This invention relates generally to a structural frame member, and more particularly to a structural frame member that can be joined together with other frame members to form a frame assembly.
Frame members, such as window frame members, are commonly formed with a key passage that is adapted to receive a corner key used to secure adjacent frame members together. Typically, the key passage is in the form of an enclosed passage located within an inner area of the frame member. The key passage is defined by a series of walls, which are typically integrally formed with each other and with the remaining structure of the frame member, such as in an extrusion or pultrusion process. The present invention seeks to improve upon such prior art by providing a key passage defined by a series of walls that are not integrally formed with each other.
In accordance one aspect of the present invention, a structural frame member includes a body portion having a first section defining a number of axially extending passages and a second section defining a key passage area. A cap portion is configured for engagement with the key passage area. The cap portion and the key passage area of the body portion cooperate to define an enclosed key passage. The key passage area of the body portion may be defined by a pair of spaced apart protrusions that extend from a wall forming a part of the body portion, and the cap portion is configured for engagement with the pair of spaced apart protrusions. In one form, the cap portion and the pair of spaced apart protrusions include snap-type engagement structure that secures the cap portion to the pair of spaced apart protrusions upon application of a transversely directed force to the cap portion. Representatively, the first section of the body portion may be an outer section and the second section of the body portion may be an inner section, with the outer and inner sections being separated at least in part by the wall from which the spaced apart protrusions extend. In one embodiment, the body portion defines a depth, and the enclosed key passage defined by the key passage area of the body portion and the cap portion extends across a majority of the depth of the body portion.
The invention also contemplates a frame assembly formed of at least a pair of structural frame members and a method of assembling a structural frame member, substantially in accordance with the foregoing summary.
Various other features, aspects, and advantages of the invention will be made apparent from the following description taken together with the drawings.
The drawings illustrate the best mode presently contemplated of carrying out the invention.
In the drawings:
The systems and methods described herein related generally to joining frame members together to form frame assemblies using corner keys which fit inside of the ends of the frame members. More particularly, the systems and methods relate to use of frame members having uniform cross-sections such as those formed by pultrusion or extrusion.
In some embodiments, the frame assembly described herein provides a high level of thermal insulation by virtue of having two or three or sometimes four enclosed longitudinal cavities defined within each frame member. In one embodiment, the frame assembly includes one or more corner keys which are positioned adjacent to an outer perimeter of the assembled frame. In some embodiments, the frame member configuration permits insertion of the corner keys without any milling, that is, without removing any material from the interior of the frame member. In one embodiment, a corner key cavity extends across at least 60% of a depth of a frame member.
In some embodiments, the frame assembly system includes a cavity for a corner key that is defined between a lineal member and a cap. In some embodiments, this corner key cavity is located adjacent to an outer perimeter of the assembled frame. This position of the corner key improves the strength and design pressure of the assembled frame.
In the FIGS., various embodiments are illustrated. Like numbers refer, where appropriate, to like parts throughout the several views.
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The concepts related to frame members and assembly methods described herein are sometimes described in the context of windows. However, the same concepts apply to joining other structural or architectural elements at a corner joint. Many of the embodiments described herein have four frame members forming a frame assembly. However, it is also possible to apply the concepts described herein to an assembly that has two frame members, three frame members, five frame members, six frame members, and other numbers of frame members. Where a frame assembly does not from a closed perimeter, such as where there are two frame linear members at right angles to each other, the inner perimeter can be defined on the side of the frame assembly that has an angle between the frame members of less than 180 degrees. The outer perimeter can be defined on the side of the frame assembly that has an angle between frame members of greater than 180 degrees.
The frames of
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The corner key cavity 44 is a longitudinal cavity that extends along the entire length of the frame member 10. The corner key cavity 44 is bounded by a closed perimeter. The presence of this bounded cavity improves the insulation value of the frame member 10.
In some embodiments, the corner key cavity 44 extends across most of the depth dimension of the frame member, thereby further increasing the strength of the assembled frame 16. The depth dimension D of the frame member 10 is measured from an outside surface 146 of an outer first side 46 to an outside surface 148 of an opposite inner second side 48 of the frame member 10. The depth extension E of the corner key 14 is measured across each of the legs 86, 88 of the corner key 14 as shown in
In some embodiments, the corner key cavity extends across at least about 60% of the depth of the frame member. In some embodiments, the corner key cavity extends across at least about 65% of the depth of the frame member. In some embodiments, the corner key cavity extends across at least about 67% of the depth of the frame member. In some embodiments, the corner key cavity extends across at least about 70% of the depth of the frame member. In some embodiments, the corner key cavity extends across at least about 72% of the depth of the frame member. In some embodiments, the corner key cavity extends across at least about 75% of the depth of the frame member. In the embodiment of
The assembled frame includes a first face and a second face. One of the faces is facing the viewer in
In one embodiment, the lineal member 40 defines a first interior cavity 50 and a second interior cavity 52. The inclusion of multiple interior cavities 50, 52 increases the insulating properties of the frame 16. The interior cavities 50, 52 are longitudinal cavities that extend along the length of the frame member 10. In one embodiment, the lineal member 40 further defines a third interior cavity 53. The third interior cavity 53 is adjacent to one side 48, while the first interior cavity is adjacent to the other side 46. The second interior cavity 52 is positioned between the first and third interior cavities 50, 53.
In one embodiment, the lineal member defines at least one interior cavity and an open area for a corner key cavity. In one embodiment, the lineal member defines at least two interior cavities and an open area for a corner key cavity. In one embodiment, the lineal member defines at least three interior cavities and an open area for a corner key cavity. In one embodiment, the lineal member defines at least four interior cavities and an open area for a corner key cavity.
The lineal member 40 and the cap 42 each include attachment structures that interact with each other to cause a snap-fit attachment of the cap 42 to the lineal member 40. The lineal member 40 shown in
Mating attachment structures 60, 61 on the cap 42 are seen in
In the embodiments of the FIGS., the attachment structures are two longitudinal protrusions with nub structures which lock into an attached position with two similar longitudinal protrusions. In some embodiments, the attachment structure of the lineal member and the attachment structure of the cap are connected by a snap-fit. A snap-fit refers to a connection between parts where mating parts exert a cam action, flexing until one part slips past a raised lip on another part. Other types of attachment structures are present in some embodiments.
The corner key joint 90 is the portion of the corner key 14 where the two legs 86, 88 or two halves are connected. In one embodiment, the joint 90 of the corner key 14 is flexible and acts as a hinge. As a result, the angle between the first and second legs 86, 88 can vary as needed depending on the frame shape.
The corner key 14 includes channels and recesses for routing and retaining adhesive that is injected into the corner area after the corner key 14 is positioned within adjacent frame members 10. The adhesive improves the structural integrity of the joint. The corner key 14 can be made from a wide variety of materials including nylon and crylonitrile-butadiene-styrene (ABS). In one embodiment, the corner key 14 is made from a non-metallic material.
The corner key 14 is configured to fit tightly within the corner key cavity 44. A measured amount of adhesive is injected into the joint once the corner key 14 is in place. The corner key cavity 44 and the corner key 14 are designed to encourage the adhesive to flow along each leg 86, 88, up against the ramp structures at the ends of the legs, through openings in the corner key and to spaces between inner and outer portions 82, 84. Bumps on the sides of the legs 86, 88 are designed to fit snuggly into the corner key cavity 44. In one embodiment, adhesive fills all the cracks and crevices in the joint area.
In one embodiment, the frame members are cut from lineal stock. In one embodiment, the frame members are formed to the lengths needed for constructing a frame assembly. In some embodiments, the frame members define a substantially hollow profile, though the interior cavity is divided into multiple cavities by interior walls in some embodiments.
In one embodiment, the frame members are made of pultruded fiberglass material. In another embodiment, the frame members are made of an extruded thermoplastic composite material. One example of a thermoplastic composite materials includes wood and polymer. A product of an extrusion process can be referred to as an extrudate. An extrudate has a uniform cross-section along its length. The frame members, lineal members and cap can be extrudates. In one embodiment, the frame members are made of vinyl.
Both pultrusion and extrusion processes form long parts with a uniform or constant cross-sections along their lengths which are also referred to as lineals. The lineal may be miter cut or cut in other ways at their ends to allow formation of an attractive joint with another lineal. The lineals may be cut to form the appearance of a mortise and tenon joint, while still using a corner key to join two frame members.
A few examples of profiles for window assemblies are illustrated herein, but it will be understood that many different further features may be present on the profiles. The invention disclosed and claimed herein is applicable to all such profiles.
Lineal member 100 of
Lineal member 102 of
In one embodiment, the frame member defines at least one interior cavity and a corner key cavity. In one embodiment, the frame member defines at least two interior cavities and a corner key cavity. In one embodiment, the frame member defines at least three interior cavities and a corner key cavity. Individual features or groups of features described herein with respect to the frame members or lineal members can also be combined with the lineal member 104.
There are many possible embodiments of methods of forming a frame assembly. In one embodiment, stock members such as the lineal members, the caps and/or frame assemblies are formed using pultrusion or extrusion so that each member has a uniform cross section over its length. In one embodiment, the members are formed by pultrusion of fiberglass.
In one embodiment, fairly long stock frame members and frame member components are formed by extrusion or pultrusion. The stock members can be formed in a standard length, such as sixteen foot lengths. In one embodiment, the frame members and frame member components are formed in the specific lengths that are are needed for making frame assemblies.
In some embodiments, each frame member has a uniform cross section along its length. The cavities that are defined within the frame member will also have uniform cross sections across their lengths. Each frame member includes a first end and a second end. The first and second ends are angled ends in one embodiment. In some embodiments, the length of the frame member, lineal member or cap which extends between the angled ends has a uniform cross section.
In some embodiments, the frame members and frame member components are painted or laminated after formation. The paint coating or lamination covering can provide increased durability and aesthetic changes to the frame members.
In one embodiment, formation of a cap stock member can be followed by attaching a cap stock member to a lineal stock member to form a stock frame assembly. In other embodiments, the frame member is formed as a unitary structure without any need to attach a cap.
To construct a particular frame assembly from the stock frame members, the next step is to cut the stock frame members to the appropriate length with the appropriate miter cut at the ends. Another step is performance of routing operations such as forming adhesive injection holes, forming venting holes, forming window balance knock-outs and other routing operations as appropriate for the type of window. Hardware may also be added if appropriate.
Next, the frame members are brought together using a clamping system, with a corner key positioned at each corner. One leg or one half of the corner key is inserted into one end of a corner key cavity of a frame member. The other leg or half if the corner key is inserted into one end of a corner key of another frame member. Then, adhesive is injected into the joint areas. In one embodiment, each joint area includes two injection holes. Each injection hole is located near one of the legs of the corner key, on opposite sides of the joint 90 of the corner key and close to the joint of the corner key. In this embodiment, two venting holes are also provided close to the joint of the corner key.
In one embodiment, adhesive is used at the joints to enhance the structural integrity of the completed frame. In some embodiments, separate mechanical fasteners are used at the joints, either alone or in addition to adhesive. In one embodiment, the joint is secured with adhesive without the use of any separate mechanical fasteners. When the frame members are formed of hollow profile material as in the preferred embodiments, the ends of the lineals are sometimes mitered. In addition to or instead of adhesive and fasteners, the mitered ends can be joined securely together by other methods, for example, by sonic welding.
In some embodiments, vinyl frame members are used in combination with ultrasonic bonding of the frame members to form a corner joint. However, it may be desirable to touch-up the appearance of the vinyl if the vinyl laminate is modified by the ultrasonic welding. The use of corner keys and adhesive to form the joint reduces the likelihood of performing a touch-up step.
Design pressure (DP) is a metric of a window's strength and is measured in pounds per square foot (pst). Measurements techniques for DP are further described in ASTM E1300, titled “Standard Practice for Determining Load Resistance of Glass in Buildings.” Windows according to the discussion herein can have a DP of at least 50 psf, a DP of at least 70 psf and DP of 90 psf in various embodiments.
Thermal performance of a window can be improved by using the frame described herein. The U -factor is a term that is used to quantify heat transfer. The units for U -factor are British thermal unit (Btu) per hour per square foot of area per degree Fahrenheit temperature difference. The computer programs Therm 5 and Window 5 are industry-standard computer tools used to simulate heat flow through the edge of the glass and window frame regions and through the center of glass. These programs also sum up the respective contribution of each component to determine the U -factor for the whole window. These computer programs were developed by the Lawrence Berkeley National Laboratory. Using these computer programs, testing was performed using the example of
An example of a system and method for forming a frame assembly has been described, but those of skill in the art will be aware of many options and alternatives to the equipment and method steps described that can be used.
Various embodiments are described in detail with reference to the drawings, wherein like reference numerals represent like parts and assemblies throughout the several views. Reference to various embodiments does not limit the scope of the claims attached hereto. Additionally, any examples set forth in this specification are not intended to be limiting and merely set forth some of the many possible embodiments for the appended claims.
This application claims the benefit of U.S. provisional patent application Ser. No. 61/555,384 filed Nov. 3, 2011 and U.S. provisional patent application Ser. No. 61/558,919 filed Nov. 11, 2011, the entire contents of which are hereby expressly incorporated by reference.
Number | Date | Country | |
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61555384 | Nov 2011 | US | |
61558919 | Nov 2011 | US |