Frames

Abstract

Frame members are assembled for two components in such a way that a flange on one component butts against a flange on the other component to form a closed hollow ridge along one side of the frame member. A projection completes the closed hollow ridge, and the projection functions to guide the flanges into correct abutting relationship.

Parent Case Text

This application is a continuation of application Ser. No. 682,302, filed Nov. 11, 1967, now abandoned.

Description

The present invention relates to frame members and to frames suitable as door or window frames assembled from the frame members. The frame members and frames are formed from plastics materials.

According to the present invention we provide a frame member having a main hollow cross section assembled from two components and having a ridge extending longitudinally therealong, said ridge being produced upon assembly of the two components by uniting a flange of the first component which flange extends at an angle to a portion of the first component which portion forms at least part of one side of the main hollow cross section, with a flange of the second component extending at an angle to an extension of a portion of the second component which portion forms at least part of an adjacent side of the main hollow cross section such that the end of the flange of the first component abuts against the flange of the second component, a projection being formed on the first or the second component for engaging the other component and locating the abutment of the flanges of the two components.

According to a further aspect of the present invention we provide a frame member having a main hollow, rectangular, cross section assembled from two components wherein the first component has a flange extending substantially perpendicularly to a portion of that component which portion forms one side of the main hollow rectangular cross section of the frame member and the second component has a flange, extending substantially perpendicularly to an extension of a portion of the second component which portion forms an adjacent side of the main hollow rectangular cross section of the frame member, when in the assembled form the end of the flange of said first component abutting against the flange on said second component, said second component being provided with at least one projection which engages with the corner of the first component between the flange of the first component and the portion of the first component which forms one side of the main hollow rectangular cross section, as the two components are brought together to guide the end of the flange of the first component into abutting relationship with the flange of the second component.

Also according to the invention we provide a frame member of generally rectangular cross section assembled from a component having a generally U-shaped cross section and a capping component which forms the fourth side of the generally rectangular cross section of the frame member, said capping component being of a generally channel-sectioned cross section having a base and flanges forming the sides of the channel, which flanges extend substantially perpendicularly to extensions of each end of the base, and when the U-shaped component and said capping component are assembled, the ends of flanges extending from the sides of the "U" of the U-shaped component abut against the flanges of said capping component, said capping component being provided with projections projecting from the channel section between the base and the extensions of the base, said projections engaging with the corners of the U-shaped component between the sides of the "U" and the flanges thereon as the U-shaped component and the capping component are brought together so as to guide the flanges of the U-shaped component into abutting relationship with the flanges of the capping component.

The invention also concerns door or window frames when assembled from frame members according to the invention. Both the outer fixed frame and the inner moving frame may be made in accordance with the invention and the term "door or window frames" is to be understood to embrace this meaning. For example, the fixed outer frame and the inner moving sash frame of a window may be assembled from frame members according to the invention.

A preferred method of producing the components is to compression mould them from a partially cured sheet of reinforced thermosetting resin, e.g., glass fiber-reinforced polyester resin.

It is preferred that the hollow cross section of the frame member should be substantially rectangular. Within the term "substantially rectangular" we intend to include cases where at least one side, and possibly more than one side, of a component is made slightly nonperpendicular to its adjacent side, e.g., by from 1/2.degree. to 3.degree.. It is particularly advantageous to provide for this degree of nonperpendicularity in components which are formed by moulding since this facilitates removal of the moulded component from the mould.

The ridge is preferably also of hollow cross section, although it need not be hollow and may assume a solid form.

The flanges of the first and second components are preferably arranged "substantially perpendicular" to said portion of the first component forming at least part of one side of the hollow cross section and to the extension of the second component respectively. Within the term "substantially perpendicular" we include cases where the flanges are slightly nonperpendicular to their associated portion or extension, e.g., by from 1/2.degree. to 3.degree..

The projection is preferably formed on the second component for ease of manufacture of the component, particularly when compression moulding of a partially cured sheet of reinforced thermosetting resin is used, and is preferably located at the junction of the extension and the portion of the second component extended by the extension. It is also desirable to make the general plane of the projection perpendicular to the portion of the second component forming at least part of said adjacent side and to its extension, and to connect the projection to this portion and extension. It is not necessary for the projection to extend the whole length of either component on which it is formed. Indeed it may only extend for a minor proportion of this length or may be broken into a plurality of spaced projections. The projection may take the form of a support and locating means for supporting the flange of the first component in spaced relationship to the extension of the second component when the ridge is hollow.

The projection is preferably cut away to provide a spigot for location in a corresponding socket in the first component, the spigot and socket being equidistant from corresponding ends of their respective components thereby serving to longitudinally locate the components with respect to each other.

The frame member is produced from the two components by bonding together the abutting surfaces of the flanges of each and bonding the projection of one component to the surface of the other component against which it abuts.

Production of the frame member may be effected by assembling the two components with the flanges and projection in an unshaped condition. Alternatively one or both of the flanges and/or the projection may be shaped to facilitate assembly, for instance channel may be formed in either of the flanges or projection to accommodate the mating part, or the abutting surfaces of the flanges and projection may be bevelled or may be formed with interengaging teeth or studs and cavities.

It is convenient during the moulding of the frame components to make provision for any functional features that may be desirable. For instance, a longitudinal channel may be moulded into the ridge for accommodating a weather sealing strip.

In order that the present invention may be more readily understood several embodiments thereof are now described by way of example only and with reference to the accompanying drawings, in which:

FIG. 1 is a cross section of parts of the two components of a frame member near a joint between the components;

FIG. 2 is a detailed cross section of two components shown in a slightly separated state, which may be assembled into a frame member;

FIG. 3 is a cross section of two components shown in a slightly separated state, which may be assembled into a frame member;

FIG. 4 is a cross section of a preferred joint between two components of a frame member, only part of the frame member being shown;

FIG. 5 is a cross section of a joint between two components of a frame member having a solid flange, only part of the frame member being shown;

FIG. 6 is a cross section of an asymmetrical frame member;

FIG. 7 is an exploded perspective view of parts of two components which may be assembled to form a window frame member;

FIGS 8 to 12 are end elevational views of parts of assembled frame members, each showing a particular and alternative way of forming the ridge;

FIGS. 13 and 14 are end elevational views of parts of frame members in separated form, each showing further ways of forming the ridge;

FIG. 15 is a sectional view along line 15--15 of FIG. 14; and

FIG. 16 is a sectional view taken through two frame members.

In FIG. 1, one side of the generally rectangular cross section of the frame member, which is shown approximately by the dotted lines, is formed by a portion 1 of a first component forming part of a side of the hollow cross section of the frame member. A flange 2 is formed on the end of portion 1 extending in a generally perpendicular direction to the portion 1. The second frame component has a portion 3 forming an adjacent side of the generally rectangular cross section, and a flange 4 extending in a generally perpendicular direction to an extension 3a of portion 3. A projection 5, having an inclined or bevelled face 6 is provided on the second component and projects upwardly at the junction of the portion 3 and the extension 3a such that as the first component is moved towards the second component in the direction of the arrow, corner 7 of the first component between portion 1 and flange 2 engages with the inclined face 6 of projection 5 to guide the end 8 of flange 2 into abutting relationship with flange 4 thereby producing a boxlike ridge.

In general, both joints between the two components will be of the same type and although this is by no means essential it is strongly preferred.

The invention is applicable to two particular forms of construction which are considered separately hereinafter.

In the first form the frame member is assembled from two similarly shaped components, each having the general cross-sectional form of an "L" with a small flange extending from the end of one limb of the "L" in a direction substantially perpendicular to that limb and away from the other limb of the "L.".

In FIG. 2 component A has a generally L-shaped cross section formed by its limbs 9a and 10a which comprise two of the sides of the hollow cross section of the frame member. The limb 9a is extended by an extension 9'. A flange 12a extends substantially perpendicularly from the end of the extension and a flange 11a extends substantially perpendicularly from the end of the limb 10 a and away from the limb 9a. Projection 13a is provided integrally with and extending from limb 9a between limb 10a and flange 12a. This projection 13a has an inclined face 14a. Component B is constructed in similar fashion, equivalent members to those in component A being designated by the same reference numeral suffixed by the letter b instead of the letter a except for the equivalent to extension 9' which is designated 9". When compounds A, B are to be joined together to produce the boxlike ridges with the end of flange 11a of component A abutting against the flange 12b of component B, and the end of the flange 11b of component B abutting against the flange 12a of component A, the projection 13a of component A engages with the corner of component B between limbs 10b and flange 11b, and projection 13b of component B engages with the corner of component A between limb 10a and flange 11a, the engagement of the projections with the corners guiding the flanges 11a, 11b into abutting relationship with the flanges 12b and 12a respectively.

When the two components are joined together corner 15a, between flange 11a and limb 10a, of component A engages with the inclined face 14b of projection 13b. Likewise corner 15b of component B engages with face 14a of projection 13a. As the components are moved closer together, i.e., as the distance between limbs 9a and 9b is decreased, the corners 15a and 15b are guided by the inclined faces 14b and 14a until the ends 16a, 16b of flanges 11a, 11b abut against flanges 12b and 12a respectively. The frame member produced from these components has an approximately hollow rectangular cross section with ridges extending in opposite directions from two opposite sides of the rectangle.

The other form of construction to which the principle of the invention is applicable is where the frame member is constructed from a generally U-shaped component.

One form of this second type of construction is illustrated in FIG. 3 in which the parts to the left of the centerline X--X are designated with the suffix a while the parts to the right are designated with the suffix b.

The generally U-shaped component has a base 17a, 17b and sides 18a, 18b at the ends of which are outwardly extending flanges 19a, 19b. The capping component is generally channel sectioned and has a base 20a, 20b and flanges 21a, 21b extending substantially perpendicularly to extensions 34a, 34b at each end of the base 20a, 20b. Projections 22a, 22b are provided between base 20a and extension 34a, and base 20b and extension 34b respectively and have inclined faces 23a, 23b.

As the generally U-shaped component is brought towards the capping component, i.e., as the distance between base 17a, 17b and base 20a, 20b is decreased, the corners 24a, 24b of the U-shaped component between sides 18a, 18b and flanges 19a, 19b respectively engage with the inclined faces 23a, 23b of projections 22a, 22b to guide the ends 25a, 25b of flanges 19a, 19b into abutting relationship with the flanges 21a, 21b. The two components are bonded together with a polyester resin.

It is seen that in each of the two particular forms of the invention described hereinbefore, the joint assumes the form illustrated in FIG. 1.

In FIG. 4 which shows a boxlike ridge of a frame member the flange 26 of one component is provided with a small, downwardly extending lip 27 directed towards the extension 33 of the second component which, when the first component is in abutting relationship with flange 28 of the second component, is seated in a recess 28a in flange 28. Also projection 29 of the second component is provided with an inclined face 30 with which corner 31 of the first component engages during assembly, and a ledge 32 on which part of the underside of flange 26 at the corner 31 is supported so as to space and support the flange 26 away from the extension 33. The projection 29 also serves to locate the flange 26 between itself and the flange 28. The components are bonded together with a polyester resin.

In the embodiments described hereinbefore, the assembled components form a boxlike ridge on the frame member, i.e., referring to FIG. 4 flange 26 is held in spaced relationship to extension 33 of the second component.

While a boxlike ridge construction is preferred, it is by no means essential. An alternative solid ridge is illustrated in FIG. 5 in which the flange 36 of the first component is seated directly on the extension 37 of the second component, and abuts against a small flange 38 on the end of extension 37. The first component is guided into the abutting position by means of a projection 39 against which corner 40 of the first component engages during assembly. The projection 39 serves to locate the flange 36 between itself and the flange 38.

The projections which engage with the corners of the other component may take the form of a series of small projections at spaced intervals along the length of the component or may be in the form of a continuous ridge along the length of the component. The height of the projection above the extension on the second component is preferably higher than that of the flange on the second component against which the end of the flange on the first component abuts. The projection need not have an inclined corner engaging face although this is to be preferred. The angle of inclination of the inclined face, i.e., angle .alpha. in FIG. 4, may be relatively small, e.g., 3.degree.-10.degree. to the perpendicular from the extension 37, or the inclined face may be curved.

The present invention is particularly suitable for application in the design of frames, e.g., window frames, made from synthetic polymeric materials, particularly fiber-reinforced polyester resins. One particularly suitable method of production is to compression mould a partially cured mat or sheet of glass fiber reinforced polyester resin such as that sold under the trade name Flomat. During such a moulding process, flanges and projections may be moulded integrally with the component.

When making components by such moulding techniques, in order to ensure easy removal of the moulding from the mould, the frame member is generally designed to make the generally rectangular cross section slightly nonrectangular, i.e., one side of a component is made slightly nonperpendicular, by a small amount, e.g., 1/2.degree. to 3.degree. to an adjacent side of the component.

Also for some applications it may be desired to make the frame member asymmetrical, for example a boxlike ridge on one side of the frame member may be of a different size to a boxlike ridge on the other side of the frame member.

Such an asymmetrical frame member is illustrated in cross section in FIG. 6 which is a cross section of an assembled asymmetrical frame member having base ridges 41, 42 of different sizes.

The window frame components 43, 44 illustrated in FIG. 7 are produced by the compression moulding of a partially cured mat of glass fiber-reinforced polyester resin and each has a flange 45 formed at the end of an extension 46 to a limb 47 and perpendicular thereto. Another limb 48 connected to the limb 47 extends perpendicular to and in the same direction as the flange 45. The flange 45 has a longitudinally extending recess 49 such that when the two components 43, 44 are assembled a lip 50 on a flange 51 at the end of the limb 48 remote from the limb 47 is able to seat therein in abutting relationship with the side of the recess 49. A projection 52 extending parallel to the flange 45 and located between the extension 46 and the limb 47 has a ledge 53 and a fillet 54. In the component 44 the fillet 54 is cut away at one end to provide a spigot 55. A socket shown by dotted lines 56 is moulded into a ridge 57 in the corresponding end of the component 43 at a distance from the end equal to that of the spigot 55 from the end of the component 44.

In order that the ends of the two assembled components 43, 44 are rendered flush with each other to provide level end faces on each end of the window frame member the spigot 55 and socket 56 are used for longitudinal location of the components, hence the spigot 55 and socket 56 are located equidistant from the ends of the components 43, 44. The spigot 55 and socket 56 are of equal length in the longitudinal direction of the components, as shown in FIG. 7, so that upon assembly of the components the spigot 55 fits into the socket 56 with a tight but sliding fit.

It is desirable to ensure that the assembled window frame member has level end faces to facilitate the mating of the member with other members also having level end faces when a complete window frame is being constructed.

The components assembled into a window frame member are preferably bonded together with a suitable bonding agent, such as a polyester resin, along mating surfaces, such as those between the lips 50 and recesses 49, and the fillets 54 and ledges 53. It has been found that the most satisfactory bond is obtained if the mating surfaces are not made tight interference fits but are such that a small space remains therebetween to locate the bonding agent so that the bonding agent is not squeezed out of the space during assembly of the components.

The components shown in all of FIGS. 8 to 16 were produced by the compression moulding of a partially cured sheet of glass fiber-reinforced polyester resin.

FIG. 8 shows a ridge 110 of hollow cross section extending longitudinally along the length of a frame member of hollow cross section (not shown in full). A first component 111 has a flange 112 perpendicular to and integral with a portion 113 forming part of one side of the hollow cross section of the member. A second component 114 has a flange 115 extending perpendicular to and integral with an extension 116 to side 117 of the rectangular cross section adjacent to the portion 113 of the first component 111. A projection 118 perpendicular to and integral with the extension 116 and side 117 of the second component 114 extends longitudinally along the second component 114 by supporting the first component 111 in the region of the connection between the flange 112 and the portion 113. The frame member 110 is assembled by bonding together the abutting surfaces of the flanges 112 and 115 and bonding the projection 118 to the first component 111 in the region of connections between the flange 112 and the portion 113, these parts being in an unshaped condition. The bonding agent is a polyester resin glue.

FIGS. 9 to 15 differ from FIG. 8 only in the manner of joining the first component to the flange and projection of the second component. Accordingly like components shown in FIGS. 9 to 15 are represented by the same reference numerals used for like components shown in FIG. 8 and the reader is referred to the description of FIG. 8 for an understanding of these later figures, apart from the description of the manner of joining the first component which is now described.

In FIG. 9, the flange 115 has a longitudinal channel or recess 120 at its upper edge extending along its inner face. Likewise, the projection 118 has a similar channel 121 facing the channel 120. The channels 120 and 121 have dimensions which will accommodate the flange 112 supporting it in spaced relation to the flange 116. The channel 121 also serves to laterally locate the flange 112 between the projection 118 and the flange 115.

The ridge 110 shown in FIG. 10 also has a channel or recess 120 in the flange 115 equivalent to that shown in FIG. 9. The projection 118 has a bevelled upper edge 122 while the first component 111 has a corresponding bevelled corner 123 between the portion 113 and the flange 112. This arrangement is such that when the first and second components 111 and 114 are assembled the bevelled corner 123 engages with the bevelled edge 122 and the beveled corner 123 is cause to slide across the bevelled edge 122 to guide the end of the flange 112 into position in the channel 120.

The construction shown in FIG. 11 is similar to that shown in FIG. 10 but the projection 118 is provided with a channel 125 facing the flange 115, and the flange 112 has a bevelled edge 126 while the flange 115 has a bevelled edge 127. The interaction between the bevelled edges 126 and 127 upon assembly of the frame member has the effect of guiding a corner 128 of the first component into position within the channel 125.

In the frame member shown in FIG. 12 the flange 115 and projection 118 of the second component 114 have facing bevelled edges 130 and 131 respectively. There is a corresponding bevelled edge 132 on the flange 112 and a bevelled corner 133 between the flange 112 and the portion 113 of the first component 111.

In FIG. 13, the flange 115 has a channel or recess 135 corresponding to the end of the flange 112. Along the edge of the projection 118 a plurality of studs 136 are arranged to be located within a corresponding plurality of cavities 137 (represented by dotted lines) in the first component 111.

In FIGS. 14 and 15, the flange 115 has a channel or recess 140 corresponding to and for receiving the end of the flange 112. The projection 118 has a castellated edge 141, as best shown in FIG. 15, whilst the first component 111 has a plurality of teeth 142 for engaging with the castellated edge 141 when the frame member is assembled.

It will be understood that a similar castellated edge may be formed on the flange 115 to engage with teeth on the flange 112 and that this may be incorporated in a frame member in which the projection 118 is attached to the first component 111 by any of the expedients described with reference to the preceding drawings.

In FIG. 16, a frame member 145 of a moving window casement frame is shown associated with a frame member 146 for installation in a window aperture in the wall of a building. Both frame members 145 and 146 are constructed in a manner already described, the ridges 147, 148, 149 and 150 being formed substantially as described with reference to FIG. 8. A longitudinal channel 151 is formed in a flange 152 of component 153, into which is bonded with a polyester resin glue a rubber sealing strip 154.

It will be understood that any of the joints between the flanges of the first and second components as described above can be used for joining the projection and the corner of the first component between the flange 112 and the portion 113, and vice versa.

Frame members made in accordance with the present invention may be used for a variety of purposes but are particularly of use in the construction of frames for building applications such as door and window frames. It will be appreciated that the generally rectangular cross section may be modified in places, for example by the provision of recesses, flanges and the like for particular purposes.

Claims

I claim:

1. A window or door frame member having a main hollow cross section and a closed hollow ridge extending along at least one of its sides, said frame member being assembled from two components which include

a. a first component having a flange extending substantially perpendicularly to a portion of said first component, which portion forms one side of the main hollow cross section of the frame member and

b. a second component having a flange extending substantially perpendicularly to an extension of a portion of said second component, which portion forms an adjacent side of the main hollow cross section of the frame member,

said closed hollow ridge being produced upon assembly of said two components by abutting the end of the flange of said first component against the flange on said second component such that the flange on said first component and the flange on said second component form two adjacent sides of said hollow closed ridge,

and said second component being provided with at least one projection which engages with a corner of the first component between the flange of the first component and the portion of the first component which forms the one side of the main hollow cross section, as the two components are brought together, to guide the end of the flange of the first component into abutting relationship with the flange of the second component.

2. A frame member according to claim 1, in which the closed hollow ridge has four sides comprising the flange of said first component, the flange of said second component, said projection and said extension.

3. A frame member according to claim 1, in which the projection comprises a plurality of spaced projections.

4. A frame member according to claim 1, in which the flange of the first component has a lip directed towards the extension of the second component and seated in a recess in the flange extending from the extension of the second component.

5. A frame member according to claim 1, in which the projection has a ledge for engaging the corner of the first component.

6. A frame member according to claim 1 in which the projection is cut away to provide a spigot for location in a corresponding socket in the first component, the spigot and socket being equidistant from corresponding ends of their respective components thereby serving to longitudinally locate the components with respect to each other.

7. A frame member according to claim 1 in which the two components are bonded together.