U.S. patent number 3,707,815 [Application Number 05/002,579] was granted by the patent office on 1973-01-02 for building construction and elements for use therein.
This patent grant is currently assigned to Econa (G. & B.) Plastics Limited. Invention is credited to George Molyneux.
United States Patent |
3,707,815 |
Molyneux |
January 2, 1973 |
BUILDING CONSTRUCTION AND ELEMENTS FOR USE THEREIN
Abstract
An upstanding channel member, serving as a mounting for a door
or window frame, has a rectangular or trapezoidal central portion
received with all-around clearance in a space between two adjoining
wall elements and bears with one or two transverse base flanges
upon an end face of one or both wall elements. Two flat anchor
members, secured to opposite sides of the central channel portion
by a dovetail fit, are independently shiftable along these surfaces
to fit between courses of building blocks or bricks constituting
the wall elements. The mortar bonding these courses together flows
into the clearance around the central channel portion and holds it,
together with the anchor members, in position between the wall
elements.
Inventors: |
Molyneux; George (Gisburn,
EN) |
Assignee: |
Econa (G. & B.) Plastics
Limited (Shirley, Solihull, EN)
|
Family
ID: |
26249200 |
Appl.
No.: |
05/002,579 |
Filed: |
January 13, 1970 |
Foreign Application Priority Data
|
|
|
|
|
Mar 11, 1969 [EN] |
|
|
12,688/69 |
Jul 7, 1969 [EN] |
|
|
34,191/69 |
|
Current U.S.
Class: |
52/213; 52/565;
52/710; 52/713 |
Current CPC
Class: |
E06B
1/003 (20130101); E04B 1/4107 (20130101); E04B
1/4185 (20130101); E06B 1/6038 (20130101); E06B
1/02 (20130101) |
Current International
Class: |
E04B
1/41 (20060101); E06B 1/56 (20060101); E06B
1/02 (20060101); E06B 1/60 (20060101); E06B
1/00 (20060101); E06b 001/58 (); E06b 001/32 ();
E05b 001/02 () |
Field of
Search: |
;52/350,565,567,561,258,252,213,214,212,257,243,252,710,738,740,706,707,696,698 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
720,691 |
|
Feb 1958 |
|
GB |
|
427,344 |
|
Apr 1935 |
|
GB |
|
665,067 |
|
Jan 1952 |
|
GB |
|
Primary Examiner: Abbott; Frank L.
Assistant Examiner: Raduazo; Henry E.
Claims
I claim:
1. A moistureproof assembly for affixing a frame to a wall,
comprising a pair of wall elements separated by a space, a
damp-proofing course element of water-impermeable
corrosion-resistant material of hollow uniform cross-section over
its entire length extending all along said frame, said course
element having a trapezoidal-cross-section body tapering away from
said frame and projecting into said space, said body having
mutually converging legs formed along the exterior thereof with
respective channels of dovetail configuration extending the full
length of the course element, the interior of said body opening in
the direction of said frame, and at least one flange extending
transversely to one of said legs and unitary therewith; means for
securing a frame element to said flange; and flat dovetail anchors
received in said wall and engaging in said channels at selected
locations therealong, said channels providing sites for said
anchors anywhere throughout the length of said course element.
2. A moistureproof assembly for affixing frame to a building wall,
comprising:
a pair of wall elements with substantially coplanar end faces each
composed of several courses of building blocks held together by
layers of adhesive material, said wall elements being separated by
a space generally perpendicular to said end faces;
an upstanding channel member of profiled sheet material having a
central portion projecting with all-around clearance into said
space and further having a base outside said space with said flange
means bearing upon at least one of said end faces;
a cementitious filler occupying said clearance and bonding said
channel member to said wall elements; and
a pair of flat anchor members positively engaging opposite outer
surfaces of said central portion within said filler and extending
laterally outwardly therefrom between successive building-block
courses of said wall elements in respective layers of said adhesive
material.
3. An assembly as defined in claim 2 wherein said opposite outer
surfaces are provided with vertical keying formations matingly
receiving adjoining ends of said anchor members.
4. An assembly as defined in claim 2 wherein said anchor members
include with each other an obtuse angle pointing toward said
base.
5. An assembly as defined in claim 4 wherein the profile of said
channel member is generally trapezoidal, said outer surfaces
converging in a direction away from said base.
6. An assembly as defined in claim 2 wherein said filler is an
overflowing mass of said adhesive material fully enveloping said
anchor members.
7. An assembly as defined in claim 2, comprising a further anchor
member positively engaging said flange means and extending into one
of said wall elements through said one of said end faces.
Description
FIELD OF THE INVENTION
This invention relates to building construction and especially to
the construction of recessed walls adjacent to openings for
windows, doors, shutters or other closures. It should be
understood, that while this specification will, in general, refer
to walls of brick, the invention is not restricted to brick walls
but can be used with walls of any material or any combination of
materials (e.g. prefabricated slabs and blocks).
BACKGROUND OF THE INVENTION
In the traditional method of forming the vertical end of an opening
in a recessed wall, it is necessary in one course to use a brick
cut to extend across one leaf (usually the inside leaf) and across
the end of the recessed, but not on to the other leaf. In the next
course a short piece of brick has to be cut, merely to lie across
the end of the recess. These cut portions of brick are referred to
respectively as three-quarter and quarter bricks, and it is a time
consuming operation for the bricklayer to produce the cut portions.
Furthermore, a layer of damp-proof course material -- usually felt
impregnated with bitumen -- has to be fitted vertically between the
one leaf of bricks and the edge formed at the ends of the
three-quarter and quarter bricks abutting this one leaf. There are
several problems with this construction and, in practice, it is
difficult to achieve a fully waterproofed seal up the sides of the
frame stiles.
Quite apart from the problems of labor costs and weatherproofing
involved with the conventional method, the two leaves of the wall
are not tied together as adequately in the region of the wall end
as in other regions because it is not possible to fit tie bars
through the vertical damp-proof course.
Moreover, if a timber window frame is being fitted, any joggles on
the frame must be built into the brickwork in which case they are
exposed to dampness, and then, after the brickwork has set, the
carpenter has to fix the frame by nailing it to wooden plugs let
into the brickwork. This is often an unsatisfactory job because, as
has been noted previously, the brickwork is not strong in this
region and the plugs may not be held.
In accordance with the invention I provide a moistureproof assembly
for affixing a frame for a door, window or the like to a recessed
building wall of the character described, i.e. a wall wherein two
wall elements with substantially coplanar end faces are separated
by a space which is generally perpendicular to these end faces,
each wall element being composed of several tiers or courses of
building blocks held together by layers of adhesive material
hereinafter referred to as mortar; the assembly includes, besides
the two wall elements, an upstanding channel member of profiled
sheet material having a central portion which projects with
all-around clearance into the space or recess between the two wall
elements and whose base, lying outside that recess, has a flange or
a pair of flanges bearing upon either or both of their end faces.
The clearance formed around the inserted central portion of the
channel member is occupied by a moistureproofing filler which bonds
that member to the wall elements and which, advantageously, is an
overflowing mass of the mortar forming bonding layers between the
building-block courses; a pair of flat tie bars, serving to anchor
the channel member to the wall elements, positively engage opposite
outer surfaces of the central portion of that member and extend
laterally outwardly therefrom between successive courses of each
wall element.
According to a more specific feature of my invention, the two
opposite outer surfaces engaged by the anchor members or tie bars
are provided with vertical keying formations, such as dovetailed
grooves, matingly receiving adjoining ends of the two anchor
members so as to enable their independent vertical displacement
therealong until the enveloping filler (mortar) has hardened. The
two anchor members advantageously include with each other an obtuse
angle pointing toward the exposed base of the channel member, as by
extending at right angles to a pair of lateral surfaces of a
generally trapezoidal profile converging in a direction away from
the base, so as to take a better grip on the adjoining wall
elements.
DESCRIPTION OF THE DRAWING
The invention will be better understood from the following
descriptions of several practical embodiments of the invention
which are described, by way of example only, with reference to the
accompanying drawing, in which:
FIG. 1 is a horizontal cross-section through the end portion of a
recessed wall whose end is closed in the conventional manner;
FIG. 2 is a perspective view of the end of a recessed wall during
construction, this view also showing the conventional method of
closing the end;
FIG. 3 is a horizontal cross-section through the end of a recessed
wall showing an embodiment of the present invention used with a
timber window or door frame;
FIG. 4 is a perspective view showing part of a window and part of a
recessed wall during construction;
FIG. 5 is a view similar to FIG. 3 but showing an alternative
embodiment, for use with a timber window or door frame;
FIG. 6 is a view similar to FIG. 5, showing another embodiment
using an element of the same kind as that illustrated in FIG.
5;
FIG. 7 is a view similar to FIG. 3 but showing an embodiment for
use with an aluminum window frame;
FIG. 8 is a view similar to FIG. 3 but showing an embodiment for
use with a steel window frame;
FIG. 9 is a view similar to FIG. 3 but showing another embodiment
for use with a timber window or door frame;
FIG. 10 is a fragmentary perspective view showing the construction
of a sub-frame;
FIG. 11 is a view similar to FIG. 10 but showing the assembled
sub-frame; and
FIG. 12 is a view similar to FIG. 3, showing the application of the
invention to a door frame.
SPECIFIC DESCRIPTION
FIGS. 1 and 2 of the drawing illustrate the conventional method of
closing the end of a recessed wall at an opening for a window or
door. The purpose of these illustrations is to show the
disadvantages of the conventional method which are overcome by the
use of the invention.
In FIGS. 1 and 2, two wall elements or leaves 10 and 12 of a
recessed brickwork wall are shown separated by a standard recess or
space 14 approximately 2 inches wide. It is necessary to close the
end of the recess to ensure correct spacing of the leaves 10 and 12
at the end and to provide a mounting for the window or door
frame.
In one course of bricks, a brick 16 is cut to a length just less
than the width of a brick plus the width of the recess, and this
brick 16 is laid as shown with its length extending across the end
of the wall from one outer face. The brick 16 therefore covers one
leaf of the wall and almost closes the end of the recess, and
because of its subsize length it is referred to as a three-quarter
brick. When the next course of bricks is laid, the part of the
threequarter brick in the leaf 10 is covered by a brick 18 which
forms part of the ordinary bond of the leaf 10. For this course,
therefore, it is necessary to cut a brick 20 to a length just less
than the width of the recess; this one is called a quarter brick
and simply extends across the end of the recess.
This construction enables a strip 22 of conventional damp-proof
course material to be laid vertically between the leaf 12 of the
wall and adjacent ends of the three-quarter and quarter bricks and
together with the three-quarter and quarter bricks it fills the end
of the recess. The vertical damp-proof course is essential to
prevent dampness from bridging the recess at the closed end.
At intervals timber pads such as shown at 24 are let into the end
of the leaf 12 during construction, so that nails or screws for
securing the window or door frame can be driven into them at a
later stage. Tie bars 26 are used in the conventional manner to
hold the two leaves 10 and 12 together, but these cannot be used at
the end where the damp-proof course 22 is fitted.
The drawbacks of the system of recess closing illustrated in FIGS.
1 and 2 are well known to those skilled in the art. Clearly the
cutting of bricks to produce the three-quarter and quarter bricks
is time-consuming and wasteful. It would be possible to provide
special bricks for this purpose, but builders try to avoid the use
of nonstandard items as far as possible because of their cost and
the additional quantities to be calculated and stored
separately.
In practice, it is often difficult to obtain proper sealing against
the ingress of moisture. This is because it is easy to bridge the
vertical damp-proof course 22 at the edges -- especially the inside
edge. This can be guarded against by the use of extra-wide
damp-proof course material, but this also involves the use of
nonstandard elements.
As far as the wall itself is concerned, it will be apparent that it
is not possible to fit ties of any kind at the end of the wall,
because of the vertical damp-proof course 22, and consequently the
two leaves 10 and 12 cannot be firmly secured to each other in the
zone of the window or door frame. This not only is deleterious in
itself, but is a source of difficulty in fitting the frame. Clearly
it is impossible to fix the frame to the wall while the wall is
being built, yet there is also the problem of the fixing pads 24
becoming loose afterwards when the mortar dries. Generally the
frame is used as a template for the building of the walls around
the opening and then, when the mortar has set, the carpenter has to
adjust the frame if necessary and nail it to the timber pads
24.
Another problem arises because timber window frames are made with
joggles (i.e., projections beyond the corners). These should be
built into the brickwork to assist in tying the frame to the
brickwork and the joggles have to be cut when the frame is fitted,
thus causing more work on the site.
In FIGS. 3 and 4 of the drawing, there is shown an inner leaf 30
and an outer leaf 32 of a brickwork wall, with a recess or space 34
between them. The two leaves or wall elements 30 and 32 are tied
together by conventional tie bars (not shown) except at the end
portions adjacent an opening for a window or door frame as
illustrated. A stile 38 at one end of a window frame (which is made
in wood) would, in the conventional construction, abut the end of
the wall, but the recess (usually 2 inches wide) would be closed by
alternate courses of (a) three-quarter bricks laid on the inside
leaf -- or, very rarely, on the outside leaf -- and (b) quarter
bricks laid in the end of the recess on the three-quarter brick
below it as described with reference to FIGS. 1 and 2.
It will be noted that in this construction there are no bricks
(three-quarter or quarter) across the end of the recess but,
instead, there is a special sealing member 36 fitted across the end
of the space 34. This end sealer forms in itself an important
feature of the invention, and will be described in some detail.
The sealer 36 is made as an extruded channel section of a plastic
material so as to be substantially rigid -- (although some
flexibility would be permissible) -- water resistant and water
impermeable. It is also desirable that the sealer should be capable
of retaining these characteristics more or less permanently, and
certainly for long periods, without protective coating. It should
be understood, however, that a sealer made of other than plastic
materials (e.g. metal) and coated with a suitable layer of plastic
would be within the scope of the invention.
Polyethylene or polyvinylchloride are suitable substances for the
manufacture of the sealer.
It is also to be noted that the sealer or channel member 36 is of
constant cross-section throughout its length. This enables it to be
produced by an extrusion process, which makes the production of
large quantities relatively cheap, and also enables the sealer to
be supplied in long lengths for cutting into the lengths required
on any particular job.
The profile of members 36 forms a deep channel portion 40 with side
walls 42 and 44, which converge toward one end, and outwardly
extending flanges 46 and 48 at the wider end. This gives the sealer
an overall "top-hat" or trapezoidal cross-sectional appearance as
seen in FIG. 3. The channel portion 40 must be capable of entering
the recess 34, and its overall width at the wider end (i.e. where
its walls join the flanges 46 and 48) is only about 1/4 inch (6
millimeters) less than the width of the recess itself, but it will
be observed that the flanges 46 and 48 extend well beyond each side
of the recess.
A series of three longitudinal flutes 50 are formed in the outside
of each side wall 42 and 44, each of these grooves being undercut
so as to be of dovetail cross-section. In addition, there are
longitudinal grooves 52 and 54 one in each of the flanges 46 and
48, but these are not undercut. Finally a series of shallow
longitudinal grooves 56 are formed in the outside of a wall 58
which forms the base of the channel portion 40 at its narrow end.
The purpose of the grooves and grooves will appear later, but it
should also be mentioned that the inwardly converging trapezoidal
section provides a large space 60 within the sealer and that this
space is open at the flanged side of the sealer. As shown, shallow
"V" grooves 51 are formed in the dovetail-shaped pieces of the side
walls between the grooves, but these are simply for ease of
manufacture.
The stile 38 of the window frame is wide enough to bridge the width
of the recess 34, with some timber projecting on each side of the
recess. When installing the sealer 36, a length of channel profile
is cut off equal to the overall height of the window frame 38. This
length is placed against the outside of the stile and is secured
thereto by nails 62 driven through the reduced portion of the
flanges 46 and 48 below the grooves 52 and 54. I have found that by
using a suitable grade of plastic material for the sealer it is
quite easy to drive nails through the flanges for securing
purposes. Of course, other methods of securing could be used, for
example holes could be preformed in the flanges to accept fastening
screws, but this would entail forming the holes after extrusion
which would add to the cost of the sealer. Again, it might be
possible to secure the sealer to the stile by an adhesive but,
whatever method is adopted, it will be apparent that the sealer
must have flanges or equivalent formations to receive fixing means
for securing the sealer to the stile.
During the construction of the building, the window frame is placed
in the required upright position resting on the conventional sill
(not shown). Then the leaves 30 and 32 of the recessed wall are
built up adjacent the window frame, and the channel portion 40 of
the sealer 36 is sandwiched between the leaves. The end bricks of
the leaves can be pressed directly against the flanges 46 and 48 or
any gap between these bricks and the flanges can be filled with
mortar. Indeed, as the wall rises, mortar 64 squeezed out from
between the bricks will flow into the grooves 52 and 54 of the
flanges 46 and 48 (so that the heads of the nails 62 will be
completely sealed) and into the narrow spaces between the side
walls 42 and 44 and the bricks. Furthermore, some mortar will flow
into the dovetailed grooves 50 so as to forming a key between the
two leaves 30 and 32 and the sealer 36. This not only holds the
sealer firmly in position, but also acts to tie the two wall leaves
together. While there will normally be a sufficient quantity of
mortar squeezed out of the leaves, the bricklayer may place extra
mortar between the courses in the area of the sealer to ensure that
a good bond is obtained.
Special tie bars or anchor members 66 are used with the sealer.
Each of these bars is made of galvanized steel plate, and has the
usual forked end 68 to engage between the courses of bricks, but
only one end is forked; the bar is shorter than usual and quite
flat, without precautions such as twisting to prevent moisture from
creeping along it. All this makes the tie bar very easy to produce;
in fact, it can be made as a stamping.
At its inner end, each tie bar has a root portion 70 which is
adapted to fit snugly in one of the grooves 50 of the sealer 36. It
should be understood that the tie bars could also be made of
plastic material if desired, and that the shape of the outer forked
end can be varied.
As illustrated in FIGS. 3 and 4, the tie bars 66 are fitted between
the side walls 42 and 44 of the sealer and the brickwork leaves 30
and 32. To fit a bar to the sealer, it is tilted about its own
longitudinal axis until its root 70 will pass into the dovetailed
groove 50, and then, when the root is within the groove, the bar is
turned into its flat position -- resting on a brick -- and its
dovetail root engages neatly in the groove.
The bar is then firmly anchored to the sealer, and can be moved
only by twisting it, which of course cannot happen once the next
course of bricks is laid on top of it. The tie bars offer
additional security to the sealer 36 and also effectively tie
together the leaves 30 and 32 in the zone where the tying is weak
in conventional constructions.
While it would be possible to fit the bars 66 into any of the
grooves 50, prefer that they should be fitted into the grooves
remote from the flanged side of the sealer. This is to ensure that
there is sufficient mortar between the bar and the end of the wall
to prevent the bar from being pulled sideways out of the brickwork
by loads applied to the window frame. Advantageously, those
recesses 50 which receive the bars 66 are spaced from the outer or
flanged end of the sealer by a distance at least equal to half the
width of the channel portion 40, and in the particular example
illustrated in FIGS. 3 and 4, it will be clear that this distance
is considerably greater than the width of the center portion
40.
The tie bars are fitted as desired, and one of the advantages of
the extruded section of the sealer is that the bars can be placed
anywhere along its length, so that the courses in the two leaves 30
and 32 do not need to be level with each other.
The window frame is fixed in position when the walls are built up
and requires no further attention. Plaster 72 is applied to the
inside reveal up to the window frame, and mastic 74 is applied to
the outside in the usual way. It will be observed that the mastic
seal is not so vital when using the invention as it is in the
conventional construction, because the center sealer itself acts to
prevent ingress of water. The flanges 46 and 48 ensure that the
frame is spaced from the brickwork -- which, of course, helps to
keep the timber stile dry -- and there are clearances 76 and 78
formed between the stile and the brickwork which act as keys for
the mastic and the plaster.
The comparatively large air space 60 is useful because it allows
moisture in the timber stile to dry out, which is not always
possible with known mounting for a window frame. Furthermore, if
there are joggles on the frame, they can be cut to fit into the
space 60 (so that it is not necessary to remove them). This
advantageous because (a) it is good practice to leave the joggles
on the frame if a shouldered tenon is not used, and (b) the joggles
are not in contact with damp brickwork.
It will be clear that the impervious nature of the sealer 36
ensures that there is a satisfactory moisture-proofing insert
between the inner and outer leaves of the recessed wall at the
critical area near to the window opening. Moisture cannot creep
around the sealer because of the grooves 56, which act as moisture
traps, nor can it cross the large gap between the side walls 42 and
44 if it should attempt to flow by capilliary action between the
flange 46 and the stile 38. Another important feature is that,
because this insertion extends throughout the height of the stile
between the sill and the lintel, it is not possible for mortar to
fall onto it and bridge the recess. It is particularly worthy of
note that the frame cannot get out of true during the building and
does not require adjustment after the mortar is set.
In FIG. 5, there is again illustrated part of a recessed wall
having leaves 80 and 82, a window-frame stile 84 and a sealer 86.
The sealer 86 differs from the sealer 36 shown in FIGS. 3 and 4 in
that (a ) its outer flange 88 is considerably longer than the
flange 46 and has two dovetail-shaped grooves 90 and (b) its inner
flange 92 projects outwardly (i.e., part way across the open end of
the space between the side walls 94 and 96 of the portion which
enters the recess) and has a right-angled leg 98. A shallow
dovetailed groove 100 is formed on the face of the flange 92 and a
shallow groove 102 is formed on the inside face of the leg 98. The
principal advantage of the sealer 86 over the sealer 36 is that it
allows the window frame to be fitted nearer to the outside of the
wall.
During construction, the sealer 86 is cut to length and fastened to
the window frame as described with reference to FIGS. 3 and 4
except that nails 104 are driven through the flange 88 and nails
106 are driven substantially at right angles to the nails 104
through the leg 98. The window frame is then placed on the sill and
the wall built up as before. In addition to the tie bars 66 which
are fitted and function exactly as described in relation to tee
sealer shown in FIGS. 3 and 4, additional tie bars or anchor
members 108 of the same kind as the bars 66 can be fitted into the
outer groove 90 of the flange 88 to project as shown into the end
of the outer leaf 80 substantially at right angles to the bars 66.
Alternatively a special tie plate can be used which is shaped to
perform the functions of both the bars 66 and 108.
Finally, mastic 110 and plaster 112 can be applied. Whereas the
mastic keys into the space between the stile 84 and the brickwork
as in the previous case, it will be observed that the plater keys
into the grooves 100 and 102 in the sealer itself. Moreover the
land 114 at the end of the leg 102 acts as a guide for the
plasterer's trowel.
In the construction shown in FIG. 6, a sealer 120 of the same
cross-section as that shown in FIG. 5 is used. Indeed, the only
difference between the construction shown in FIG. 5 and that shown
in FIG. 6 is that the latter illustrates the use of a timber spacer
122 between the leg 98 and the stile 124 of the window frame. This
construction enables the window frame to be fitted nearer to the
outside of the wall, and in FIG. 6 the stile 124 is almost entirely
at the front of the recess.
Metal window frames are now commonly used, and the invention can be
adapted to such frames. In FIG. 7 a recessed wall is shown with an
outside leaf 130 and an inside leaf 132, and a space 134 between
them. Element 136 is the stile of an aluminum window frame of well
known type, and unit 138 is the sealer.
It will be apparent that this sealer 138 resembles the sealer 136
in many respects, including the channel portion 140 which is
adapted to enter the recess 134, and has grooves 142 to act as
mortar keys and anchors for tie bars 144 which are of the same kind
as the bars 66 previously described.
However, the sealer does not have diverging flanges, but instead
there are extensions 146 and 148 of its side walls. Both extensions
have inturned lips 150, but whereas the extension 146 is
flat-sided, the extension 148 has a dovetailed groove 152. In
addition there are lugs 154 projecting inwardly from the walls of
the channel portion 140.
When the sealer 138 has been cut to length, and before it can be
fixed to the window frame, a wooden insert 156, which just fills
the space bounded by the extensions 146 and 148, the lips 150 and
the lugs 154, is introduced. The insert can be slid into the sealer
from one end, or the extensions 146 and 148 can be distended to
allow the timber insert to be pushed between the lips 150. In any
event, it is preferable that the insert shall be slightly wider
than the space between the extensions 146 and 148 so that the
latter grip the insert tightly.
In order to fix the sealer onto the aluminum stile 136, a wood
screw 158 is passed through a clearance hole 160 provided in the
stile and is screwed into the insert 156. It is possible to fit the
sealer so that a narrow gap 162 is left between the flat face of
the extension 146 and a flange 164 on the stile. This gap 162
provides an additional key for mastic 166. Once the sealer 138 has
been emplaced, the building construction can proceed as described
in the previous examples. The groove 152 acts as a key for plaster
168.
FIG. 8 shows a sealer 170 in many respects similar to that shown in
FIG. 7 but adapted for use with a steel window frame with a stile
172 of small cross-section. A short extension 174 is formed on the
outside wall of the central channel portion of the sealer, and a
flange 176 extends from the inner wall of this portion part way
across the open end of the channel, there being a leg 178 on the
end of the flange 176. The flange 176 and its leg are somewhat
similar to the arrangement of flange and leg shown in FIG. 5, but
it will be apparent that the leg 178 is parallel to the extension
174.
Lips 180 are formed on the ends of the extension 174 and the leg
178, and there is a leg 182 on the inside of the front wall of the
channel portion. It is possible therefore to slide or press a
timber insert 184 into the space bounded by the extension 174 the
leg 178, the lips 180 and the leg 182. Dovetailed grooves 186 are
formed in the flange 176 and leg 178 to act as keys for plaster
188.
The sealer is secured to the stile 172 by a wood screw 190 passed
through a hole 192 in the stile and screwed into the timber insert
184, and then the window frame can be fitted as described in the
previous examples.
Another variant of the invention is shown in FIG. 9. The actual
sealer 200 is similar to that shown in FIGS. 5 and 6, and is fitted
to a timber window frame in the same way as illustrated in those
Figures. However, although it has a central channel portion 202
which is capable of entering the recess of the wall, this portion
is much shallower than those shown in all the other Figures.
In fact, the channel portion comprises a short outer wall 204 with
a single dovetailed groove 206, a corresponding inner wall 208 with
a single groove 210, a cross-wall 212 with moisture-trap grooves
214, and two oblique walls 216 and 218 joining their respective
side walls 202 and 208 to the cross wall 212. A dovetailed groove
220 is formed in the outside of each of the oblique walls 216 and
218.
During the build-up of the wall, tie bars 222 identical with the
bars 66 shown in FIGS. 3 and 4 are anchored in the grooves 220.
Thus the tie bars extend at approximately 45.degree. to the face of
the wall and, despite the fact that their roots are quite near to
the wall end, are well secured in the leaves of the wall because
their forked ends are some distance from the wall end.
For metal or plastic window frames it is usual to employ a timber
sub-frame. It is possible to use the present invention for this
purpose also. In FIGS. 10 and 11 there is shown a sealer strip 240
which is of the cross-section illustrated in FIG. 7. This strip is
cut to the length required for the height of the sub-frame between
its head and its sill. A timber insert 241 is cut to the length of
the full height of the sub-frame, and when this insert is installed
it projects at each end of the sealer. Two such strips are provided
(each with its timber inserts) to form the stiles of the
sub-frame.
The head and sill of the sub-frame are formed from standard
Z-section metal or plastic strip, and only the sill 242 being shown
in the drawing. A notch 243 is cut at each end of the head and sill
to receive the projecting end of the insert 241.
When the head and sill sections are fitted to the stiles, they are
secured by nails or screws 244. This provides a very easily
constructed sub-frame incorporating all the advantages of the
invention.
In the arrangement shown in FIG. 12, element 250 is part of the
outer leaf of a recessed wall adjacent a door opening, and element
252 is part of the inner leaf. It will be noted that the outer leaf
250 extends beyond the inner leaf so that there is a reveal on the
inside.
A sealer 254 is fitted into the recess and into the reveal. This
sealer is made as an extrusion from plastic material, as in the
previous examples, but its shape is quite different. There is a
short channel portion 256 which enters the recess, and the opposed
side walls of this portion have dovetailed grooves 258 similar to
the previously described sealers, but in this instance the opposed
side walls are parallel. An end wall 260 with moisture-trap grooves
joins the side walls.
On the inside, there is a short flange 262 with a leg 264 at right
angles to it, and a lip 266 on the end of the leg forms a groove
268 between itself and the end of the leaf 252. The flange 262
abuts the end of the leaf 252 and plaster covers that end and seats
in the groove 268. The wide face of the lip 266 acts as a guide for
the plasterer's trowel.
The outside wall 272 of the sealer extends just beyond the end of
the outer leaf 250 and has an outwardly directed flange 274 with an
inturned lip 276. On the outside of the wall 274 there are
diverging protrusions 278 forming dovetailed grooves 280.
A timber insert 282 is held in place by nails or screws 284 and 286
passed respectively through the leg 264 and a rib 288 formed on the
wall 272. The insert must be rabbeted to receive the rib 288, but
as it is on the inside of the building it can be made of timber of
a lower quality than that which would be required outside.
Special tie bars 290 are used in the inside leaf, and these are
similar to the bars 66, but their dovetail roots 292 are so beveled
that the bars extend at approximately 45.degree. into the leaf 252
when the roots are fitted into the recess 258.
Special tie plates 294 are used to tie the sealer 254 to the outer
leaf 250. These plates are generally A-shaped. One leg 296 is
formed with a dovetail root 298 to fit into one of the grooves 258,
but the other has an arrowhead root 300 which fits into a corner
groove 302.
When the sealer is installed as shown in FIG. 12, it provides a
complete jamb of a door frame, and the door abuts the inside face
of the wall 272 where the latter projects beyond the rib 288. This
form of sealer can be used to form both jambs and a top cross-piece
of a complete door frame.
It should be understood that the invention is not restricted to
features specifically shown in the foregoing embodiments. For
instance, the anchoring grooves need not be dovetail-shaped so long
as they provide a proper key for mortar or for the roots of the tie
bars. Further, the moisture-trap grooves could be replaced by a
single dovetailed groove in the cross-wall of the sealer.
It should also be understood that while most of the embodiments
have referred to window frames, the sealers described could be used
with door frames or with other building components. Furthermore,
some of the sealers could be used horizontally as lintels, header
members or sills.
In the foregoing examples, the invention has been described in
relation to recessed walls made of bricks. However, it will be
readily appreciated that it could be used with other types of wall
construction. For example, the two leaves of the walls could be
made of formed blocks but the application of the invention would be
exactly the same as described above. On the other hand, if the wall
were made with a single outer leaf of bricks or blocks, and an
inner leaf consisting of a timber frame with paneled covering, it
would be desirable to secure the sealer to the timber frame (e.g.,
by special tie bars) but the brick or block leaf could be secured
by its mortar and/or by tie bars. Again, if the invention is used
with a wall made of solid mortar, the channel portion of the sealer
will be completely embedded in the wall during forming.
For solid walls or walls with a narrow recess, the hollow central
portion of the channel member constituting the sealer may be
replaced by a single solid flange with grooves to anchor the mortar
and tie bars in its opposite faces.
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