
case as it will be further explained below. Furthermore, only one
bore 44, 46 may extend across each of the inner corner faces 28, 30
and outer corner faces 32, 34. However, if desired, and for
increased rigidity, several bores 44, 46 may extend across each of
the inner corner faces 28, 30 and outer corner faces 32, 34. In the
illustrated example, the corner key 10 has three bores 44, 46
extending across each of the inner corner faces 28, 30 and outer
corner faces 32, 34.
[0063] As it will be appreciated, when the profiles 12, 14 are
inserted into the tabs 40, 42 of the corner key 10, the bores 44,
46 are in registration with the respective securing bores 24, 26 in
the profiles 12, 14.
[0064] In order to create a stable and durable locking arrangement
between the corner key 10 and the profiles 12, 14, a set of
fasteners 48, 50 are respectively inserted in the bores 44, 46 of
the corner key 10 and the securing bores 24, 26 of the profiles 12,
14. Preferably, the fasteners 48, 50 are metal screws but any other
type of fastener may be used for the purpose of locking the corner
key 10 to its profiles 12, 14. For example, the fastener may be a
serrated metal rivet, a bonded rivet or a fusion welded rivet. In
another embodiment of the invention, the fastener may be a certain
type of adhesive glue or sealer that hardens inside the bores 44,
46 of the corner key and the securing bores 24, 26 of the profiles
12, 14. In that particular case, and as already mentioned above,
the bores 44, 46 need not to be non-intersecting with each other.
Alternatively, an ultrasound weld may also be used instead of the
adhesive.
[0065] In the illustrated example, three screws 48 are inserted in
the bores 44 of the corner key 10 from the outer corner face 32 and
into the securing bores 24 of profile 12. Similarly, three screws
50 are inserted in the bores 46 of the corner key 10 from the outer
corner face 34 and into the securing bores 26 of profile 14. It is
to be understood, however, that in another embodiment of the
invention, only a single screw can be inserted from each of the
outer corner faces 32, 34, into the bores 44, 46 and securing bores
24, 26. These bores would then be preferably located in the middle
of the corner key 10.
[0066] The fasteners 48, 50 are solely responsible for the
permanence of the frame work assembly (not shown) that can be
built. The axial or longitudinal insertion of the fasteners 48, 50
relative to the profiles 12, 14 assures an intimate contact between
the cut end faces 13, 15 of the profiles 12, 14 and the mating
inner corner faces 28, 30 of the corner key 10. A sealing element,
such as a foamed hot-melt sealing bead 60, in addition to the
fasteners 48, 50 may assist in the permanence of the frame work
assembly. The sealing beads 60 provide the corner key 10 with
long-lasting sealing properties to intimately seal the interfaces
between the lineal profiles 12, 14 and the corner keys.
[0067] The corner key 10 is also provided with a drainage and
venting passage 52 extending between the first and second inner
corner faces 28, 30. This drainage and venting passage 52 has
opposite end openings 54, 56 in registration with the drainage and
venting passages 20, 22 of the profiles 12, 14 when these are
coupled with the corner key 10. As it will be further explained
below with reference to FIGS. 4 and 5, the purpose of the drainage
and venting passage 52 in the corner key 10 and the drainage and
venting passages 20, 22 in the profiles 12, 14 is to allow water
and air to flow therethrough. The drainage and venting passage 52
of the corner key 10 acts as an opening for pressure equalization
within the rain screen principle discussed above.
[0068] The sealing element can also include silicone or a solid
sealant such as preformed or stamped foam gaskets. In addition to
reinforcing the permanence of the joint at the interface between
the end faces 13, 15 of the profiles and the inner corner faces 28,
30 of the corner key 10 as mentioned above, this sealing element
eliminates possible water leaks from the drainage and venting
passage 52 dripping into the wall cavity surrounding a window or a
door frame, for example.
[0069] Preferably, the sealing element, such as the foamed hot-melt
sealing bead 60, is applied onto the inner adjacent corner faces
28, 30 for sealing the drainage channel 52 of the corner key with
those of the profiles 12, 14 when the profiles 12, 14 are coupled
to the corner key 10.
[0070] It is also preferable that the inner corner faces 28, 30 of
the corner key 10 be provided with strategically positioned sealing
recesses 63 located adjacent to the base of the tabs 40, 42, where
they meet the inner corner faces 28, 30 of the corner key 10. The
sealing recesses 63 are shaped to receive and contain the sealing
bead 60, and preclude it from dripping when it is laid therein. As
illustrated, the sealing bead 60 is preferably laid along a
continuous line adjacent to each of the tabs 40, 42 and the
drainage and venting passage 52.
[0071] Preferably, the bores 44, 46 of the corner key 10 are
located adjacent to the tabs 40, 42 of the corner key 10. In this
manner, the screws 48, 50 are strategically positioned, adjacent to
the critical contact line formed by the tabs 40, 42 and the sealing
beads 60.
[0072] Referring to FIGS. 2A and 2B, there is shown an alternative
embodiment of the present invention wherein no sealing bead 60 is
applied in the between the corner key 10 and profile 12. However,
the inner corner face 28 is still provided with the sealing recess
63 that is formed of a sloped wall surface 68 on the inner corner
face 28. This sloped wall surface 68 assists in the action of
wedging the lineal profile 12 into the sealing recess 63.
[0073] Referring to FIGS. 3A and 3B, there is shown the same
configuration as in FIGS. 2A and 2B, but with the sealing bead 60
being applied in the sealing recess 63, for further enhancing the
sealing feature of the design.
[0074] Preferably, and as is best illustrated with reference to
FIGS. 1, 2A, 2B, 3A and 3B, the inner and/or outer side corner
faces 36, 38 have extension fins 70 for masking the joints 72 that
are created between the corner key 10 and the profiles 12, 14, when
the profiles 12, 14 are coupled to the corner key 10. In other
words, the inner and outer side corner faces 36, 38 can be extended
to overlap the plane of contact between the cut faces 13, 15 of the
profiles 12, 14 and the designated contact inner corner faces 28,
30 of the corner key 10. The added feature of such face extensions
is the structural overlapping and the visual masking of the
assembly joint 72 between the cut end faces 13, 15 of the lineal
profiles 12, 14 and the corresponding faces of the corner key for
the purpose of covering up irregularities of the profiles' 12, 14
end-cuts 13, 15, of guiding the application of the sealing bead 60,
and of masking any sealing bead overflow. The extension of corner
surfaces for the purpose of overlapping the assembly joint 72 can
be applied to other surfaces of the corner key 10, particularly to
those which remain exposed to the eye after the completion of
installation of an assembled window or door.
[0075] Advantageously, the extension fins 70 provided on the inner
and outer side corner faces 36, 38 may also form part of the sloped
wall surface 68 of the sealing recess 63 provided on the inner
corner faces 28, 30.
[0076] Furthermore, those skilled in the art will understand, the
corner key 10 may be provided without any sealing recesses 63 and
sealing beads 60. Such a configuration may be advantageous because
it is easier and less expensive to make. However, when a sealing
bead is applied between the corner key and the profile, there may
be leakage problems as there is not enough sealant mass to
compensate for irregular contact faces and/or gaps created by
distortion and by movement of contact surfaces at the joints.
[0077] Referring to FIGS. 4 and 5, there is shown another
embodiment of the present invention showing a corner key 10 that is
similar to the one shown in FIG. 1. As mentioned above, the corner
key 10 that is illustrated in FIGS. 1, 4 and 5 is preferably used
as a right-side lower corner key because its outer side corner face
38 is provided with a water evacuation vent 58 that is in
communication with the drainage and venting passage 52 of the
corner key 10 and the drainage and venting passage 22, 20 of each
profile 12, 14 when these are coupled together. As those skilled in
the art will understand, upper corner keys do not need to be
provided with such vent 58.
[0078] In use, when water infiltrates into the drainage and venting
passages 20, 22 of the profiles, such as in case of rain or high
humidity, this configuration allows for water evacuation through
the vent 58. It is preferable that the vent 58 and the drainage
passage 52 have substantially flush bottom surfaces declining
toward the outer side corner face 38. This downward slope
facilitates the water evacuation as depicted by arrow and water
drop 64.
[0079] As shown in FIG. 5, the corner key 10 with its vent 58 also
has the advantage of providing pressure equalization between the
inside of the profiles 12, 14 and the ambient air outside, as
depicted by arrow 66.
[0080] Preferably, the drainage and venting passage 52 has an
opening 59 in one of the inner corner faces 28, 30. In the
illustrated example, the opening 59 is on the inner corner face 30,
above the end opening 54 of the drainage and venting passage 52.
The corresponding profile 14 also has its drainage and venting
passage 22 provided with an opening 61 that communicates with the
opening 59. These openings 59, 61 are provided so that sashes or
any component of a frame can be inserted therein, as those skilled
in the art will understand.
[0081] Advantageously, the inner and outer side corner faces 36, 38
can bear logos, trademarks, information or decoration designs for
advertisement, publicity and/or decoration purposes. Also, the
inner side corner face 36 may have a chamfered and rounded corner
62 extending between the inner corner faces 28, 30. A chamfered and
rounded corner may also be provided between the outer corner faces
32, 34. The chamfered and rounded corner 62 provides a design that
may be appealing, and which is visible on an assembled sash or
window frame.
[0082] Use of the corner key of the present invention eliminates
the need for expensive production equipment and large floor space,
and therefore provides a cost efficient solution for the
fabrication of window or door frame assemblies in particular, but
also for general purpose frame work assemblies.
[0083] Furthermore, the frame work assembly according to the
present invention eliminates the need for mitre-cuts, welding and
weld cleaning, nor is any punching, routing or drilling needed
since all operational functions of a complete window or door
assembly are incorporated into the corner keys. It also allows the
use of unskilled labor due to the simplicity of its assembly
process.
[0084] An advantage of the present invention is that the pressure
equalization and water evacuation openings are provided as an
integral part of the design of the corner keys, thus eliminating
the need for the otherwise required additional machining
effort.
[0085] The frame work assembly of the present invention may be used
for the creation of windows having any type of operation, such as
fixed, horizontally and vertically sliding, inward and outward
projecting, etc.
[0086] The frame work assembly may also be used for the creation of
doors of any type of operation, such as sliding, inward and outward
projecting, etc.
[0087] Although the present invention has been exemplified with
frame profiles, those skilled in the art will understand that the
present teachings are also applicable to sash profiles.
[0088] Furthermore, although the profiles are mainly used in the
context of a window or door frame assembly, those skilled in the
art will understand that the corner key and profiles of the present
invention may be used to assemble such diverse frame work
assemblies as walls of a building, a container, or any general
purpose structure or frame work assembly.
[0089] Although a preferred embodiment of the present invention has
been described in detail herein and illustrated in the accompanying
drawings, it is to be understood that the invention is not limited
to this precise embodiment and that various changes and
modifications may be effected therein without departing from the
scope or spirit of the present invention.
* * * * *