FIELD OF THE INVENTION
[0001] The present invention relates to a beadless frame assembly for a fenestration unit,
a fenestration unit comprising said beadless frame assembly, a kit of parts for assembling
said fenestration unit and a method of assembling the same.
BACKGROUND OF THE INVENTION
[0002] Modern fenestration units typically comprise a frame assembly, into which a panel,
such as a glass pane, or a sealed double glazing unit, is inserted in a direction
generally normal to the plane of the panel. Typically, such frame assemblies are pre-assembled
prior to the panel being inserted. A bead is then secured to the frame assembly after
the panel has been inserted into the frame assembly, for securing said panel within
the frame assembly.
[0003] However, such beads are easily removable with the appropriate knowledge and tools
and are often accessible from a building's exterior. Therefore, fenestration units
featuring this design are often vulnerable to home intrusion as the bead, and subsequently
the panel secured within the frame assembly, can be easily removed without breaking
the glass or other panel material, thereby allowing access into the building in which
the fenestration unit is installed. More recently, window beads have been moved onto
the interior side of the fenestration unit to help address this issue. However, with
the correct know-how, it is still possible to externally access and dislodge the bead
in these designs, thereby enabling access into the building.
[0004] Furthermore, domestic frame assemblies are typically made from uPVC. uPVC is a lower
strength material and can therefore be more easily drilled or broken to enable access
to the bead.
[0005] Therefore, the aim of the present invention is to provide a way of alleviating at
least some of the aforementioned issues.
SUMMARY OF THE INVENTION
[0006] According to a first aspect of the invention, there is provided a beadless frame
assembly for a fenestration unit, the frame assembly comprising a plurality of frame
members, each frame member comprising a pair of bevelled edges configured to interface
with a respective bevelled edge of a neighbouring frame member so as to form a mitre
joint; and a plurality of connectors configured to secure neighbouring frame members
at each of the respective of mitre joints, wherein each of the frame members comprise
a groove for receiving a panel of the fenestration unit, and wherein the frame assembly
is a metallic frame assembly.
[0007] The provision of a plurality of frame members, each having a groove for receiving
a panel of the fenestration unit, enables the panel to be installed into the frame
assembly without requiring a bead, thereby improving the security provided by the
frame assembly once the fenestration unit has been installed. The provision of metallic
frame members further improves the security provided by the frame assembly.
[0008] The frame assembly may comprise frame members comprising an internal profile section
and an external profile section and a thermal break sandwiched between the internal
profile section and the external profile section.
[0009] Advantageously this enables the frame assembly to have enhanced security and greater
insulation properties to enable its use in building structures such as dwellings and
offices.
[0010] The internal and external profile sections may comprise a body portion and an upstanding
projection, the upstanding projections defining the groove.
[0011] An opening to receive the connectors may be provided in the body portion of one or
both of the internal and/or external profile sections.
[0012] The body portions have a suitable space to provide a void for the connector, and,
if connectors are provided in both sections, the load may be substantially evenly
shared across the mitre joint
[0013] The frame assembly may comprise a plurality of corner spacers configured to be received
within the groove of each frame member at each of the respective mitre joints.
[0014] The provision of a plurality of corner spacers provides the advantage of ensuring
correct positioning of the panel in 2 axes (height/width) of the frame assembly.
[0015] The plurality of corner spacers may be substantially L-shaped.
[0016] This provision allows each spacer to be more easily located at each of the mitre
joints thereby reducing installation times. Furthermore, such spacers do not require
cutting to shape in order to fit within the groove at the respective mitre joint.
This further reduces installation times and also improves ease of installation.
[0017] The plurality of corner spacers may each comprise at least one corner gasket comprising
a resilient material, preferably a rubber-like material, and most preferably EDPM.
[0018] This provision provides the advantage of improved sealing.
[0019] The plurality of corner spacers may each comprise a groove configured to receive
a corner of the panel of the fenestration unit.
[0020] The provision of a groove provides the further advantage of ensuring correct positioning
of the panel along a further axis (depth) of the frame assembly. Furthermore, this
provision also provides a more uniform stress around the circumference of the panel
which enables a more uniform, and therefore better, seal to be achieved around the
panel once the fenestration unit has been completed.
[0021] Each connector may comprise first and second fasteners configured to secure respective
neighbouring frame members to the connector.
[0022] This provision reduces the number of parts and allows for fastener installation.
[0023] The plurality of frame members may each define a hollow profile having at least one
opening at a respective bevelled edge of each frame member, each opening being configured
to receive one of the plurality of connectors; and each of the plurality of connectors
may comprise a first arm configured to extend within a hollow profile defined by a
first frame member, and a second arm configured to extend within a hollow profile
defined by a second frame member.
[0024] This provision allows for easier location of the connectors at the mitre joint, and
subsequently reduces the likelihood of fastener misalignment.
[0025] Each fastener may be a threaded fastener. Preferably each fastener may be a self-tapping
threaded fastener. Each fastener may comprise a frusto-conical leading end.
[0026] This provision enables the fasteners to secure neighbouring frame members without
requiring any further fastening elements, thereby reducing the number of parts and
allowing for fastener installation.
[0027] At least one mount may be located at an external surface of the frame assembly, the
at least one mount being configured to releasably secure the beadless frame assembly
within a casing.
[0028] This provision allows for easier replacement of the panel once the fenestration unit
has been installed without requiring the entire fenestration unit to be removed.
[0029] The plurality of frame members may comprise at least four modular frame members,
and the plurality of connectors may comprise at least four connectors.
[0030] This provision enables the frame assembly to be manufactured as series of modular
sections and therefore improves ease and cost of manufacturing.
[0031] The metallic frame assembly may comprise aluminium.
[0032] This provision provides the advantage of improved durability.
[0033] For example, where the frame assembly comprises an internal profile section and an
external profile section these may be formed substantially entirely of aluminium (which
term encompasses aluminium alloys). These profile sections provide the majority of
the structural strength of the frame members.
[0034] However if a thermal break is present this is manufactured from a non-metallic material
with a lower thermal such as plastics material - e.g. polyamide. The thermal break
is typically non-structural.
[0035] According to a second aspect of the invention, there is provided a kit of parts for
assembling a fenestration unit, the kit of parts comprising a beadless frame assembly
according to the first aspect of the invention, and a panel configured to be received
within the beadless frame assembly.
[0036] According to a third aspect of the invention, there is provided a fenestration unit
comprising a panel and the beadless frame assembly according to the first aspect of
the present invention.
[0037] According to a fourth aspect of the invention, there is provided a method of assembling
a fenestration unit comprising the steps of providing a plurality of metallic frame
members, each frame member comprising a pair of bevelled edges and a groove for receiving
a panel of the fenestration unit; locating a first frame member about a panel, such
that the panel is received within the groove of a first frame member; abutting a second
frame member with the first frame member such that the panel is received within the
groove of the second frame, and such that at least one bevelled edge of the first
frame member and at least one bevelled edge of the second frame member interface to
form a mitre joint; and securing a connector at the mitre joint so as to secure the
first and second frame members.
[0038] The plurality of metallic frame members may comprise at least three metallic frame
members, and the method may further comprise the steps of abutting a portion of the
frame members such that at least one bevelled edge of each frame member interfaces
to form a mitre joint; and securing a respective connector at the mitre joint so as
to secure the frame members thereby forming the first frame member, wherein the steps
of abutting and securing the first frame member take place prior to locating the first
frame member about the panel.
[0039] This provision reduces the number of joints required to complete the fenestration
unit once the panel is in place. This provides the advantage of reducing installation
times and also reduces the likelihood of damage to the panel during installation.
[0040] The plurality of metallic frame members may comprise at least four modular metallic
frame members, and the method may further comprise the steps of abutting three of
the modular metallic frame members such that at least one bevelled edge of each frame
member interfaces to form a respective mitre joint; and securing a respective connector
at each of the mitre joints so as to secure the frame members thereby forming the
first frame member, wherein the steps of abutting and securing the first frame member
take place prior to locating the first frame member about the panel, and wherein the
step of locating the first frame member about the panel comprises sliding the panel
into the respective grooves of the three modular metallic frame members which make
up the first frame member. This provision enables the panel to be easily received
within the frame members prior to the final frame member being attached, thereby allowing
for easier assembly of the fenestration unit. Furthermore, this provision means that
only two joints require securing once the panel is in place. This provides the advantage
of reducing installation times and also reduces the likelihood of damage to the panel
during installation.
[0041] The method may further comprise the steps of providing at least one gasket, and locating
said at least one gasket about each of the plurality of metallic frame members.
[0042] The step of locating said at least one gasket about each of the plurality of metallic
frame members may take place after the first frame member and second frame member
have been secured.
[0043] A fifth aspect of the present invention provides a frame member for constructing
a beadless frame assembly, the frame member comprising bevelled edges configured to
interface with a respective bevelled edge of a neighbouring frame member so as to
form a mitre joint; and wherein each of the frame members comprises an internal profile
section and an external profile section and a thermal break sandwiched between the
internal profile section and the external profile section.
[0044] The frame member may be configured to receive at least one connector to secure the
frame member to a neighbouring frame member.
[0045] The connector(s) may be received in one or both of the internal and external profile
sections.
[0046] The internal and external profile sections may comprise a body portion and an upstanding
projection, the upstanding projections defining the groove.
[0047] An opening to receive the connectors may be provided in the body portion of one or
both of the internal and/or external profile sections.
[0048] The body portions have a suitable space to provide a void for the connector, and,
if connectors are provided in both sections, the load may be substantially evenly
shared across the mitre joint.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049]
Figure 1 is a front view of a fenestration unit having a beadless frame assembly according
to an embodiment of the present invention;
Figure 2 is a cross-sectional view of a frame member of the beadless frame assembly
according to the embodiment illustrated in Figure 1;
Figure 3 is an isometric view of part of a mitre joint of the beadless frame assembly
according to the embodiment illustrated in Figures 1 and 2;
Figure 4 is an isometric view of the mitre joint of Figure 3 in a partially assembled
state;
Figure 5 is an exploded front view of the fenestration unit according to the embodiment
illustrated in Figure 1;
Figure 5A is a simplified cross sectional view of the beadless frame assembly on the
plane A-A of Figure 1, proximate a corner thereof;
Figure 5B is a further cross-sectional view of the frame member of the beadless frame
assembly on the plane B-B of Figure 1 at a mid-point of the frame member;
Figure 5C is a schematic cross-sectional view of the frame member illustrated in Figure
5B showing the gasket in both a compressed and an uncompressed state;
Figure 6 is a front view of the fenestration unit according to the embodiment illustrated
in Figure 1, and a casing for housing the fenestration unit;
Figures 7A-E illustrate a method of assembling a fenestration unit according to an
embodiment of the present invention;
Figures 8A-C illustrate an alternative method of assembling a fenestration unit according
to an embodiment of the present invention; and
Figures 9A-D illustrate a further alternative method of assembling a fenestration
unit according to an embodiment of the present invention.
DETAILED DESCRIPTION OF EMBODIMENT(S)
[0050] Figure 1 shows a fenestration unit generally indicated at 1, having a frame assembly
2 made up of a plurality of frame members 12a-d. The fenestration unit 1 of this embodiment
is suitable for a window, door or other type of fenestration, such as a vent or cladding
panel. The frame assembly 2 is configured to receive and support a pane or panel 3,
such as a pane of glass, a double or triple glazed sealed unit, or a panel of wood,
aluminium or other suitable material. The frame assembly of the present invention
is a beadless frame assembly meaning that the panel 3 is secured within the frame
assembly without the use of a bead. This is achieved by providing the frame members
12a-d with a groove, or channel - i.e. the frame members have a 'U'-shaped cross-sectional
profile to receive the pane or panel 3 securely as discussed in more detail below.
[0051] Each frame member 12 comprises a pair of angled or bevelled edges 13. The bevelled
edges 13 of each frame member 12 are configured to interface with a corresponding
bevelled edge 13 of a neighbouring frame member 12 so as to form a mitre joint 10.
In the embodiment illustrated in Figure 1, the frame assembly 2 is made up of four
modular frame members 12a-d, with each frame member 12a-d comprising a respective
pair of bevelled edges 13a-h. The bevelled edges 13a-h are each configured to interface
with a respective bevelled edge 13 of a neighbouring frame member 12 to form four
mitre joints 10a-d, one at each corner 4a-d of the frame assembly 2. A first mitre
joint 10a is formed at the interface between the bevelled edge 13b of the first frame
member 12a and the bevelled edge 13c of the second frame member 12b. A second mitre
joint 10b is formed at the interface between the bevelled edge 13d of the second frame
member 12b and the bevelled edge 13e of the third frame member 12c. A third mitre
joint 10c is formed at the interface between the bevelled edge 13f of the third frame
member 12c and the bevelled edge 13g of the fourth frame member 12d, and a fourth
mitre joint 10d is formed at the interface between the bevelled edge 13h of the fourth
frame member 12d and the bevelled edge 13a of the first frame member 12a.
[0052] However, it shall be appreciated that in other embodiments the frame assembly may
comprise a pair of corresponding L-shaped frame members in elevation, may comprise
a U-shaped frame member in elevation and a corresponding frame member configured to
interface with the bevelled edges of the U-shaped frame member, or may comprise any
other suitable configuration of frame members. It shall be appreciated that in such
embodiments, the frame assembly may comprise fewer than four mitre joints. For example,
one embodiment may comprise two mitre joints. In other embodiments comprising more
than four frame members, it shall be appreciated that the frame assembly may comprise
more than four mitre joints.
[0053] The frame assembly 2 of the present invention is a metallic frame assembly, i.e.
a frame assembly 2 having frame members 12 that are at least in part metallic. A metallic
frame assembly as described here may include features or components of some non-metallic
or composite material, such as plastics material or wood. However, the majority of
the structural strength is provided by the metallic parts.
[0054] Typically, the frame assembly is an aluminium frame assembly, i.e. a frame assembly
2 having frame members 12 comprising at least part aluminium. The frame members 12a-d
of this embodiment comprise a 6063T6 aluminium alloy. However, it shall be appreciated
that any other suitable material may be used. In one alternative, the frame members
are of some other suitable material, such as some other 6063 series aluminium alloy,
or a 6060 series aluminium alloy.
[0055] The frame members 12a-d of this embodiment are typically manufactured by extrusion.
However, it shall be appreciated that other suitable manufacturing methods may be
used.
[0056] Figure 2 shows a cross-sectional view of one of the frame members 12a illustrated
in Figure 1. Whilst only the first frame member 12a is illustrated in Figure 2, it
shall be appreciated that frame members 12b-d are substantially the same configuration,
and therefore, for reasons of conciseness and brevity, only frame member 12a shall
be described herein. Like components of frame members 12b-d shall be denoted by like
reference numerals.
[0057] The frame member 12a comprises an internal profile section 5a, an external profile
section 6a and a thermal break 7a sandwiched therebetween comprising a low thermal
conductivity material such as a plastics or foam. However, it shall be appreciated
that other suitable thermal breaks may be used, or alternatively, the thermal break
may be omitted. The internal 5a and external 6a profile sections are metallic profile
sections, typically comprising aluminium, although it shall be appreciated that any
other suitable metal, or metallic material, may be used. As noted above, these profile
sections 5a and 6a are typically manufactured by extrusion of aluminium alloys and
have a relatively high thermal conductivity, whereas the foam or plastics material
has a relatively low thermal conductivity to enhance the overall thermal insulation
properties of the frame member.
[0058] The internal 5a and external 6a profile sections each comprise a respective body
portion 30a, 32a and an upstanding projection 34a, 36a extending upwardly therefrom.
In this embodiment it can be seen that these are unitarily or monolithically formed,
e.g. by the extrusion process, which enhances the strength thereof. A groove 38a is
defined between the respective upstanding projections 34a, 36a, which is configured
to receive the panel 3 of the fenestration unit 1, thereby enabling the panel 3 to
be secured within the frame assembly 2 without requiring a bead. The method of assembly
shall be described in greater detail at a later stage within this application.
[0059] A mitre joint 10a of the internal profile 6a frame assembly 2 is shown in Figure
3. Whilst only the first mitre joint 10a is illustrated in Figure 3, it shall be appreciated
that mitre joints 10b-d are substantially the same configuration, and therefore, for
reasons of conciseness and brevity, only the first mitre joint 10a shall be described
herein. Like components of mitre joints 10b-d shall be denoted by like reference numerals.
[0060] When the mitre joint 10a is in the assembled state, as shown in Figure 3, the frame
members 12a, 12b abut to form a corner 4a of the frame assembly 2. When the first
and second frame members 12a, 12b are abutted, the bevelled edge 13b of first frame
member 12a and the corresponding bevelled edge 13c of the second frame member 12b
interface with one another thereby forming the mitre joint 10a. In this embodiment,
as indicated at a, b, the bevelled edges 13b, 13c are both angled at 45°, i.e. the
angle is 45° and the angle b is 45°. In alternative embodiments, the bevelled edges
13b, 13c may have some other angle. In such embodiments, the first and second frame
members 12a, 12b may be of a different width to one another, so that the bevelled
edge 13b of the first frame member 12a may require a different angle to the bevelled
edge 13c of the second frame member 12b. In this embodiment the frame members 12a,
12b form a 90° corner 4a. However, in alternative embodiments, the frame assembly
may have corners of some other angle, e.g. between 60° and 120°. In such embodiments,
the bevelled edges are of equal angles. In alternative embodiments where the frame
has a corner or corners of some non-90° angle, and where the first and second frame
members are of different widths to one another, the bevelled edges may be of different
angles to one another.
[0061] Each of the respective frame members 12 are secured at each of the respective mitre
joints 10 via a respective connector. Typically, in embodiments which comprise four
modular frame members, such as the embodiment illustrated in Figures 1 and 2, eight
connectors are provided, two at each mitre joint with one connector securing a neighbouring
pair of internal profile sections 5 and the other securing a neighbouring pair of
external profile sections 6. However, it shall be appreciated that in other embodiments,
a single connector may be provided at each mitre joint 10, or alternatively, three
or more connectors may be provided at each mitre joint. Furthermore, in embodiments
comprising "U" or "L" shaped frame members, in which there are fewer than four mitre
joints, fewer than four connectors may be provided.
[0062] A connector 16 according to one embodiment of the present invention is illustrated
in Figure 4. Whilst the connector 16 is described in relation to mitre joint 10a,
it shall be appreciated that the frame members 12 at each of the other respective
mitre joints 10b-d are joined in substantially the same way as is described below
for mitre joint 10a. However, it shall also be appreciated that in other embodiments,
the connector may comprise a screw connector, an adhesive, or may be any other suitable
connector type. Furthermore, in such embodiments, it shall be appreciated that the
hollow profiles and respective openings at each of the bevelled edges may be omitted.
[0063] The connector 16 of this embodiment is formed by injection moulding, and is of glass
filled nylon. In an alternative embodiment the connector is of some other material
suitable for injection moulding. In alternative embodiments the connector is die-cast,
and is of some other suitable material, such as a zinc based material.
[0064] The connector 16 locates the frame members 12a, 12b in relation to one another, and
is substantially L-shaped. The connector 16 has a first arm 20a and a second arm 20b
which meet to form a corner 20c. In this embodiment, the frame members 12a, 12b form
a 90° corner 4a. However, in embodiments where the frame assembly 2 has corners of
some other angle, the connector arms meet at a corresponding angle.
[0065] The connector 16 comprises first and second fasteners 18a, 18b. The fasteners 18a,
18b are configured to secure the respective first and second frame members 12a, 12b
to the connector 16.
[0066] Each frame member 12a, 12b defines a hollow profile 22a, 22b. Each frame member 12a,
12b further comprises a pair of openings 23b, 23c located at a respective bevelled
edge 13b, 13c of the first and second frame members 12a, 12b, which enable external
access to the hollow profile 22a, 22b of the each frame member 12a, 12b. In the embodiment
illustrated in Figure 4, the openings 23b, 23c are provided at the respective body
portions 30a, 30b of the first and second frame members 12a, 12b.
[0067] The first arm 20a of the connector 16 is configured to extend within the first member
profile 22a, via the opening 23b. When the first arm 20a extends within the first
frame member profile 22a, the first fastener 18a engages the first frame member 12a.
The second arm 20b of the connector 16 is configured to extend within the second frame
member profile 22b, via the opening 23c. When the second arm 20b extends within the
second frame member profile 22b the second fastener 18b engages the second frame member
12b.
[0068] The engagement of the fasteners 18a, 18b with the respective frame members 12a, 12b
secures the frame members 12a, 12b to the connector 16, creating a secure joint 10.
[0069] The fasteners 18a, 18b of this embodiment are threaded fasteners. In this embodiment,
the fasteners 18a, 18b are self-tapping grub screws. In an alternative embodiment,
some other suitable type of fastener is provided. For example, some other type of
threaded fastener is provided. The leading end of each grub screw 18a, 18b in this
embodiment is at least partially conical, or frusto-conical. The conical shape of
the leading end aids self-tapping of each grub screw 18a, 18b with the respective
frame members 12a, 12b. It should be noted that in embodiments where the fasteners
are self-tapping, the frame members are of a metallic material that is less hard than
the material of the fasteners, so that a thread can be formed in the frame members
by the fasteners.
[0070] Each profile 22a, 22b further defines at least two projections 24 (four as depicted)
extending from the profile 22a, 22b to engage the respective fastener 18a, 18b. The
projections 24 engage the fasteners 18a, 18b at discrete, separate engagement points
(not shown), where each engagement point is distinct from the next. The projections
24 are arranged about the fasteners 18a, 18b such that the engagement points provide
balanced support, e.g. such that the engagement points are evenly arranged about a
periphery of each fastener 18a, 18b. Advantageously, this arrangement provides stability
to the engagement between a fastener 18a, 18b and the frame members 12a, 12b whilst
reducing the amount of material used in the profile 22a, 22b. Providing an engagement
point rather than a solid block or a face of a profile wall or the like for fastener
engagement can also improve ease of engagement, in particular where the fastener is
a self-tapping screw, due to the reduced amount of material used.
[0071] In this embodiment, engagement of the projections 24 and the fastener 18a, 18b at
the engagement points cover less than 25% of the total circumference of each fastener
18a, 18b. In alternative embodiments, the engagement points cover less than 50% of
the total periphery of each fastener, or less than 35%.
[0072] Each connector further 16 defines an access aperture 26. Each access aperture 26
is configured to provide access to a respective fastener 18a, 18b for a tool, for
example an Allen key or a screwdriver (not shown) which is configured for engagement
with fasteners 18a and 18b respectively.
[0073] As the fasteners of this embodiment are engaged with an Allen key, or other suitable
means, and subsequently screwed in a first direction, the self-tapping grub screws
18a, 18b of this embodiment create a thread within the respective hollow profiles
22a, 22b of the first and second frame members 12a, 12b thereby securing the frame
members 12a, 12b to the connector 16 at the mitre joint 10a.
[0074] A further access aperture 28 is provided in each frame member 12a, 12b such that
when each frame member 12a, 12b is in the assembled state as shown in Figure 3, the
access apertures 26, 28 of the connector 16 and the frame members 12a, 12b are aligned
with one another. This arrangement allows the first frame member 12a to be located,
and potentially secured, to the connector 16, then the second frame member 12b to
be located and secured to the connector 16, as access is provided to the fastener
18b via the access aperture 28 of the first frame member 12b, and the access aperture
26 of the first connector arm 20a. Alternatively, the second frame member 12b can
be located and potentially secured to the connector 16 prior to location of the first
frame member 12a.
[0075] Figure 4 is a cut-away view showing only the external profiles sections 6a, 6b of
the first and second frame members 12a, 12b. Although not shown in Figure 4, it shall
be appreciated that further openings are provided at the respective body portions
32a, 32b of the first and second frame members 12a, 12b. The first arm of a further
connector is configured to extend within the first member profile 22a, via the further
opening to further engage the first frame member 12a. The second arm of the further
connector is configured to extend within the second frame member profile 22b, via
the further opening to further engages the second frame member 12b.
[0076] It shall also be appreciated that in other embodiments, any number of openings and
respective connectors may be provided for securing the first and second frame members
12a, 12b. In one such embodiment, the first and second frame members 12a, 12b may
comprise a single opening such that the first and second frame members 12a, 12b are
secured at the mitre joint 10a by a single connector. Alternatively, additional openings
may be provided. Furthermore, it shall be appreciated that in other alternatives,
the openings may be located at substantially any cross-sectional location of the frame
members, and are therefore not limited to being housed in the respective body portions
of the internal and external profile sections.
[0077] An exploded view of the assembled frame assembly 2 is shown in Figure 5. A plurality
of corner spacers 40a-d are located in each of the respective corners 3a-d of the
panel 3. The corner spacers 40a-d are configured to be received within the respective
grooves 38a-d of each frame member 12a-d at each of the respective mitre joints 10a-d.
The corner spacers 40 are typically L-shaped and further comprise a groove 42a-d configured
to receive a respective corner 3a of the panel 3, as illustrated in Figure 5A. However,
it shall be appreciated that the corner spacers may alternatively be any suitable
shape, or in an alternative embodiment, may be omitted.
[0078] The corner spacers 40 ensure the correct positioning of the panel 3 in both the X
(width-wise) and Y (height-wise) axes. Furthermore, grooves 42a-d also ensure correct
positioning of the panel in the Z (depth-wise) axis.
[0079] The plurality of corner spacers 40a-d typically comprise at least one corner gasket.
Typically, the plurality of corner spacers comprise an internal gasket configured
to abut and seal against an interior side of the panel 3 and an external gasket configured
to abut and seal against an exterior side of the panel 3. The corner gasket may be
integrally formed as a part of each corner spacer 40a-d or may be provided as a separate
component. Each corner gasket is typically made up of a resilient material to provide
a sealing effect about the panel 3 at each corner 4a-d of the frame assembly 2. Typically,
the corner gaskets comprise a rubber-like material, in particular EDPM, although it
shall be appreciated that any other suitable material may be used. Typically, the
corner gaskets are made from a different, more resilient material, to that of rest
of the corner spacers 40a-d.
[0080] A plurality of gaskets 44a-d are also located within the respective grooves 38a-d
of each frame member 12a-d as is illustrated in Figure 5B. The gaskets 44a-d span
along the groove 38a-d of each frame member 12a-d between the respective corner spacers
40a-d. Typically, each groove 38a-d houses a pair of gaskets 43a-d, 45a-d as shown
in Figure 5B. An internal gasket 43a is located between the panel 3 and the upstanding
projection 36a of the internal profile section 5a of the first frame member 12a, and
an external gasket 45a is located between the panel 3 and the upstanding projection
38a of the external profile section 6a of the first frame member 12a. However, it
shall be appreciated that a single gasket may be provided at each of the respective
frame members or, in a further alternative, the gaskets may be omitted.
[0081] The internal 43 and external 45 gaskets are typically sized to be larger than the
space provided between the panel 3 and the frame member 12. As the respective internal
43 and external gaskets 45 are located within the groove 38, between the panel 3 and
a respective upstanding portion 36, 38, the gaskets become compressed, as shown in
Figure 5C, thereby achieving an effective seal between the frame member 12 and the
panel 3. Typically the gaskets 43 and 45 are inserted into the gap between the panel
and the upstanding projections 36 and 38 after the frame members have been assembled
and secured around the panel. To facilitate this, the gaskets 43 and 45 have a generally
wedge shaped leading profile, as shown in 45a'. Further, in this embodiment, the gaskets
have a ridge, as shown in 45a", positioned on one face, such that when correctly inserted
this ridge is seated under an undercut of the respective upstanding projection 36
or 38. This allows the fitter to have physical feedback on when the gasket is inserted
to the correct position, and also inhibits the removal of the gasket either under
the action of forces generated by its own resilience under compression, or an external
force.
[0082] The plurality of gaskets 44a-d are typically made up of a resilient material configured
to provide a sealing effect about the panel 3. In particular, the plurality of gaskets
44a-d comprise a rubber-like material, in particular EDPM, although it shall be appreciated
that any other suitable material may be used. Furthermore, the gaskets 44a-d may be
made from the same, or different, material to the corner spacers 40a-d.
[0083] Frame assemblies according to the prior art typically comprise a single gasket that
is inserted around the circumference of the frame assembly and is "doubled up" at
the corner regions. At the corner regions the gasket is therefore typically under
greater amounts of compression loading than the gasket at other regions of the frame
assembly. Whilst this creates a good seal at the corner, this can also lead to reduced
compressive loads being placed on the gasket in other regions of the frame assembly,
thereby providing regions of poorer sealing. The provision of gaskets pre-formed as
part of the corner spacers provides a more uniform stress loading around the circumference
of the panel which enables a more uniform, and therefore better, sealing to be achieved
around the panel once the fenestration unit has been completed. It also avoids the
difficulty of fitting the gaskets to the corners.
[0084] In certain configurations, the frame assembly 2 further comprises at least one mount,
illustrated in Figure 6. In Figure 6, the mount of the frame assembly 2 comprises
a plurality of packers 46, located on an exterior surface 48 of the frame assembly
2. The packers 46 are configured to releasably secure the frame assembly 2 within
a casing 50, configured to house the fenestration unit 1.
[0085] In the embodiment illustrated in Figure 6, the packers 46 are provided as a plurality
of clips, which clip into corresponding receptacles (not shown) located within the
casing 50. However, in an alternative embodiment, the packers, or packer, may be provided
in any other suitable form. In another embodiment, the mount may be provided in the
form of a hinge such that the fenestration unit 1 is pivotable relative to the casing
50.
[0086] This provision enables the panel 3 of the fenestration unit 1 to be replaced without
requiring replacement of the entire fenestration unit 1 and casing 50. Once the respective
packers 46 have been released, or the frame assembly 2 has been decoupled from the
hinge, the frame assembly 2 can be partially dismantled, for example via de-coupling
one of the frame members 12 from a respective connector 16, to facilitate removal
of the panel 3. Once the panel 3 has been replaced, the frame member 12 can be re-attached
via re-coupling the frame member 12 to the respective connector 16 before re-securing
the frame assembly 2 into the casing 50. Therefore, this provision allows for easier
replacement of the fenestration unit post-installation.
[0087] A method of assembling a fenestration unit according to an embodiment of the present
invention shall now be described with reference to Figures 7A-E.
[0088] In a first step illustrated in Figure 7A, the corner spacers 40a-d are applied at
the respective corners 3a-d of the panel 3. Once the corner spacers 40a-d have been
applied, the first frame member 12a is located about the panel 3, as shown in Figure
7B, such that the panel 3 is received within the groove 38a of the first frame member
12a. The first arm 20a of the connector 16 is then applied to the hollow profile 22a
of the first frame member 12a, via the opening 23b. A further connector is also applied
to the hollow profile 22a of the first frame member 12a, via a further opening such
that a pair of connectors are located at the bevelled edge 13b of the first frame
member 12a, one in the opening 23b provided at the body portion 30a of the first frame
member 12a, and another at the opening provided at the body portion 32a of the first
frame member 12a. The second frame member 12b is then located about the panel 3, as
illustrated in Figure 7C, via pushing the frame member 12b onto the panel 3 such that
the panel 3 is received within the groove 38b of the second frame member 12b, and
sliding the second frame member 12b down the panel 3 such that the second arm 20b
of the connector 16 is located within the hollow profile 22b of the second frame member
12b via the opening 23c provided at the body portion 30b, and the second arm of the
further connector is located within the hollow profile 22b of the second frame member
22b via the further opening, provided at the body portion 32b. As the second frame
member 12b is located about the panel 3, the second frame member 12b abuts the first
frame member 12a such that the bevelled edge 13c of the second frame member 12b interfaces
with the bevelled edge 13b of the first frame member 12a to form the mitre joint 10a.
The connectors 16 can then be secured at the mitre joint 10a via engaging an Allen
key, or other suitable tool, with the respective fastener 18a, 18b via access apertures
26, 28 so as to secure the first and second frame members 12a, 12b. This process can
then be repeated to locate and secure the fourth frame member 12d and then the third
frame member 12c about the panel 3 to complete the assembly of the fenestration unit,
as shown in Figures 7D and 7E.
[0089] The frame members and connectors can be assembled in an alternative order, depending
on preference. Furthermore, it shall be appreciated that fewer than two, or more than
two connectors may be provided and secured at the respective mitre joints 10a-d. Furthermore,
in an alternative embodiment, each of the frame members 12a-d may be located about
the panel 3 prior to the step of securing a connector at each of the respective mitre
joints 10a-d. Although the method is described using the connector 16, as described
in Figure 4, it shall be appreciated that any other type of suitable connector, such
as a screw connector, may be used. In such embodiments, the openings and hollow profiles
may be omitted. It should be noted that in embodiments featuring the connectors 16,
as illustrated in Figure 4, connectors are applied to the hollow profiles of the second
and fourth frame members 12b, 12d, located at bevelled edges 13d and 13g respectively,
prior to the third frame member 12c being located and secured to complete the frame
assembly 2. However, in embodiments featuring other connectors, the connectors may
be applied in any order and at any suitable stage, for example after respective frame
members 12 have been abutted to form a mitre joint.
[0090] Once each of the frame members 12a-d have been secured at each of the respective
mitre joints 10a-d, internal 43 and external 45 gaskets are applied to each of the
frame members 12a-d to complete the fenestration unit 1. However, it shall be appreciated
that in some embodiments the plurality of gaskets may be pre-applied within each of
the frame members 12a-d prior to assembly, for example, the plurality of gaskets may
be pre-formed within the grooves 38a-d of each frame member 12a-d. Furthermore, in
another embodiment, the plurality of gaskets 44 and/or corner spacers 40a-d may be
omitted.
[0091] An alternative method of assembling a fenestration unit is illustrated in Figures
8A-B.
[0092] In a first step of this alternative method, first and second connectors are applied
to the hollow profile 22a of the first frame member 12a, as has been described previously.
Further connectors are also applied to the hollow profile of the fourth frame member
12d at respective openings located at the bevelled edge 13g in substantially the same
way as has previously been described.
[0093] The first frame member 12a is then abutted with the second frame member 12b and the
fourth frame member 12b is abutted with the third frame member 12c such that the bevelled
edge 13b of the first frame member 12a interfaces with the bevelled edge 13c of the
second frame member 12b to form the mitre joint 10a, and the bevelled edge 13g of
the fourth frame member 12d interfaces with the bevelled edge 13f of the third frame
member 12c to form the mitre joint 10c. As the first frame member 12a is abutted with
the second frame member 12b, the second arms of the respective connectors are located
within the hollow profile 22b of the second frame member 12b. Similarly, as the fourth
frame member 12d is abutted with the third frame member 12c, the second arms of the
respective connectors are located within the hollow profile of the third frame member
12c. The connectors are then secured at the respective mitre joints 10a, 10c in the
same way as has been previously described so as to secure the first and second 12a,
12b and third and fourth 12c, 12d frame members respectively thereby providing a pair
of corresponding L-shaped members 50, 52, as shown in Figure 8B.
[0094] In the method described in Figure 8, the corner spacers 40a-d can be applied to the
panel 3 in substantially the same way as has been described in Figure 7. Alternatively,
corner spacers 40a and 40c may instead be located within the groove 38 formed at the
mitre joints 10a, 10c of the respective L-shaped members 50, 52.
[0095] Further connectors are then applied to the hollow profiles of the first and second
frame members 12a, 12b located at bevelled edges 13a and 13d respectively. The first
and second L-shaped members 50, 52 are then substantially simultaneously located about
the panel 3 such that the panel 3 is received within the groove 38 of the first and
second 12a, 12b and third and fourth frame members 12c, 12d. As the L-shaped members
50, 52 are located about the panel, the second and third frame members 12b, 12c and
the first and fourth frame member 12a, 12d subsequently abut with each other such
that the bevelled edge 13a of the first frame member 12a interfaces with the bevelled
edge 13h of the fourth frame member 12d to form the mitre joint 10d and the bevelled
edge 13d of the second frame member 12b interfaces with the bevelled edge 13e of the
third frame member 12c to form the mitre joint 10b. The connectors are then be secured
at the respective mitre joints 10b, 10d in the same way as has been previously described
to secure the corresponding L-shaped members 50, 52 thereby completing the assembly
of the fenestration unit.
[0096] It shall be noted that the frame members and connectors may be assembled in an alternative
order, depending on preference.
[0097] The plurality of gaskets may then be applied in substantially the same way as has
been described previously, although it shall also be appreciated that this step may
be omitted.
[0098] Yet a further alternative method of assembling a fenestration unit is illustrated
in Figure 9.
[0099] In a first step of this alternative method, first and second connectors are applied
to the hollow profile of the second frame member 12b at respective openings located
at the bevelled edge 13d in substantially the same way as has been described previously.
Further connectors are also applied to the hollow profile of the fourth frame member
12d at respective openings located at the bevelled edge 13g in substantially the same
way as has previously been described.
[0100] The second, third and fourth frame members 12b, 12c, 12d are then abutted with each
other, as shown in Figure 9B, such that the bevelled edge 13d of the second frame
member 12b interfaces with the bevelled edge 13e of the third frame member 12c to
form the mitre joint 10b, and the bevelled edge 13g of the fourth frame member 12d
interfaces with the bevelled edge 13f of the third frame member 12c to form the mitre
joint 10c. As the frame members 12 are abutted, the second arms of the respective
connectors become located within the respective hollow profiles of the third frame
member 12c located at the bevelled edges 13e and 13f respectively. The connectors
are then be secured at the respective mitre joints 10b, 10c in the same way as has
been previously described so as to secure the second, third and fourth frame members
12b, 12c, 12d thereby forming a U-shaped member 54.
[0101] Once the U-shaped member 54 has been provided, the corner spacers 40a-d can be applied
to the panel 3 in substantially the same way as has been described in Figure 7. Alternatively,
corner spacers 40b and 40c may instead be located within the groove 38 formed at each
mitre joint 10b, 10c of the U-shaped member 54. The U-shaped member 54 is then located
about the panel 3 via sliding the panel 38 into the respective grooves 38b-d of the
second, third and fourth frame members 12b, 12c, 12d, which make up the U-shaped member
54.
[0102] Further connectors are then applied to the hollow profile 22a of the first frame
member 12a, located at bevelled edges 13a and 13b respectively.
[0103] The first frame member 12a is then located about the panel 3, as illustrated in Figure
9D, such that the panel 3 is received within the groove 38a of the first frame member
12a. As the first frame member 12a is applied, and the second arms of the further
connectors become located within the hollow profiles of the second frame member 12b,
located at the bevelled edge 13c, and the fourth frame member, located at the bevelled
edge 13h. As the first frame member 12a is located about the panel 3, first frame
member 12a abuts the second and fourth frame members 12b, 12d such that the bevelled
edge 13a of the first frame member 12b interfaces with the bevelled edge 13h of the
fourth frame member 12d and the bevelled edge 13b of the first frame member 12a interfaces
with the bevelled edge 13c of the second frame member 12b to form mitre joints 10a
and 10d respective. The connectors can then be secured at the mitre joints 10a, 10d
via engaging an Allen key, or other suitable tool, with the respective fastener 18a,
18b of each connector, via access apertures 26, 28, thereby completing the assembly
of the fenestration unit.
[0104] The plurality of gaskets may then be applied in substantially the same way as has
been described previously, although it shall also be appreciated that this step may
be omitted.
[0105] It shall be noted that the frame members and connectors may be assembled in an alternative
order, depending on preference.
[0106] Both alternative methods described in Figures 8 and 9 reduce the number of joints
required to complete the fenestration unit once the panel is in place. This provides
the advantageous effect of reducing installation times, since it is often more difficult
to assemble a joint once the panel is in place. This also reduces the likelihood of
damage to the panel during installation.
[0107] Furthermore, by enabling the panel to be slid into position, the method described
in Figure 9 has the further advantage of enabling the frame members to be more easily
located about the panel, thereby allowing for easier and faster assembly of the fenestration
unit.
[0108] Whichever method is employed, it will be appreciated that mounting the pane or panel
within a groove defined by fixed upstanding projections enhances the security of the
frame assembly, whilst allowing for fast and simple assembly compared with known approaches
that utilise a removable bead.
[0109] It should be noted that although the methods illustrated in Figures 7-9 are described
as using the connectors 16 as described in Figure 4, it shall be appreciated that
any other suitable connector type may be used. For example, in methods using a screw
connector, the connectors may be instead be applied after the respective frame members
have been abutted.
[0110] Where the word 'or' appears this is to be construed to mean 'and/or' such that items
referred to are not necessarily mutually exclusive and may be used in any appropriate
combination.
[0111] Although the invention has been described above with reference to one or more preferred
embodiments, it will be appreciated that various changes or modifications may be made
without departing from the scope of the invention as defined in the appended claims.
1. A beadless frame assembly for a fenestration unit, the frame assembly comprising:
a plurality of frame members, each frame member comprising a pair of bevelled edges
configured to interface with a respective bevelled edge of a neighbouring frame member
so as to form a mitre joint; and
a plurality of connectors configured to secure neighbouring frame members at each
of the respective of mitre joints, wherein each of the frame members comprise a groove
for receiving a panel of the fenestration unit, and wherein the frame assembly is
a metallic frame assembly.
2. The beadless frame assembly of claim 1 wherein each of the frame members comprises
an internal profile section and an external profile section and a thermal break sandwiched
between the internal profile section and the external profile section.
3. The beadless frame assembly of claim 2 wherein the internal and external profile sections
comprise a body portion and an upstanding projection, the upstanding projections defining
the groove.
4. The beadless frame assembly according to any preceding claim, wherein the frame assembly
further comprises a plurality of corner spacers configured to be received within the
groove of each frame member at each of the respective mitre joints, optionally wherein
the plurality of corner spacers are substantially L-shaped, optionally wherein the
plurality of corner spacers each comprise at least one corner gasket comprising a
resilient material, preferably a rubber-like material, and most preferably EDPM.
5. The beadless frame assembly according to claim 4, wherein the plurality of corner
spacers each comprise a groove configured to receive a corner of the panel of the
fenestration unit.
6. A beadless frame assembly according to any preceding claim, wherein each connector
comprises first and second fasteners configured to secure respective neighbouring
frame members to the connector.
7. The beadless frame assembly according to any preceding claim, wherein the plurality
of frame members each define a hollow profile having at least one opening at a respective
bevelled edge of each frame member, each opening being configured to receive one of
the plurality of connectors; and wherein each of the plurality of connectors comprises
a first arm configured to extend within a hollow profile defined by a first frame
member, and a second arm configured to extend within a hollow profile defined by a
second frame member.
8. The beadless frame assembly according to claim 6 or 7, wherein each fastener is a
threaded fastener, preferably wherein each fastener is a self-tapping threaded fastener,
and/or wherein each fastener comprises a frusto-conical leading end.
9. The beadless frame assembly according to any preceding claim, further comprising at
least one mount located at an external surface of the frame assembly, the at least
one mount being configured to releasably secure the beadless frame assembly within
a casing.
10. A kit of parts for assembling a fenestration unit, the kit of parts comprising:
a beadless frame assembly according to any preceding claim; and
a panel configured to be received within the beadless frame assembly.
11. A fenestration unit comprising a panel and the beadless frame assembly according to
any preceding claim.
12. A method of assembling a fenestration unit comprising the steps of:
a) providing a plurality of metallic frame members, each frame member comprising a
pair of bevelled edges and a groove for receiving a panel of the fenestration unit;
b) locating a first frame member about a panel, such that the panel is received within
the groove of a first frame member;
c) abutting a second frame member with the first frame member such that the panel
is received within the groove of the second frame, and such that at least one bevelled
edge of the first frame member and at least one bevelled edge of the second frame
member interface to form a mitre joint; and
d) securing a connector at the mitre joint so as to secure the first and second frame
members.
13. The method according to claim 12, wherein the plurality of metallic frame members
comprise at least three metallic frame members, the method further comprising the
steps of:
abutting a portion of the frame members such that at least one bevelled edge of each
frame member interfaces to form a mitre joint; and
securing a respective connector at the mitre joint so as to secure the frame members
thereby forming the first frame member, wherein the steps of abutting and securing
the first frame member take place prior to locating the first frame member about the
panel.
14. The method according to claim 12 or claim 13 further comprising the steps of:
providing at least one gasket; and
locating said at least one gasket about each of the plurality of metallic frame members;
optionally wherein the step of locating said at least one gasket about each of the
plurality of metallic frame members takes place after the first frame member and second
frame member have been secured.
15. A frame member for constructing a beadless frame assembly, the frame member comprising
bevelled edges configured to interface with a respective bevelled edge of a neighbouring
frame member so as to form a mitre joint; and wherein each of the frame members comprises
an internal profile section and an external profile section and a thermal break sandwiched
between the internal profile section and the external profile section.