Patent Application
20140260064
The embodiments herein relate generally to composite frame apparatus and components therefor. More specifically, the embodiments herein relate to thermally insulating composite frame apparatus and thermal insulating strip members for use in mounting windows, doors, curtain walls, storefront framing systems, panels, and in similar applications. In particular, the embodiments herein relate to an improved thermally insulating composite frame apparatus comprising spaced apart first and second elongated frame profile members structurally interconnected by a single thermally insulating bridge member.
Thermally insulating composite frame members for windows, curtain walls, storefront framing systems, and the like are known wherein elongated inner and outer metallic frame members are structurally interconnected by a thermal isolator formed of a plastic or other material. For example, U.S. Pat. No. 4,330,919 to Bischlipp discloses a connecting element which has two elongated profiled members bounding with one another in a channel wherein the two elongated profiled members are connected with at least two thermal separating members. The thermal separating members are formed by supplying a hardenable heat insulating material into the sections of the channel so as to harden and to form the heat insulating inserts separated from the intermediate hollow space by the bottom walls. The metallic profiled members together with the bottom walls form a unitary one-piece profiled element. In order to thermally isolate the metallic profiled members, a de-bridging operation is needed wherein a grinding tool is inserted into the intermediate hollow space for removal of selected portions of the profile material to separate the bottom walls from the remainder portions of the profiled members as well as to remove the same from the intermediate hollow space. De-bridging is a costly, dirty, and time consuming procedure.
U.S. Pat. No. 5,469,683 to McKenna discloses a thermally insulating composite frame member having a snap-in thermal isolator and which overcomes the need for a de-bridging operation wherein the snap-in thermal isolator is an elongated extrusion of generally H-shaped cross section. The complicated H-shape is necessary to hold the inner and outer frame members in alignment during assembly of the composite frame member. In this regard, the disclosed thermal isolator includes a pair of resilient, spaced apart legs projecting forward from an outwardly facing portion of the isolator. A second pair of resilient, spaced apart legs project rearward from an inwardly facing portion of the isolator. Each of the first and second pairs of spaced apart legs forms a jaw-like clamp configured to engage and to secure about a corresponding one of the facing flanges. In order to improve the shear force characteristics of the construction, the isolator of the disclosed embodiment is adhesively bonded to the gutter member and to the frame member in addition to the mechanical coupling provided by the jaw-like clamps of the isolator. Also in the disclosed embodiment mutually engaging surfaces of each of the jaw-like clamps and their respective flanges are knurled to provide further enhanced resistance to longitudinal shear forces.
In accordance with an example embodiment, a composite frame apparatus comprises first and second elongate profile members extending in a direction along a longitudinal axis, a first connection region on the first profile member, a second connection region on the second profile member, and a bridge member supporting the first and second profile members in a spaced relationship. The first connection region comprises spaced apart first and second flange members defining a first landing region therebetween, the first and second flange members of the first connection region being selectively crimpable inwardly in a direction along a transverse axis, wherein the transverse axis is perpendicular to the longitudinal axis. The second connection region comprises spaced apart first and second flange members defining a second landing region therebetween, the first and second flange members of the second connection region being selectively crimpable inwardly in a direction along the transverse axis. The bridge member comprises a body portion and first and second head portions. The body portion extends in a direction along the longitudinal axis and has at least first and second longitudinal edges on opposite sides of the body portion in a direction along a height axis, wherein the height axis is perpendicular to the transverse and longitudinal axes. The first and second head portions are carried at the first and second longitudinal edges respectively. The first head portion defines a first outer planar surface and first and second inner planar surfaces, the first outer planar surface and the first and second inner planar surfaces being mutually parallel and spaced apart in a direction along the height axis, the first outer planar surface abuts the first landing region of the first connection region and the first and second inner planar surfaces abut the first and second flange members of the first connection region crimped inwardly. The second head portion defines a first outer planar surface and first and second inner planar surfaces, the first outer planar surface and the first and second inner planar surfaces being mutually parallel and spaced apart in a direction along the height axis, the first outer planar surface abuts the second landing region of the second connection region and the first and second inner planar surfaces abut the first and second flange members of the second connection region crimped inwardly.
In accordance with a further example embodiment, a thermal insulation strip is provided for connecting with an associated first profile member of an associated thermally insulating frame system comprising the first profile member and an associated profile member. The thermal insulation strip includes a body portion, a first head portion, and first and second foot members. The body portion extends along a longitudinal axis and has a central wall portion and first and second edges on opposite sides of the wall portion in a height axis perpendicular to the longitudinal axis. The first head portion is defined on the first edge of the body portion. The first and second foot members extend in opposite directions along a transverse axis from the first head portion, wherein the transverse axis is perpendicular to the longitudinal and height axes. The first and second foot members define an outer planar surface at a top end of the strip. The first and second foot members define an inner planar surface, the inner planar surface being parallel to the outer planar surface and being spaced apart from the outer planar surface by a thickness of the first and second foot members along the height axis.
In accordance with a still further example embodiment, a connection method comprises receiving a first head portion of a bridge member in a first connection region of a first elongate profile member extending in a direction along a longitudinal axis, locating a first outer planar surface of the bridge member in abutting contact with a first landing region of the first connection region, and crimping first and second flange members of the first connection region inwardly whereby a first planar clamping portion of the first flange member engages the first inner planar surface of the first head portion and a second planar clamping portion of the second flange member engages the second inner planar surface of the first head portion. In the embodiment, the first connection region comprises spaced apart first and second flange members defining a first landing region therebetween, the first and second flange members of the first connection region being selectively crimpable inwardly in a direction along a transverse axis, wherein the transverse axis is perpendicular to the longitudinal axis. Also in the embodiment, the bridge member comprises a body portion extending in a direction along the longitudinal axis and having at least a first longitudinal edge on an end of the body portion in a direction along a height axis, wherein the height axis is perpendicular to the transverse and longitudinal axes; a first head portion carried at the first longitudinal edge of the body portion, wherein the first head portion defines a first outer planar surface and first and second inner planar surfaces, the first outer planar surface and the first and second inner planar surfaces are mutually parallel and spaced apart in a direction along the height axis.
a-8c are diagrammatic views of components of the composite structural frame apparatus depicted in
a-10c are diagrammatic views of components of the composite structural frame apparatus depicted in
a-11c are enlarged end views of the thermally insulating bridge member received in the reglet connector portion illustrating the stages of mechanical deformation of the reglet connector portion during the crimping steps of
Embodiments of the present teachings will be described in greater detail below with references to the Figures. The same features/elements are marked with the same reference numbers in all Figures. For the purpose of clarity, all reference numbers have not been inserted into all Figures. Also, not all views of the components have been shown in separate drawing Figures where the components are the same as or mirror images of components that are shown in one or more separate drawing Figures. In particular, however, for convenience of reference, components that are mirror images of, or mirror image equivalents of, components that are shown in one or more separate drawing Figures will be referred to herein and in the claims to follow using a prime (′) suffix notation. The 3-dimensional (X, Y, Z) reference system shown in
Referring now to the drawings wherein the showings are for purposes of illustrating the example embodiments only and not for purposes of limiting same and in which like numerals indicate like elements throughout the several views.
The first profile frame member 12 is an elongated aluminum extrusion of indeterminate length in the longitudinal direction along the longitudinal (Z) axis and comprises an outwardly facing portion 20 defining a substantially flat or planar surface 22, and an inwardly facing portion 30 carrying a connection portion 90. Similarly, the second profile frame member 14 is an elongate aluminum extrusion of indeterminate length in the longitudinal direction along the longitudinal (Z) axis and comprises an outwardly facing portion 50 defining a substantially flat or planar surface 52, and an inwardly facing portion 60 carrying a connection portion 100. For convenience and as a matter of convention, the first and second profile members 12, 14 have an overall length of about six (6) meters (19.68 feet). The outwardly facing planar surfaces 22, 52, of the first and second profile members 12, 14 are adapted for flat abutment against corresponding planar surfaces of associated structures such as, for example, building walls, ceilings, floors and other support surfaces or the like. As illustrated, the connection portions 90, 100 are carried on the ends of the inwardly facing portions 30, 60 of the first and second profile members 12, 14, respectively. However, it is to be appreciated that the connection portions 90, 100 can be connected or formed integrally with any region of the first and second profile members 12, 14 or connected with or formed integrally with any one or more structures other than the first and second profile members as necessary or desired.
A partial concave region 32 of the inwardly facing portion 30 of the first profile member 12 carries a first hook member 34 and, similarly, a partial concave region 62 of the inwardly facing portion 60 of the second profile member 14 carries a second hook member 64. Collectively, the partial concave regions 32, 62 form a concave portion 70 of the composite apparatus 300 when the bridge member 16 is joined with the first and second profile members 12, 14 in their assembly and composite conformations such as shown in
The bridge member 16 of the example embodiment is a thermally insulating strip member 400 shown in cross-section in
As will be appreciated, the thermally insulating strip member 400 maintains the inner and outer profiles or frames 12, 14 in a mechanically connected and spaced apart relationship. However, for creation of a thermal barrier between the first and second profiles 12, 14, the strip member 400 is made of a material exhibiting low thermal conductivity characteristics in order to substantially minimize heat transfer from a warm side to a cold side of the composite structure. Accordingly, the thermal strip member 400 of the example embodiment is comprised of plastic such as polyamide (PA) or for example polyamide filled with fiber such as, for example, 42% fiber, though other materials such as ABS, Hard-PVC, PA, PET, PPT, PA/PPE, ASA, PA66, etc., with or without fiber reinforcement such as, e.g. PA66 GF25, or foams made of thermosetting plastics, such as PU having an appropriate density, preferably foams of lower density (0.01 to 0.3 kg/l) are also suitable. In one embodiment the base material of the isolator 16 of the disclosed embodiment is ABS. A weatherable polymer such as acrylic styrene acrylonitrile, commercially available from GE Plastics under the designation Geloy, is optionally applied to lateral surfaces of the thermal isolator 16 to provide U.V. protection. In a further alternate embodiment, the lateral surfaces of the isolator bridge member 16 are coated with Geloy to provide U.V. protection. The surfaces of the enlarged head portions of the isolator bridge member 16 may be optionally coated with a flexible polyurethane to increase the shear strength.
As shown best in
In the example embodiment, each of the longitudinal edges 410, 412 define enlarged first and second head portions 420, 422, respectively. In addition, the central web or wall portion 414 is coupled with the head portions 420, 422 by thicker crank or base regions 424, 426 of the strip member 400, respectively. As can be seen in the Figures, the crank regions 424, 426 are substantially thicker than the wall portion 414 to ensure the mechanical strength of the strip member 400. However, in order for the strip member 400 to more efficiently block the communication of thermal energy between the first and second profile members 12, 14, the central wall portion 414 has a reduced thickness relative to the crank regions 424, 426. The reduced thickness of the wall portion 414 also saves on material costs and weight of the overall composite frame apparatus 300. In example embodiments, the thickness of the crank regions 424, 426 is in the range of about 1.5-1.1 times the thickness of the wall portion 414. In the example embodiment illustrated, however, the thickness of the crank regions 424, 426 is about 1.3 times the thickness of the wall portion 414. However, the ratio of the thickness between the crank regions and the web portion can be selected as desired. In addition, although the strip member 400 of the example embodiment illustrated is of a solid extrusion construction, it is to be appreciated that for purposes of reducing weight, material costs, and thermal conductivity, and for other reasons such as to provide a shear-resistant connection of the two profiles or frames even when the respective profiles or frames are subjected to different temperature environments, portions of the strip in the web and/or crank regions may be perforated wherein openings may be provided as desired penetrating through one or more walls of the strip body spaced from each other in the transverse (X), height (Y), and/or longitudinal (Z) direction(s) of the strip body.
With continued reference to
In the embodiment illustrated, the first outer planar surface 432 is comprised of spaced apart partial planar surfaces 432a and 432b separated by a recessed region 432c. Similarly, the second outer planar surface 452 of the second head portion 422 is comprised of spaced apart partial planar surfaces 452a and 452b separated by a recessed region 452c. Although the first and second outer planar surfaces 432, 452 may be formed as single contiguous surfaces, it has been found that the size and location of the recessed region 432c relative to the partial inner planar surfaces 434a, 434b, and of the recessed region 452c relative to the partial inner planar surfaces 454a, 454b provide advantages relative to alignment of the profile members during manufacture of the composite frame apparatus 300 (
The foot members 430, 440 of the first head portion 420 and the foot members 450, 460 of the second head portion 422 further advantageously define planar regions and curved regions for enabling easy manufacture of the subject composite frame apparatus and for providing superior shear strength and good dimensional tolerance characteristics of the apparatus. More particularly and with initial reference to the first head portion 420, the foot members 430, 440 collectively define an inner planar surface 434 wherein, in the example embodiment, the inner planar surface 434 is parallel to the first outer planar surface 432. As shown, the inner planar surface 434 is comprised of a pair of partial inner planar surfaces 434a, 434b defined by the foot members 430, 440, respectively and are arranged on opposite sides of the upper crank portion 424. In the embodiment, each of the first outer and inner planar surfaces 432, 434 extend lengthwise in the longitudinal direction (Z) and have a width dimension in the transverse direction (X).
With continued reference to the first head portion 420, a concave connection region 436 is defined between the partial inner planar surface 434a and the upper crank region 424 and, similarly, a further or complementary concave connection region 438 is defined between the partial inner planar surface 434b and the upper crank region 424. Continuous transitions are provided on both sides of each concave connection region 436, 438. In this regard, there is a continuous transition between the partial inner planar surface 434a and the concave connection region 436, and there is a continuous transition between the partial inner planar surface 434b and the concave connection region 438. Also, there is a continuous transition between the concave connection region 436 and the first side 424a of the wall portion 414, and there is a continuous transition between the concave connection region 438 and the second side 424b of the wall portion 414. In the example embodiment, each of the concave connection regions 436, 438 are semi-circular subtending an angle of about 90 degrees and each have a predefined radius R.
With reference next to the second head portion 422, the foot members 450, 460 collectively define a second inner planar surface 454 wherein, in the example embodiment, the second inner planar surface 454 is parallel to the second outer planar surface 452. As shown, the inner planar surface 454 is comprised of a pair of partial inner planar surfaces 454a, 454b defined by the foot members 450, 460, respectively and are arranged on opposite sides of the lower crank region 426. In the embodiment, each of the second outer and inner planar surfaces 452, 454 extend lengthwise in the longitudinal direction (Z) and have a width dimension in the transverse direction (X).
With continued reference to the second head portion 422 shown in
As shown in the drawing Figure, in the example embodiment, the inner planar surfaces 434a and 434b are completely overlapped in the transverse (X) axis by the outer planar surfaces 432a and 432b. Also as shown, in the example embodiment, none of the recessed region 432c overlaps the outer planar surfaces 432a and 432b in a direction along the transverse (X) axis. In that way, crimping forces to be described in greater detail below generated during manufacture or assembly of the subject composite frame apparatus are directed directly through the material forming the foot members 430, 440 without any intervening air gaps, free space or spaces void of material, thereby providing for a secure and highly efficient connection at the bottom end of the strip member 400 and also thereby helping to avoid any distortion or misalignment while crimping during manufacture.
Similarly, in the example embodiment, the inner planar surfaces 454a and 454b are completely overlapped in the transverse (X) axis by the outer planar surfaces 452a and 452b. Also as shown, in the example embodiment, none of the recessed region 452c overlaps the outer planar surfaces 452a and 452b in a direction along the transverse (X) axis. In that way, crimping forces to be described in greater detail below generated during manufacture or assembly of the subject composite frame apparatus are directed directly through the material forming the foot members 450, 460 without any intervening air gaps, free space or spaces void of material, thereby providing for a secure and highly efficient connection at the top end of the strip member 400 and also thereby helping to avoid any distortion or misalignment while crimping during manufacture.
The first flange member 510 comprises an arm member 530 including a planar clamping region 532, a convex locating region 534, and a locking region 536. Similarly, the second flange member 512 comprises an arm member 540 including a planar clamping region 542, a convex locating region 544, and a locking region 546. Each of the “hammers” or flange members 510, 512 are formed of metal such as aluminum and are therefore configured to be moved such as by cold working or crimping between an opened orientation such as shown in
In the example embodiment such as shown in
As shown in the Figure, none of the clamping force F is directed through the recessed region 452c (
Further in the example embodiment, the convex locating regions 534, 544 of the first and second arm members 530, 540 are configured in the closed or crimped orientations thereof to engage the concave connection regions 456, 458 of the second head portion 422 of the strip member 400. In the example embodiment, each of the convex locating regions 534, 544 correspond identically with the concave connection regions 456, 458 and are therefore semi-circular subtending an angle of about 90 degrees and have a predefined radius R. Mutual engagement of the convex locating regions 534, 544 with the concave connection regions 456, 458 results in superior sealing and shear strength properties of the strip member 400 relative to the profile members 12, 14 in the composite frame apparatus 300. Mutual opposite forces L are generated between the surfaces forming the convex locating regions 434, 544 and the concave connection regions 456, 458 for effectively aligning and locating the strip 400 relative to the respective profile member and severely holding the strip relative to the profile member.
For providing further sealing and shear strength properties of the strip member 400 relative to movement of the profile members 12, 14 along the longitudinal (Z) axis, the locking regions 536, 546 of each arm member 530, 540 carries on mutually facing portions of the arm members at least one ridge member 538, 548, respectively. As shown in
It is to be appreciated that for ease of discussion and description only the connection portion 100 is shown in an enlarged view in the drawing Figures as the connection portion 90 (
The connection region 90 includes a pair of spaced apart opposed flange members 510′, 512′ defining a landing region 514′ therebetween. The landing region 514′ defines a planar locating surface 520′ configured to locate and support the head portion 420 of the strip member 400. In accordance with the example embodiment, the planar locating surface 520′ is sized and shaped to correspond with the size and shape of the outer planar surface 432 of the foot members 430, 440 of the first head portion 420. More particularly, the planar locating surface 520′ is configured to receive the foot members 430, 440 and make abutting contact with the partial planar surfaces 432a, 432b so that the strip member is positively located relative to the second profile member 14.
The first flange member 510′ comprises an arm member 530′ including a planar clamping region 532′, a convex locating region 534′, and a locking region 536′. Similarly, the second flange member 512′ comprises an arm member 540′ including a planar clamping region 542′, a convex locating region 544′, and a locking region 546′. Each of the flange members 510′, 512′ are formed of metal such as aluminum and are therefore configured to be moved such as by cold working or crimping between an opened orientation such as shown in
In a manner such as shown in
It is to be appreciated that, in the example embodiment, none of the clamping force F is directed through the recessed region 432c (
Further in the example embodiment, the convex locating regions 534′, 544′ of the arm members 530′, 540′ are configured in the closed or crimped orientations thereof to engage the concave connection regions 436, 438 of the first head portion 424 of the strip member 400. In the example embodiment, each of the convex connection regions 532′, 542′ correspond identically with the concave connection regions 436, 438 and are therefore semi-circular subtending an angle of about 90 degrees and have a predefined radius R. Mutual engagement of the convex connection regions 532′, 542′ with the concave connection regions 436, 438 results in superior sealing and shear strength properties of the strip member 400 relative to the profile members 12, 14 in the composite frame apparatus 300.
For providing further sealing and shear strength properties of the strip member 400 relative to movement of the profile members 12, 14 along the longitudinal (Z) axis, the locking regions 536′, 546′ of each arm member 530′, 540′ carries on mutually facing portions of the arm members at least one ridge member 538′, 548′, respectively. The ridge members 538′, 548′ penetrate into the crank region 424 of the first head portion 420 of the strip member when the arm members 530′, 540′ are moved to their closed or crimped positions. In the example embodiment, the ridge members 538′, 548′ extend along the connection region 90 in the longitudinal direction (Z). In a further embodiment, the ridge members 538′, 548′ are optionally provided with a roughened or knurled inner surface during manufacture thereof such as by use of a knurling tool (not shown) before the strip member 400 is received into the connection region 500′ and prior to the cold working or crimping of the flange members 510, 512 onto the foot members 430, 440 of the head portion 420. In general, the knurled lateral surfaces of the selected areas increase surface area for enhanced mechanical bonding to further prevent longitudinal displacement of the profile frame members 12, 14 with respect to the thermal isolator 16 along the longitudinal (Z) axis in response to longitudinal shear forces.
Assembly of the first profile member 12, the second profile member 14, and the thermal isolator bridge 16 to form the thermally insulating composite frame apparatus 300 (
With continued reference to
Further in the example embodiment, after processing the assembly 200 through the second crimping station 804 (
When thus assembled, engagement between the planar and curved surfaces of the connection region 500 with corresponding planar and curved surfaces of the head portion provides a mechanical interlock to prevent longitudinal displacement of the profile frame members 12, 14 with respect to the thermal isolator 16 in response to longitudinal shear forces.
Assembly of the first profile member 12, the second profile member 14, and the thermal isolator bridge 16 to form the thermally insulating composite frame apparatus 300 (
With continued reference to
Further in the example embodiment, after processing the assembly 200 through the second crimping station 1004, the relative location and arrangement of the connection region 500 and the strip member 400 is as shown in
When thus assembled, engagement between the planar and curved surfaces of the connection region 500 with corresponding planar and curved surfaces of the head portion provides a mechanical interlock to prevent longitudinal displacement of the profile frame members 12, 14 with respect to the thermal isolator 16 in response to longitudinal shear forces.
The preferred design of the strip member 400 having the first head portion 420 defining the first outer planar surface 432 and complementary foot portions 430, 440 defining the first and second inner planar surfaces 434a, 434b parallel to and spaced apart in a direction along the height (Y) axis from the first outer planar surface 432, and with the first and second concave connection portions 436, 438 in a continuous transition from the first and second inner planar surfaces 434a, 434b enables a self-centering connection with the corresponding complementary connection portion 90, 100 of the profile member 12, 14. The symmetric design allows, in cooperation with a correspondingly designed symmetric connection portion 90, 100, to apply a symmetric crimping process such that the simultaneous crimping (rolling in) of the flange members (hammers) 510, 512 avoids distortion of the resulting composite profile without having to apply additional measures/steps. Such distortions of the composite profiles are usually the result of the non-symmetric design of the connection portion of the profile member with fixed hammer and hammer to be deformed during the crimping (rolling). The non-symmetric design of the connection portion of the profile member results in a design of the heads of the strip member requiring slant abutment surfaces for the hammers pressing the strip member heads against the anvil and hammer.
While the preferred embodiments have been disclosed with respect to a window frame member, it will be appreciated that the design is easily adapted to doors, curtain walls, storefront framing systems, and many other frame applications in which a thermally insulating composite frame member would be advantageous.
Finally, it will be understood that the preferred embodiments have been disclosed by way of example, and that other modifications may occur to those skilled in the art without departing from the scope and spirit of the appended claims.
It is to be appreciated that each of the various features and teachings disclosed above may be utilized separately or in conjunction with other features and teachings to provide improved spacer profiles, and insulating window units and methods for designing, manufacturing and using the same. Representative examples of the present invention, which examples utilize many of these additional features and teachings both separately and in combination, were described above in detail with reference to the attached drawings. This detailed description is merely intended to teach a person of skill in the art further details for practicing preferred aspects of the present teachings and is not intended to limit the scope of the invention. Therefore, combinations of features and steps disclosed in the detailed description may not be necessary to practice the invention in the broadest sense, and are instead taught merely to particularly describe representative examples of the present teachings.
Moreover, the various features of the representative examples and the dependent claims may be combined in ways that are not specifically and explicitly enumerated in order to provide additional useful embodiments of the present teachings. In addition, it is expressly noted that all features disclosed in the description and/or the claims are intended to be disclosed separately and independently from each other for the purpose of original disclosure, as well as for the purpose of restricting the claimed subject matter independent of the compositions of the features in the embodiments and/or the claims. It is also expressly noted that all value ranges or indications of groups of entities disclose every possible intermediate value or intermediate entity for the purpose of original disclosure, as well as for the purpose of restricting the claimed subject matter.
