WO1999032751A1

WO1999032751A1 - Building elements

Info

Publication number: WO1999032751A1
Application number: PCT/AU1998/000875
Authority: WO
Inventors: Robert Andrew Allen; Colin Sharpels; Leonard Mckeown
Original assignee: James Hardie Research Pty Ltd
Current assignee: James Hardie Research Pty Ltd
Priority date: 1997-12-19
Filing date: 1998-10-21
Publication date: 1999-07-01
Anticipated expiration: 2000-06-19
Also published as: NZ504881A; AUPP104497A0

Abstract

An elongate joining or edging element (9) for securing to a member (7, 8) formed from an at least partially resiliently deformable material such as timber. The element includes a generally planar surface (13, 14), from which extends a substantially 'U-shaped' cavity (11) formed by two opposed first side walls (18). The cavity includes a first tongue section (19, 20) extending intermediate and parallel to the side walls. The side walls (18) and tongue section (19, 20) are configured to frictionally and/or physically interact by means of a press fit with corresponding substantially parallel slots (22) and/or edge surfaces (23) formed in a connecting surface of the resilient member (7, 8) so as to secure the element (9) thereto.

Description

TITLE: "BUILDING ELEMENTS"

FIELD OF THE INVENTION

The present invention relates to an elongate joining or edging element for securing to

at least one member formed from a partially resiliency deformable material such as timber,

and in the preferred application to a composite frame element including such a joining or

edging element.

BACKGROUND OF THE INVENTION

The invention has been developed primarily for use in relation to timber door and

window frames and will be described predominantly with reference to this application.

However, it will be appreciated that the invention is not limited to this particular use and

that it can readily be used in other joining or edging applications using other materials or

combinations of materials.

Timber window and door frame elements, such as door jambs, often require a

relatively complex cross-sectional profile. Conventionally, this profile has been formed by

moulding a single length of milled rectangular timber stock into the required shape.

Unfortunately, this method has a low yield, as it is an inherently inefficient use of materials

due to the amount of material lost through the moulding process. Timber, by its nature, is

also difficult to accurately machine to close tolerances and, furthermore, is prone to

warpage making the production of effective sealing surfaces difficult to achieve.

In an effort to avoid this waste of materials, it has been known to laminate or

otherwise connect a number of separate simple timber components together, optionally

using locating dowels to thereby form the more complex frame element. This is a very

time consuming and labour intensive batch procedure. It is also difficult to prevent

rainwater from penetrating the elements along the joins and glue lines if they are not glued correctly. As such, this technique is generally capital intensive and requires considerable

skill and expertise.

In this regard, the deflection loading characteristics, rigidity and "straightness" of a

window or door frame assembly, fundamentally influence its ability to provide an effective

seal against the corresponding door or window sash. Accordingly, whilst the sealing

abilities of internal doors or windows are often not crucial, the waterproofing requirements

of external doors and windows requires that the frame assemblies adhere to strict

manufacturing tolerances and deflection loading limitations.

Additionally, use of such lamination techniques to produce complex cross-section

members complicates the mechanisation of window making processes.

It is an object of the present invention in its broadest form to provide an elongate

joining or edging element that can overcome or substantially ameliorate at least one of the

disadvantages of the prior art, or to provide a useful alternative thereto.

The present invention, in at least one of it's preferred forms, provides an improved

composite frame element and method of making that element which overcomes or

substantially ameliorates one or more of the disadvantages of the prior art, or at least offers

a useful alternative thereto.

DISCLOSURE OF THE INVENTION

According to a first aspect of the invention there is provided an elongate joining or

edging element for securing to a member formed from an at least partially resiliently

deformable material such as timber, said element having:

a generally planar surface,

one substantially "U-shaped" cavity formed by two opposed first side walls

extending outwardly from said planar surface, the cavity including a first tongue section extending intermediate and parallel to the

side walls,

the side walls and tongue section being configured to frictionally and/or physically

interact by means of a press fit with corresponding substantially parallel slots and/or edge

surfaces formed in a connecting surface of the resilient member so as to secure the element

thereto.

In a preferred form a surface of the tongue and/or a surface of one or both of the side

walls opposite the tongue includes thereon engaging formations to physically interact with

the material of the resilient member. More preferably, a surface of the tongue and/or the

surface of one or both of the side walls is tapered so as to urge the material of the resilient

member towards securing interaction with said engaging formations.

According to a second aspect of the invention there is provided a composite frame

element including an elongate joining element according to the first aspect and one or more

elongate, generally planar building members suitably adapted for press fitting engagement

with said joining element.

Preferably the joining element is specifically configured for use in frames for

building construction and optionally can include retaining formations adapted to captively

retain a cladding panel inserted therein. More preferably one or more external surfaces of

the joining element remain exposed after the securing of said building elements thereto,

thereby providing a substantially straight abutment surface for a complementary

construction component. Even more preferably, the frame element is configured for a

window or door application in which the construction component is a window sash or door.

A particularly preferred form of the first aspect includes first and second mutually

opposed, substantially U-shaped, cavities extending outwardly from two opposite planar surfaces formed on a central web, so as to define a substantially I-shaped section, the

element further includes first and second directly opposed tongue sections extending

outwardly from their respective cavities. In an alternative preferred form, the abutment

surface extends past one end of the I-shaped section. In another highly preferred form the

abutment surface extends past both ends of the I-shaped section. In yet another highly

preferred form particularly suited for use in a jamb or head, one of the opposed side walls

of one of the cavities is omitted. In another preferred form more than one tongue and

corresponding side wall or walls may be included on any one planar surface.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described, by way of example only, with reference to the

accompanying drawings, in which:

Figure 1 is a sectional part view of a window incorporating a conventional prior art

component moulded from one solid timber element with attached trim;

Figure 2 is a sectional part view of a window incorporating a composite frame

element in the form of a jamb or head that includes a first embodiment joining element

according to the present invention;

Figure 3 is a sectional view of a first embodiment joining element according to the

invention;

Figure 4 is a sectional view of a second embodiment joining element according to the

invention;

Figure 5 is a sectional part view of a composite mullion frame element that includes a

second embodiment joining element according to the present invention; Figure 6 is a sectional part view of a window incorporating a composite frame

element in the form of a mullion that includes a second embodiment joining element

according to the present invention;

Figure 7 is a sectional part view of a composite jamb frame element that includes a

first embodiment joining element according to the present invention;

Figure 8 is another sectional part view of a composite jamb frame element that

includes a first embodiment joining element according to the present invention;

Figure 9 is a sectional view of a first embodiment building member according to the

present invention as used in Figure 5;

Figure 10 is a sectional view of a second embodiment building member according to

the present invention as used in Figure 6.

Figure 1 1 is a sectional view of a third embodiment joining element according to the

invention;

Figure 12 is a sectional part view of a window incorporating a composite frame

element in the form of a jamb or head that includes the third embodiment joining element

shown in Figure 11.

PREFERRED EMBODIMENT OF THE INVENTION

Figure 1 shows a sectional view of part of a prior art window 1 ' constructed using

conventional techniques. The window 1' includes a frame member 2' in the form of a jamb

, a glazing panel 3', and a beading strip 4' to retain panel 3' within the window frame. As

shown by broken lines 5' a substantial amount of timber is lost in the moulding process

required to produce frame member 2' from the standard stock. Additionally, it can be seen

that there is no barrier to the capillary action ingress of water from external side 6' of the

frame to the internal side 7' of the frame. Figure 2 shows an equivalent window 1 having a jamb 2 with a structure according to

the present invention. The jamb includes internal and external jamb members 7 and 8,

joined by an elongate joining element 9.

Joining element 9 is shown in further detail in Figure 3. The elongate element 9

defines, in cross-section, two substantially U-shaped cavities 1 1 and 12 which are attached

to respective opposed planar surfaces 13 and 14 of a central core element in the form of

web 15. Each cavity is in turn defined by opposed pairs of tapered side walls 18.

Extending outwardly from each of these cavities 11 and 12 are respective serrated tongues

19 and 20. Web 15 extends past the planar surfaces, at one end, to provide a barrier strip

21. In other embodiments the barrier strip includes means for attachment to a surrounding

structure, hinge elements, means of attaching flexible weather seals and other components.

In the preferred forms the joining element 9 is constructed of extruded aluminium,

but may in other embodiments be made from any one of the materials selected from the

following group including: extruded or cast metal; folded or fabricated metal; extruded or

cast polymeric material or pultruded reinforced polymeric materials.

In use, and returning to Figure 2, the internal and external members 7 and 8, which

are provided with central slots 22 and tapered connecting edge surfaces 23, are pressed into

engagement with respective sides of the joining element 9. As each jamb element 7 and 8

is forced into cavities 11 and 12, tapered side walls 18 force the material surrounding slots

22 into engagement with the serrated tongues 19 and 20. With the application of

compressive force by side walls 18 onto the correspondingly tapered edge surfaces 23 of

element 9, the tendency of prior art joints employing tongues and slots, whereby the

building element splits about the slot, is avoided. Additionally, because the strongest area of engagement is about the tongue, there is less chance of damage to the corners of the

building elements by the application of stress to the joint.

It is clear that the amount of timber lost as waste during the milling process to

produce members 7 and 8 is significantly less than that lost in the production of the prior

art jamb. Moreover, a jamb similar to the prior art example has been produced using two

smaller members 7 and 8. Thus, this jamb 2 can be more efficiently produced from

standard sized stock. Additionally, supplies of larger section timber stock are becoming

progressively more expensive than the smaller sections utilised in the present invention.

Another benefit of the present invention is that elements 7 and 8 may each be

fabricated from different grades of timber, or various other materials. This allows the use

of visually attractive materials for internal members 7 and weather resistant materials for

external members 8.

In other embodiments (not shown) one or both of members 7 and 8 are constructed of

PVC, metal or the like. Such elements would be constructed such that a separate engaging

member is provided to interact with each tapered side wall 18 and each face of the joiner's

tongue. As each element is forced into cavities 11 and 12 parts of adjacent engaging

members are forced inwardly and thus engage the walls 18 and tongue by resilient

response.

When the jamb is incorporated into a window, a glazing panel 3 may be abutted

against one side of said barrier strip 21 and fixed into position by a beading strip 4.

In other embodiments, where the composite frame element is to be used in a frame

for an openable door or window, the joining elements, shown in Figure 11, can include

means 30 for retaining a resilient sealing strip 31 against which the window or door forms

a substantially weathertight seal. These retaining means can be present around all or part of the frame. In embodiments where a horizontally hinged awning window is used (as

shown in Figure 12) the joining element 35 can include an extension which has a curved

hinge element 36 which, in combination with a corresponding element 37 on the sash,

provides an integral hinge. Advantageously, such a hinge is also substantially

weathertight. Alternative hinge formations may also be used.

In the embodiments illustrated the members to be joined are directly opposite each

other, but it will be appreciated that in alternative forms they can be in planes parallel to

but offset from one another or in planes perpendicular or at an angle to one another such as

may be required in a frame element for a bay window for example. Also, if thick sectioned

members are to be joined, then it may be appropriate to use a joiner having two or more

axially parallel U-shaped cavities, each with one or more respective tongues, all acting

together to retain the inserted member. Alternatively, a single U-shaped cavity may

include more than one tongue. In such examples it will not necessarily be the case that all

cavities are coplanar. Indeed, it may be necessary that they are in a stepped relationship to

each other to accommodate the configuration of the members to be joined.

Another advantage of such a structure according to the preferred form shown in

Figure 2 is that the glazing panel 3 is directly seated against barrier strip 21 of the joining

element 9. This affords a better seal, as a straighter edge adjacent the glazing is provided

by the material of the joining element. Clearly this also applies to window sashes and

doors sealing against the corresponding frame jamb portion provided by, or at least

supported by, a joining element according to the present invention. Furthermore, it can be

seen that barrier strip 21 provides a moisture barrier between external and internal elements

8 and 7, thus preventing any travel by capillary action of water between these external and

internal elements. In a further embodiment, particularly useful as a window jamb or head a U-shaped

cavity is present on each of the opposed abutment surfaces as shown in either of the

illustrated embodiments in Figures 3 or 4, except that the only barrier strip included

extends towards the surrounding structure. This particular embodiment is different

however in that one of the side walls 18 adjacent the interior of the jamb is omitted

allowing the timber jamb member to extend over the top of the joining element. The

benefit associated with this embodiment is that the appearance of the timber frame is not

interrupted by the metal joining element.

In embodiments where the element only includes one U-shaped cavity and one

associated tongue section the element is suitable for use as an edging element. An example

of where such a section may be useful is providing a durable edge to a fascia or timber

table or the like.

In other embodiments (not illustrated) the central web 15 is of hollow construction.

Such hollow cavities may be partially or completely filled with other elements, for example

steel sections, to obtain increases in strength or rigidity. Alternatively the cavity may be

used for the running of electrical wires or other services.

To achieve joining elements of greater complexity each element may include a

number of separately formed sub-elements.

Figures 5, 6 and 7 show other frame structure embodiments possible using the

invention. It will be noted that, in Figures 4 and 5, the central web 15 extends beyond both

ends of said abutment surfaces to provide a barrier strip 21 at each end of the web.

Although the invention has been described with reference to specific examples it will

be appreciated by those skilled in the art that the invention may be embodied in many other

forms.

Claims

1 An elongate joining or edging element for securing to a member formed from an at least partially resiliently deformable material such as timber, said element having: a generally planar surface, one substantially "U-shaped" cavity formed by two opposed first side walls extending outwardly from said planar surface, said cavity including a first tongue section extending intermediate and parallel to the side walls, said side walls and tongue section being configured to frictionally and/or physically interact by means of a press fit with corresponding parallel slots and/or edge surfaces formed in a connecting surface of said resilient member so as to secure the element thereto.

2. An element according to claim 1 wherein one or more surfaces of the tongue and/or one or more surfaces of one or both of said side walls opposite said tongue includes thereon engaging formations to physically interact with the material of the resilient member.

3. An element according to claim 1 or claim 2 wherein a surface of the tongue and/or the surface of one of said side walls is tapered so as to urge the material of the resilient member toward securing interaction with one or another surface of said first tongue or sidewalls.

4. An element according to claim 3 wherein said tapered surface is opposite a surface including engaging formations.

5. An element according to any one of the preceding claims configured as a joiner wherein the first planar surface is formed on one side of a central core section and a second planar surface formed on another side of said core section, wherein said second surface of said core element has extending outwardly therefrom a second tongue section and at least one second side wall spaced therefrom.

6. An element according to claim 5 wherein the surfaces of said second tongue and/or second wall include one or more tapers and/or engaging formations.

7. An element according to claim 5 or claim 6 wherein said core section comprises a generally planar web section with first and second tongue formations extending outwardly from directly opposed first and second planar surfaces.

8. An element according to any one of claims 5 to 7 wherein said opposed tongue formations and or one or more of said side walls are laterally offset from one another.

9. An element according to any one of claims 5 to 8 wherein said first and second

planar surfaces are at an included angle of less than 180° to each other.

10. An element according to any one of claims 5 to 9 wherein said core section is of a hollow construction.

11. An element according to claim 10 including a strengthening insert within said hollow core section.

12. An element according to any one of the preceding claims wherein said element is constructed of a plurality of sub-elements.

13. An element according to any one of the preceding claims including more than one tongue on any one planar surface.

14. An element according to claim 13 wherein each tongue on any one planar surface has at least one corresponding side wall.

15. An element according to any one of the preceding claims including additional means for attachment of said element to a surrounding structure.

16. An element according to any one of the preceding claims constructed from any one of the materials selected from the following group including: extruded or cast metal; folded or fabricated metal; extruded or cast polymeric material or pultruded reinforced polymeric materials.

17. A composite frame element including an elongate joining element according to any one of the preceding claims and one or more elongate, generally planar building members suitably adapted for press fitting engagement with said joining element.

18. A frame element according to claim 17 specifically configured for use in frames for building construction wherein said joining element includes a retaining formation adapted to captively retain a cladding panel inserted therein.

19. A composite frame element according to claim 17 or claim 18 wherein one or more external surfaces of said joining element remain exposed after the securing of said building members thereto, thereby providing a substantially straight planar abutment surface for a complementary construction component.

20. A frame element according to claim 19 configured for a window or door application wherein said construction component is a window sash or door.

21. A frame element according to any one of claims 17 to 20 wherein said building members are made from timber.

22. A frame element according to any one of claims 17 to 20 wherein at least one of said building members is made from PVC, metal or the like.

23. A frame element according to claim 22 wherein said building member includes a separate engaging member for engaging each of said side walls and each face of said tongue.

24. An elongate element according to claim 1 including first and second mutually opposed, substantially "U-shaped", cavities extending outwardly from two opposite abutment surfaces formed on a central web so as to define a substantially "I-shaped" section, said element further including first and second directly opposed tongue sections extending outwardly from their respective cavities.

25. An element according to claim 24 wherein said planar surface extends past one end of said "I-shaped" section to form a moisture barrier between two adjacent joined building members.

26. An element according to claim 24 wherein said abutment surface extends past both ends of said "I-shaped" section to form a moisture barrier between two adjacent, joined building elements.

27. An element according to claim 24 where one of said opposed side walls of one of the cavities is omitted.

28. A composite frame element including one or more elongate joining elements according to any one of claims 24 to 27 and two or more generally planar building members suitably adapted for press fitting engagement with said joining elements.