Patent Application
20240191557
The teaching disclosed herein relate to window frames, and in particular to a hybrid window frame assembly with improved corner seals between a primary window frame formed of a first material and a cladding frame formed of a second material.
US20090293409A1 (Capece) relates to an innovative sectional element for door and window frames for the residential and industrial building sector. The sectional element is substantially made up of two structural elements rigidly fixed to one another: a first structural element preferably made of aluminum and having a preferably open cross section, and a second structural element made of laminated plastic having preferably also a decorative function.
U.S. Pat. No. 3,703,063A (Budich et al.) discloses a profile member for windows, doors or the like. The profile member is formed by a hollow closed metal section having a shell of synthetic material providing one or more projections including a glaze projection for accommodating a glass pane, a connecting projection which facilitates connection of the member to a structural building part, and an abutment projection for effecting contact producing closure with another profile member.
FR2759111 B1 (Fromentin et al.) discloses an assembly element for hollow extrusions of the same cross-section, joined by mitred corners. The assembly element consists of an L-shaped right-angled component with branches of the same size as the apertures in the extrusions and fixed in place with an adhesive injected through a hole corner of the assembled extrusions connecting with a second hole in the assembly element. The adhesive, which is quick-setting and compatible with the material of the extrusions and the assembly component, especially an epoxy or hot-melt adhesive, emerges through apertures in the assembly component and adheres to the inner walls of the extrusion.
WO2005021916A1 (Lee et al.) discloses a composite material structure comprising a metal core having an uneven and grooved outer face, and a synthetic resin. The composite material structure is produced by co-extruding the metal core and the synthetic resin in in-line mode, thereby satisfying the required structural strength, eliminating the need of an adhesive, improving the workability, lessening post-processing steps, and expressing various desired colors. Conventional composite material structures can enhance the adhesion and prevent peeling between different materials by applying an adhesive upon co-extrusion of the materials. In contrast, the disclosed composite material structure can prevent peeling between different materials by structurally designing the outer face of the metal core so as to have serrations and co-extruding the materials without the use of an adhesive. The synthetic resin allows the disclosed composite material structure to exhibit superior durability and weather resistance, and to express various desired colors. The inner metal core, such as aluminum, co-extruded in in-line mode, together with the synthetic resin, allows the disclosed composite material structure to satisfy the required structural strength.
The following summary is intended to introduce the reader to various aspects of the applicant's teaching, but not to define any invention.
In one aspect, a hybrid window frame assembly is disclosed. The hybrid window frame assembly includes a primary window frame formed of a first material and including a pair of horizontally spaced apart vertical window frame members connected by an upper horizontal window frame member and a lower horizontal window frame member arranged to define a central window opening. The window frame includes a peripheral bead having a bead outer sidewall extending about and projecting from a perimeter of the window frame, a bead inner sidewall inboard of the outer sidewall, and a bead front wall extending between respective distal ends of the bead outer and inner sidewalls. The window frame has four window frame corners. Each window frame corner is formed at a junction between an end of one of the vertical window frame members and a corresponding end of one of the horizontal window frame members. The hybrid window frame assembly further includes a cladding frame formed of metal and including a pair of horizontally spaced apart vertical cladding frame members connected by an upper horizontal cladding frame member and a lower horizontal cladding frame member. The cladding frame includes a peripheral channel having a channel outer sidewall, a channel inner sidewall inboard of the channel outer sidewall, and a channel front wall extending between respective distal ends of the channel outer and inner sidewalls. The channel outer sidewall, the channel inner sidewall and the channel front wall define a recess in which the peripheral bead is received to connect the cladding frame to the window frame. The cladding frame has four cladding frame corners. Each cladding frame corner is aligned with a corresponding one of the window frame corners and formed at a junction between an end of one of the vertical cladding frame members and a corresponding end of one of the horizontal cladding frame members. The hybrid window frame further includes four injection block cutouts. Each injection block cutout extends through at least a portion of the channel outer sidewall, the bead outer sidewall and the bead inner sidewall to provide a cut bead inner sidewall portion and to expose a portion of the channel inner sidewall at a respective one of the cladding frame corners. The hybrid window frame assembly further includes four injection blocks. Each injection block is sized to fit in a respective one of the injection block cutouts. Each injection block includes at least one injection hole accessible from an exterior of the hybrid window frame assembly. The hybrid window frame assembly further includes sealant injected through the at least one injection hole of each injection block to seal the window frame to the cladding frame along an interior junction of the window frame and the cladding frame, the interior junction comprising a width of the channel inner sidewall of the cladding frame, wherein the sealant seals the width of the channel inner sidewall to the cut bead inner sidewall portion.
In some examples, the first material is polyvinyl chloride.
In some examples, the second material is metal.
In some examples, the second material is aluminum.
In some examples, the sealant comprises silicone.
In some examples, the at least one injection hole of each injection block includes spaced apart first and second injection holes.
In some examples, the central window opening is configured to engage one or more window panes.
In some examples, each of the vertical and horizontal window frame members defining the window opening have an inner surface configured to engage a respective side of a window sash.
In another aspect, a hybrid window frame assembly is disclosed. The hybrid window frame assembly includes a window frame formed of a first material and including at least three window frame members arranged to define a central window opening. The window frame has a peripheral bead extending about and projecting from a perimeter of the window frame. The window frame has at least three window frame corners. Each window frame corner is formed at a junction between two abutting window frame members of the at least three window frame members. The hybrid window frame assembly further includes a cladding frame formed of a second material and including at least three cladding frame members. Each cladding frame member is associated with a respective one of the window frame members. The cladding frame has a peripheral channel extending about a perimeter of the cladding frame. The channel defines a recess in which the peripheral bead is received to connect the cladding frame to the window frame. The cladding frame has at least three cladding frame corners. Each cladding frame corner is aligned with a respective one of the window frame corners and formed at a junction between two abutting cladding frame members of the at least three cladding frame members. The hybrid window frame assembly further includes at least three injection block cutouts. Each injection block cutout extends through at least a portion of the peripheral bead and the peripheral channel to provide a cut bead inner sidewall portion and to expose a portion of the inner sidewall of the channel at a respective one of the cladding frame corners. The hybrid window frame assembly further includes at least three injection blocks. Each injection block is sized to fit in a respective one of the injection block cutouts. Each injection block includes at least one injection hole accessible from an exterior of the window frame assembly. The hybrid window frame assembly further includes sealant injected through the at least one injection hole of each injection block to seal the bead inner sidewall of the window frame to the cladding frame along an interior junction of the window frame and the cladding frame, the interior junction comprising a width of the channel inner sidewall of the cladding frame, wherein the sealant seals the width of the channel inner sidewall to the cut bead inner sidewall portion.
In some examples, the first material is polyvinyl chloride (PVC).
In some examples, the second material is metal. In other examples, the second material is aluminum.
In some examples, the peripheral bead has a bead outer sidewall extending about and projecting from the perimeter of the window frame, a bead inner sidewall inboard of the bead outer sidewall, and a bead front wall extending between respective distal ends of the bead outer and inner sidewalls.
In some examples, the peripheral channel has a channel outer sidewall, a channel inner sidewall inboard of the channel outer sidewall, and a channel front wall extending between respective distal ends of the channel outer and inner sidewalls, and the recess in which the peripheral bead is received is defined by the channel outer sidewall, the channel inner sidewall and the channel front wall.
In some examples, the sealant comprises silicone.
In some examples, the at least one injection hole of each injection block includes spaced apart first and second injection holes.
In some examples, the central window opening is configured to engage one or more window panes.
In some examples, each of the vertical and horizontal window frame members defining the window opening have an inner surface configured to engage a respective side of a window sash.
In another aspect, a method of manufacturing a hybrid window frame assembly is disclosed. The method comprises positioning a cladding frame made from a first material on a window frame made from a second material to produce a hybrid window frame; providing an opening at each outer corner of the hybrid window frame that exposes an inner sidewall of the cladding frame, inserting an injection block into each of the openings, each injection block having at least one injection hole, and injecting sealant through the at least one injection hole of each injection block to create watertight seals between the cladding frame and the window frame at an interior junction of the window and cladding frames at each corner of the hybrid window frame.
In some examples, the method further includes, after said injecting, cutting and then welding the hybrid window frame assembly.
In some examples, the method further includes, before said positioning, cutting and then welding the cladding frame; and, before said positioning, cutting and then welding the window frame.
In some examples, said providing the opening at each corner of the hybrid window frame comprises using a cutting machine to cut the openings.
In another aspect, a hybrid window frame injection block is disclosed, which is sized to fit in a respective injection block cutout extending through an outer corner portion of a window frame assembly and comprises an inner face configured to make contact with the window frame assembly when the injection block is inserted in the injection block cutout, an outer face comprising at least one injection hole configured to receive injection of a sealant from an exterior corner of the window frame assembly when the injection block is inserted in the injection block cutout, and at least one sealant channel defined along the inner face, wherein the sealant channel is confluent with the at least one injection hole and is configured to distribute the sealant injected into the injection hole along an interior junction of a window frame and a cladding frame comprised in the window frame assembly.
In some examples, the at least one injection hole comprises two or more spaced apart injection holes.
In some examples, the at least one sealant channel comprises two or more confluent sealant channels.
In some examples, the at least one sealant channel comprises two or more interconnected cavities.
In some examples, one or more vents disposed in a distal end of the injection block.
Other aspects and features of the teachings disclosed herein will become apparent to those ordinarily skilled in the art, upon review of the following description of the specific examples of the present disclosure.
For a better understanding of the described examples and to show more clearly how they may be carried into effect, reference will now be made, by way of example, to the accompanying drawings in which:
The drawings included herewith are for illustrating various examples of apparatuses and methods of the teaching of the present specification and are not intended to limit the scope of what is taught in any way.
Various apparatuses or processes will be described below to provide an example of each claimed invention. No example described below limits any claimed invention and any claimed invention may cover processes or apparatuses that differ from those described below. The claimed inventions are not limited to apparatuses or processes having all of the features of any one apparatus or process described below or to features common to multiple or all of the apparatuses described below. It is possible that an apparatus or process described below is not an example of any claimed invention. Any invention disclosed in an apparatus or process described below that is not claimed in this document may be the subject matter of another protective instrument, for example, a continuing patent application, and the applicants, inventors, or owners do not intend to abandon, disclaim, or dedicate to the public any such invention by its disclosure in this document.
A challenge of hybrid window frame assemblies (e.g., a PVC window frame covered with aluminum cladding) lies in the ability to seal the cladding frame to the window frame to prevent water infiltration. The primary window frame and cladding frame are made of different materials so providing a watertight seal between the two can be challenging. Conventional approaches to manufacturing such hybrid window frame assemblies consist mainly in assembling cladding components (cut, machined and/or punched) to be assembled on a pre-welded primary window frame. There are also mechanical frame assemblies where the corners are screwed together. In either case, to prevent water infiltration, the cladding frame must be sealed to the primary window frame linearly and at the corners.
Among the methods currently used to seal the frame, the most common is to use a sealant. The sealant is typically applied to the perimeter of the cladding frame thus linearly sealing the cladding frame and the primary window frame. Applying the sealant to the corners of the primary window frame before inserting the cladding frame thus seals the junction at the corners of the cladding frame and the primary window frame.
The known assembly operations of hybrid window frame assemblies are labour intensive, requiring many steps and manual intervention. The primary window frames are cut and welded separately from the cladding frame which are also cut and prepared (e.g., punched and cut). The primary window frame and cladding frame are then assembled, followed by manual sealing steps.
The hybrid window frame assembly disclosed herein provides for a simplified manufacturing process that can be automated. Cutting the cladding frame when assembled on the primary window frame eliminates the need to cut the primary window frame and cladding frame separately and having to assemble them afterwards. This would considerably reduce the manufacturing burden. Welders can weld a window frame with a cladding frame simultaneously, regardless of whether they are cut together or assembled prior to welding.
A problem that remains is that the simultaneous welding of the window frame and the cladding frame does not ensure any sealing of the cladding frame to the window frame at the corners. Water can still easily infiltrate the junction and pass under the cladding frame and seep through. To address this problem, some manufacturers seal the corners by putting an exposed surface seal in the corners. However, this is a visible seal at the corners and is detrimental to the aesthetic of the hybrid window frame assembly.
Referring to
The window frame 104 includes at least three window frame members that are arranged to define a central window opening. For example, a rectangular window frame has a pair of horizontally spaced apart vertical window frame members 13 connected by an upper horizontal window frame member 132 and a lower horizontal window frame member 138.
The cladding frame 108 includes at least three cladding frame members. Each cladding frame member is associated with (e.g., covers) a respective one of the window frame members (i.e., a rectangular cladding frame 108 is used to cover a rectangular window frame 104, a triangular cladding frame 108 is used to cover a triangular window frame 104, and so on). For example, a rectangular cladding frame 108 includes a pair of horizontally spaced apart vertical cladding frame members 144 connected by an upper horizontal cladding frame member 142 and a lower horizontal cladding frame member 146.
As best shown in
With reference to
As disclosed in more detail subsequently herein, the window frame assembly 100 provides improved corner seals between the primary window frame 104 and the cladding frame 108. To provide a hidden seal at the corners, as shown in
With reference to
As shown in
In preferred embodiments, injection block cutout 114 is formed such to avoid compromising the aesthetic of the hybrid window frame assembly when viewed from the front. For example,
Referring to
In the illustrated examples of
In embodiments, the inner face 190 of injection block 114 can comprise one or more interconnected sealant channels that are confluent with injection holes 126 to direct and distribute sealant along a desired path to seal junction 118. Having multiple spaced apart injection holes 126 and/or multiple interconnected channels may facilitate a more even distribution of sealant along the interior junction 118 compared to having only a single injection hole 126 or a single sealant channel 194.
As shown in
In preferred embodiments, as shown in
One advantage of the hybrid window frame assembly 100 is that the cladding frame 108 can be assembled on the window frame 104 before or after cutting and welding.
A hybrid window frame as herein disclosed is assembled by positioning a cladding frame on a window frame to produce a hybrid window frame. Each outer corner of the hybrid window frame is then opened (e.g., by cutting or machining) such to expose an inner sidewall corner of the cladding frame as herein described. An injection block is inserted into each of the openings, each injection block having at least one injection hole. Sealant is then directly injected through the at least one injection hole of each injection block to create watertight seals between the cladding frame and the primary window frame at each corner of the hybrid window frame. Once the window and cladding frames are sealed together to form a hybrid window frame assembly, the hybrid window frame assembly can then be cut and welded.
Alternatively, a hybrid window frame can be assembled by cutting and then welding a cladding frame and cutting and then welding a window frame prior to positioning the cladding frame on the window frame to produce a hybrid window frame.
The opening at each outer corner of a hybrid window frame can be provided using a cutting machine to cut the openings as herein described, for example using a cutting machine having a rotating blade such as a conventional window corner cleaner known in the art (e.g., Stürtz® machinery 4AS corner cleaner).
The hybrid window frame assembly 100 does not necessarily require that a cladding frame 108 be installed on the window frame 104 before cutting and welding. The hybrid window frame assembly 100 can be assembled in a conventional way (cut and weld separate window and cladding frames, assemble the cladding and window frames in a second step), and then using injection blocks 122 to inject sealant 130 as discussed above.
It is to be understood that “a”, “an” and “the” include plural referents unless the content clearly dictates otherwise.
What has been described above is intended to be illustrative of examples of the teaching disclosed herein, without limiting the scope of patent claims granted herefrom. The scope of such claims should be given the broadest interpretation consistent with the description as a whole.
This disclosure claims priority to U.S. Provisional Pat. App. No. 63/431,342 filed Dec. 9, 2022, which is hereby incorporated by reference herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63431342 | Dec 2022 | US |
