METHOD FOR MANUFACTURING A FACADE LOUVER, AND FACADE LOUVER

Abstract

 The invention relates to a method for manufacturing a facade louver, and to the corresponding facade louver. The louver comprises a number of parallel slats (1) spaced at a distance from each other and having a uniform cross-sectional profile, and end frames (2) at the ends of the slats for supporting the slats. According to the invention, openings (3) corresponding to the cross-sectional profile of the slats (1) are machined in both of the end frames (2) at said distance from each other, and holes (4) are machined in both ends of the slats in the same position in each of the slats. The slats are then pushed from their ends through the openings of the end frames, so that the holes machined in them pass to the other side of the end frames. Then, a pipe (5) is pushed through the holes arranged in the same position in each of the slats, and an expanding means is drawn through the pipe, the expanding means being larger than the inner diameter of the pipe, so as to expand the pipe in the areas between the slats, thereby locking the slats in place around the pipe.

Description

FIELD OF THE INVENTION

[0001] The invention relates to a method of manufacturing a facade louver, and to the corresponding facade louver, for use mainly in exterior walls of different types of buildings.

BACKGROUND OF THE INVENTION

[0002] Facade louvers are widely used in various, mostly public, buildings as a surface structure for the walls to give a specific look for the wall, and/or to protect the wall against direct sunlight or rain and wind. Louvers are also widely used for example in parking halls as the sole wall structure to give protection against weather, but still allow the air to flow freely in the parking floors.

[0003] However, the manufacture of louvers is expensive and slow because of the current manufacturing methods. The slats are cut to a proper size, and are welded from their ends to common frames with a desired even spacing. When the frame looks ready, it must be smoothed and cleaned, and then surface-treated, such as painted, in a desired colour. If the slats were already painted before welding, it would still be necessary to smooth and paint the weld seams; however, repainting the seams only would make the louver look untidy. Thus, the surface treatment has to be given to the finished louver, which is, however, a complicated and difficult task because of the surface differences of the louver.

OBJECT OF THE INVENTION

[0004] The object of the invention is to remedy or mitigate at least one of the defects of the above described prior art. Specifically, the object of the invention is to disclose a new louver structure and a method of manufacturing it in such a way that different components of the louver may be surface-treated separately, or in the form of long slats before being cut to a fixed size, so as to avoid the final coating of the end product, which is difficult due to the surface differences.

SUMMARY OF THE INVENTION

[0005] The method according to the invention relates to the manufacture of a facade louver. The facade louver comprises a number of parallel slats spaced at a distance from each other and having a uniform cross-sectional profile, and end frames or corresponding support structures at the ends of the slats for supporting the slats in order to form a rigid assembly.

[0006] In the method according to the invention, openings corresponding to the cross-sectional profile of the slats are machined in both of the end frames at said distance from each other. The openings are made nearly without play, i.e. so precisely to correspond to the cross-section of the slat that the slat may just be pushed through the opening. After the slats have been cut to a fixed size and equal length, holes are machined in both ends of the slats in the same position in each of the slats, and the slats are then pushed from their ends through the openings of the end frames, so that the holes machined in them pass through the openings to the other side of the end frames. Then, a pipe is pushed through the holes arranged in the same position in each of the slats, the outer diameter of the pipe corresponding to the diameter of the holes of the slats. Finally, an expanding means such as a ball or a corresponding round object is drawn through the pipe, the expanding means being slightly larger than the inner diameter of the pipe, so as to expand the pipe in the areas between the slats, and in the area of the slat to tighten the pipe against the slat, thereby locking the slats rigidly and immovably in place around the pipe. At the same time as the slats become rigidly set in their place, they also become locked in the openings of the end frame, i.e. the end frame, the slats and the pipe together form a rigid and stable assembly without any welding or corresponding joining operations. Preferably these three parts, i.e. the end frame, the pipe and the slats, are positioned relative to each other in such a way that the holes of the slats are pushed just through the end frames, whereby the pipe pushed through the holes practically comes into contact with the outer surface of the end frame. This ensures a very firm and reliable connection between different parts.

[0007] In a preferred embodiment of the invention, the end frames are rigidly connected from their ends by means of horizontal frames, such that they jointly form a rectangular framing surrounding the slats from all sides. Thus, holes are preferably machined also in the horizontal frames, these holes corresponding to the holes of the slats, whereby the pipes at both ends of the louver are also pushed and locked in the holes of the horizontal frames.

[0008] In one embodiment of the invention, the end frames and/or the horizontal frames have an outwardly opening U-profile or a corresponding shape, the ends of the slats pushed through the frames being left between the flanges of the profile, and are locked there with the pipes pushed through their holes. For finishing, the U-profiles may be covered and locked using a frame cap attached to the ends of the flanges of the profile. The frame cap may be hinged to one of the flanges of the profile, it may be closable by pushing with a snap-fit, or it may use other methods of attachment, such as gluing, screwing, slide rails etc.

[0009] The holes may be machined in the slats at a uniform distance from the end of the slat, or the holes may be machined in the slats so that they extend partly beyond the ends of the slats, such that the centre of the hole in the slat is spaced from the end of the slat at a distance smaller than the radius of the hole. The rigid slat will be locked against the rigid pipe, even if part of the hole extends beyond the slat. This way the slats can be made shorter, i.e. the material costs are lowered, and also the frame profile surrounding the louver can be made smaller, as the end of the slat does not require so much space.

[0010] With the method according to the invention it is possible to make the slats and the frame parts from pre-coated metal profiles, such as aluminium profiles. Whatever the type and material of the coating, it will not be changed or damaged when different parts of the louver are assembled according to the invention. It is also possible to use uncoated material, i.e., for example clear aluminium profiles; however, in this case it is more advantageous to coat, such as paint, these parts before assembling them according to the invention, either in the form of long rods or in the form of parts cut to a fixed size.

[0011] As stated above, the pipe may be manufactured from aluminium. Alternatively the pipe may be manufactured from stainless steel or alloys of various metals. Preferably the pipe does not have seams, such that the friction exerted on the expanding means may be equally strong in all directions. The diameter of the pipe and its wall thickness may vary. For example, a pipe with a total diameter of 10, 12 or 15 mm before expanding may be used. Also pipes with a thicker total diameter, for example 20 or 25 mm, may be suitable for heavier structures. The wall thickness of the pipe before expanding may be 1 - 5 mm, e.g. 2 mm.

[0012] The slats with a uniform profile are rigid and robust; however, if their length extends up to several meters, it is advantageous to use additional supports in the middle area of the slats. The additional supports are suitably made in the way that corresponds to the invention, i.e. by making holes in the same position in the slats, and by pushing a pipe through the holes, the pipe being expanded against the slats in order to form an additional support for the louver.

[0013] Preferably, slats that all have the same cross-sectional profile are used in the method according to the invention. Thus, due to the identical slats and the identical holes in the end frames the manufacture of the louver is simple and fast. With the method according to the invention it is possible to manufacture facade louvers with various widths, heights and their respective ratios. By the method according to the invention it is possible to manufacture facade louvers sized as e.g. 1 m × 1 m, 0.5 m × 1 m, 4 m × 4 m, 1 m × 4 m or 2 m × 2 m. In other words, the width and height of the louvers being manufactured may independently vary in the range of 0.5 m - 4 m.

[0014] The invention also relates to a facade louver comprising a number of parallel slats spaced at a distance from each other and having a uniform cross-sectional profile, and end frames at the ends of the slats for supporting the slats. According to the invention the end frames are provided with openings corresponding to the cross-sectional profile of the slats, and the ends of the slats are provided with holes, whereby the ends of the slats having been pushed through the openings are connected by means of a pipe pushed through the holes, and the pipe is outwardly expanded against the holes of the slats. In the structure according to the invention the openings of the end frames correspond, substantially without play, to the cross-sectional profile of the slats, and the exterior shape of the pipe corresponds, substantially without play, to the holes at the ends of the slats, such that the parts are insertable one within the other, but fit together as tightly as possible.

[0015] Preferably, the ends of the end frames are connected by means of horizontal frames in order to form a rigid rectangular frame around the slats.

[0016] Preferably, the pipe is in contact with the outer surface of the end frame, i.e. the slats are pushed through the end frame in such a way that the hole in the slats just comes out from the profile of the end frame, so that when the pipe is outwardly expanded, the slats, the end frame and the pipe are thereby pressed together as a rigid assembly.

ADVANTAGES ACHIEVED WITH THE INVENTION

[0017] The facade louver and the method of manufacturing it according to the invention provide significant advantages over the prior art. The invention enables the manufacture of the facade louver without welding as usual. The invention also obviates the need for smoothing, cleaning and painting the welded louver. Just machining the parts and assembling them, whereby the amount of work needed for manufacturing the louver drops to 10-20 % from the prior art. Furthermore, the end result looks much tidier and more finished, because no weld seams or other traces from machining are visible in the louver.

SHORT DESCRIPTION OF THE DRAWINGS

[0018] The invention will now be described in detail with reference to the accompanying drawings, in which

Fig. 1 illustrates one facade louver according to the invention,

Fig. 2 shows a cross-section of the facade louver of Fig. 1,

Fig. 3 is a partial enlargement of Fig. 2,

Fig. 4 illustrates a detail of the facade louver of Fig. 1,

Fig. 5 illustrates another detail of the facade louver of Fig. 1,

Fig. 6 illustrates another facade louver according to the invention,

Fig. 7 illustrates one detail of the facade louver of Fig. 6,

Fig. 8 illustrates another detail of the facade louver of Fig. 6, and

Fig. 9 illustrates a third detail of the facade louver of Fig. 6.

DETAILED DESCRIPTION OF THE INVENTION

[0019] Fig. 1-5 illustrate one facade louver according to the invention. The louver is formed by a large number of parallel slats 1 having a uniform cross-section and secured from their ends to end frames 2. In this embodiment, the end frame is formed by a closed rectangular profile. From section II-II of Fig. 1, i.e. from Fig. 2 and 3, it can be seen that the slats 1 are in the same position, and are spaced at the same uniform distance from each other. Without the sectional transversal lines of the slats, Fig. 3 could just as well illustrate openings 3 made in the end frame 2 at an even spacing, the openings corresponding in size and shape to the cross-sectional shape of the slats as accurately as possible. Thus, as the slat 1 is pushed into the opening 3, it fills the opening precisely, substantially without play, and in a close-fitting manner.

[0020] As can be seen from Fig. 4, there is a hole 4 at the end of each of the slats 1, i.e. in proximity to the end of the slat. The slat 1 is pushed through the opening 3 into the end frame 2, such that the holes 4 are inside the profile forming the end frame, and are in alignment with each other. A pipe 5 is then pushed through these holes 4, the outer diameter of the pipe corresponding closely to the diameter of the holes 4. The pipe 5 used is an aluminium pipe, which is suitably and relatively easily formable. When the slats and the pipe are inserted in place in the profile formed by the end frame 2, a suitable expanding tool is drawn through the pipe 5, the expanding tool being an object with a slightly larger diameter than the inner diameter of the pipe. The expanding tool expands the pipe in the area between the slats 1, and in the area of the slats it tightens the pipe against the slats. At the same time it tightens the slats in place in the openings 3 of the end frames 2.

[0021] Fig. 6-9 illustrate another facade louver according to the invention. In this louver the end frames 2 are connected from their upper and lower ends by means of horizontal frames 6. The framing thus formed supports the slats 1 arranged in the rectangular space between the frames from all sides, and the slats are secured in place from both ends using the holes 4 made at the ends of the slats 1 and the pipe 4 pushed through the holes.

[0022] In this embodiment the holes 4 at the ends of the slats 1 are open, i.e. they are made so close to the end of the slat 1 that the hole does not extend fully into the slat, but continues slightly beyond the slat. The pipe 5 stays nevertheless in place in the hole 4, because more than half of the hole is in the area of the slat. Thus, the length of the slat is minimized, and also the space needed for the end of the slat inside the end frame is as small as possible. In addition, in this embodiment the end frame 2 and the horizontal frame 6 are made from two parts, i.e. they comprise a separate frame cap 7 by means of which the frames may be covered and finished after all connections between the frames and the slats are ready. The frame caps 7 are preferably fastened in place for example by means of a snap-fit, a slide rail or the like, such that no screws or other fasteners are visible from outside. This way the louver is given a tidy and finished look.

[0023] In the louver of Fig. 1 and Fig. 6, the slats 1 are also connected in the middle area by means of a middle support 8. The middle support 8 is a pipe corresponding to pipe 4, and it is inserted in holes made in the same position in the slats, and then outwardly expanded in a corresponding manner against the slats by drawing an expanding tool through the pipe in order to outwardly expand the pipe.

[0024] The invention has been described above by way of example, with reference to the accompanying drawings, without in any way limiting the invention exclusively to the structures presented herein. However, different embodiments of the invention are possible within the scope defined by the claims.

Claims

1. A method for manufacturing a facade louver, the louver comprising a number of parallel slats (1) spaced at a distance from each other and having a uniform cross-sectional profile, and end frames (2) at the ends of the slats for supporting the slats, characterized in that openings (3) corresponding to the cross-sectional profile of the slats (1) are machined in both of the end frames (2) at said distance from each other, holes (4) are machined in both ends of the slats in the same position in each of the slats, the slats are pushed from their ends through the openings of the end frames, so that the holes machined in them pass to the other side of the end frames, a pipe (5) is pushed through the holes arranged in the same position in each of the slats, and an expanding means is drawn through the pipe, the expanding means being larger than the inner diameter of the pipe, so as to expand the pipe in the areas between the slats, thereby locking the slats in place around the pipe.

2. The method according to claim 1, characterized in that the end frames (2) are rigidly connected from their ends by means of horizontal frames (6) .

3. The method according to claim 1 or 2, characterized in that the end frames (2) and/or the horizontal frames (6) have an outwardly opening U-profile, and are lastly closed using frame caps (7).

4. The method according to any one of claims 1-3, characterized in that the holes (4) are machined in the slats (1) at a uniform distance from the end of the slat.

5. The method according to any one of claims 1-3, characterized in that the holes (4) are machined in the slats (1) such that the centre of the hole in the slat is spaced from the end of the slat at a distance smaller than the radius of the hole.

6. The method according to any one of claims 1-5, characterized in that the slats (1) and the frame parts (2,6) are made from pre-coated metal profiles, such as aluminium profiles.

7. The method according to any one of claims 1-5, characterized in that the slats (1) and the frame parts (2,6) are coated, such as painted, before assembling them.

8. The method according to any one of claims 1-7, characterized in that holes are made in the same position in the middle area of the slats (1), and a pipe is pushed through the holes, the pipe being expanded against the slats in order to form a middle support (8) for the louver.

9. The method according to any one of claims 1-8, characterized in that slats that all have the same cross-sectional profile are being used.

10. A facade louver, comprising a number of parallel slats (1) spaced at a distance from each other and having a uniform cross-sectional profile, and end frames (2) at the ends of the slats for supporting the slats, characterized in that the end frames (2) are provided with openings (3) corresponding to the cross-sectional profile of the slats (1), and the ends of the slats are provided with holes (4), whereby the ends of the slats having been pushed through the openings are connected by means of a pipe (5) pushed through the holes, and the pipe is outwardly expanded against the holes of the slats.

11. The facade louver according to claim 10, characterized in that the ends of the end frames (2) are connected by means of horizontal frames (6) in order to form a rigid rectangular frame around the slats.

12. The facade louver according to claim 10 or 11, characterized in that the pipe (5) is in contact with the outer surface of the end frame (2), so that when the pipe is outwardly expanded, the slats (1), the end frame and the pipe are thereby pressed together as a rigid assembly.

Drawing