INSTALLATION SPACER AND USE OF SUCH A DEVICE

Abstract

 An installation spacer (20) for guiding a fastener (50) when fixing a building component (40) such as a door or a window frame to a wall (45) comprises an essentially flat mounting base (22) defining a base plane (21), a guiding tube (26) with a central through hole (29) around its longitudinal axis (25) and a first end (27) and a second end (28) and a wedge element (24) fixedly connecting said guide tube (26) with the mounting base (22). The wedge element is construed to define an acute angle α between the axis (25) and the base plane (21) such that the first end (28) is located closer to the base plane (21) than the second end (28). α is being chosen from a value between 5° to 30°, preferably α is being chosen to be 6°.
A respective method for installing a building component (40) such as a door or a window to a wall (45) includes providing a building component (40) with an outer, frame-like structure which a plurality of installation spacers (20) mounted to the outer frame surface, placing the building component (40) adjacent to a wall opening, aligning the building component (40) in its target position and screwing in a screw (50) through the installation spacer's (20) guiding tube (26) into a section to the wall.

Description

[0001] The present invention addresses the installation of new and/or replacement of older windows and doors in buildings, more precisely the placing and precisely adjusting of such building components relative to the openings of buildings and the structural parts used to allow for that.

BACKGROUND

[0002] Depending on the construction method, the outer frames of building components such as windows and doors can be placed and mounted within a wall opening or in front of it (pre-wall installation). Pre-wall installation of windows has its advantages, because further installations such as plumbing, electrical wiring, heating pipes and insulation can be installed simply on the surface of the load-bearing wall and later be covered by insulation and/or dry-wall construction elements.

PRIOR ART

[0003] Several methods for installing doors and windows in a pre-wall installation situation are known. Very common are steel brackets, angle connectors or metal ribbons (collectively mounting elements) which are on one end attached to the frame of the window/door and on the other end to be attached to the load bearing wall. It is obvious, that windows and doors need to be exactly aligned in order to allow for the building component to function properly. This requires adjustability in all three spatial axes. Traditionally this can be achieved by elongated holes provided in the mounting elements or dedicated adjustment elements, or by inserting spacers, shims or washers in connection with screws, nails or bolts between window and wall.

DRAWBACKS IN THE ART

[0004] While adjusting the height and the tilt of a window can be accomplished by straightening the lower edge of the frame, the distance relative to the wall opening needs to be regulated at several positions of the frame. Figure 1 shows such a common mounting type. An angled bracket 14 is being attached to an edge area 13 of a frame 12 via a screw 18. A further screw 16 is being inserted into a prepared bore in the wall to connect wall 10 and bracket 14. The distance between wall 10 and frame 12 is being adjusted to the specified value by loosening screw 18, aligning the frame 12 and tightening the screw 18 again. The process of loosening and tightening has to be done for each bracket.

[0005] It is the object of the invention to allow for a simplified adjustment process by means of a dedicated installation spacer.

DESCRIPTION OF THE INVENTION

[0006] Such an inventive installation spacer can provide three functions in one component: guiding a fastener when fixing a building component such as a door or a window frame to a wall, permitting to adjust a distance between the wall and the window, and eventually blocking the door or window at said position even against the actions of the other fasteners used in the mounting process, thus preventing any movement of the window.
Such installation spacer essentially comprises three parts. Firstly, an essentially flat mounting base defining a base plane. The mounting base is being used to attach the installation spacer to the frame of a window or door. It goes without saying that the mounting base may be equipped with fixtures known in the art, such as through holes, elongated holes, clip-like elements that support or enable attaching of an installation spacer / mounting base to the frame. The term "essentially flat" indicates that the mounting base needs not to be perfectly flat, but extending in a plane being defined above as base plane. The mounting base may have strengthening ribs or other reinforcing textures.
Secondly, the installation spacer comprises a guiding tube with a central through hole around its longitudinal axis. Said tube has a first end and a second end. Thirdly, a wedge element fixedly connects said guide tube with the mounting base. The term wedge indicates that the wedge element is construed to define an acute angle α between the axis and the base plane such that the first end is located closer to the base plane than the second end. In other words, the tube and its central axis are not arranged in parallel, but inclined relative to each other. Consequently the second end and the axis are aiming away from the mounting base whereas the first end is aiming towards the mounting base.

[0007] Preferably, the wedge element is being construed such that α is being chosen as a value between 5° to 30°, in a second preferred embodiment between 5° to 12° including both values in each case. In a third preferred embodiment, α is being chosen to be 6°. This inclination of the guiding tube relative to the mounting base results in the guiding tube facing away from the frame, when the installation spacer is being installed properly. By this inclination, the edge distance of the fastener in the wall is increased. Furthermore, this inclination contributes to the counterforces of the fasteners' actions towards each other, reinforcing the blocking of any movements of the window, and thus supporting to the keeping of the desired distance.

[0008] Such an installation spacer can preferably be manufactured from a (thermo-) plastic such as PE, PP, PA, PC, PVC or other suitable material. If required, such plastic material can be reinforced by adding glass or carbon fibres for enhanced strength. The preferred method of manufacturing is injection molding.

[0009] While the installation spacer can be used as a pure guiding tube for a fastener such as a screw; it can be further improved by tailoring the inner dimensions specifically. In a first embodiment of that feature, an installation spacer can be construed to exhibit a through hole with at least 2 sections, a first section with a first diameter D1 and a length L1 starting off at the first end and an adjacent second section with a second diameter D2 and a length L2. For the diameter shall be valid D1 > D2. In other words, the diameter of the tube is wider in the first section and narrower in the second. This simplifies introducing the fastener during mounting the frame to a wall opening.
In a further variant an installation spacer can exhibit a third section in said through hole with a third diameter D3 and a length L3, starting off at the second end. Again, D3 is of a different dimension than D2, depending on the application D3>D2 or D3<D2 is valid.

[0010] The installation spacer can be complemented with a fastener to establish a fastener arrangement. Said fastening arrangement comprises an installation spacer as described above and a screw with a core diameter D_C and thread diameter D_T for which is valid D_C ≤ D2 < D_T. By choosing such a diameter range the fastener will, when inserted into the guiding tube, be cutting a thread into the second section of the guiding tube. The advantage of this behavior shall be explained in more detail below with reference to the figures attached.

[0011] In order to describe a method for installing a building component such as a door or a window to a wall, one may look at the following steps. The tasks are described in a logical or proposed chronological order. Intermediate steps are of course possible without compromising the inventive idea behind.
First, a building component needs to be provided with an outer, frame-like structure. The frame is the part to be attached to the wall or wall portion with the respective opening to be covered by the door / window.
As a preparation a plurality of installation spacers as described above will be mounted to the outer frame surface. "Surface of the frame" means the area to be oriented perpendicularly to said wall. The installation spacer(s) are positioned such that the guiding tube is consequently facing the wall with its second end. Then the building component is being placed adjacent to a wall opening and aligned in its target position. Then a screw is being inserted through the installation spacer's guiding tube into a section to the wall and fixated (screwed in). The installation spacer can also be used as drilling jig to guide a drill for creating a properly angled hole at the intended position in the wall.

[0012] In a further variant of the mounting method the screw has a core diameter D_C and thread diameter D_T for which is valid Dc ≤ D2 < D_T resulting in a thread being cut into the inner surface of the guiding tube. Further detailed explanation can be found down below with respect to figure 5-8.

[0013] The context and the figures shown herein tell the man skilled in the art, that the mounting of said building component (door, window) is for an embodiment as shown in Fig. 1 and 2, where the frame of the building component is placed onto or in front of a rigid wall section (pre-wall installation) and not inside an opening - unless it exhibits additional surface areas to allow for such a pre-wall installation).

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] 

Figure 1 shows a prior-art mounting situation with a bracket.

Figure 2 exhibits a mounting situation according to one embodiment of the invention

Figure 3 is a longitudinal section through an inventive installation spacer

Figure 4 is a view onto the first end of such an installation spacer

Figures 5-8 exhibit screws to be advantageously used with an inventive spacer

Figure 9 shows a completed mounting situation of a window in a wall opening.

DETAILED DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 has been referred to in detail in section "drawbacks in the art" above.

[0016] Figure 2 shows a building component 40 (frame) with an installation spacer 20 mounted to the outer frame surface in a cross section. Said surface is shown to be oriented rectangular to wall 45, such that the guiding tube of the installation spacer is facing the wall with its second end. A fastener 50 has been screwed through the guiding tube, which here exhibits a three-section design.

[0017] Figure 3 shows a longitudinal cut through an installation spacer 20. The bottom is formed by mounting base 22 defining a base plane 21. A guide tube 26 is firmly connected to said mounting base 22 via a wedge element 24. The guide tube has a central through hole 29 around a central axis 25. As can be easily understood from figure 3, the wedge element 24 serves the purpose to ensure a defined acute angle α between said axis 25 / through hole 29 and the base plane 21 or mounting base 22. The through hole has 2 openings, a first (lower) end 27 and second (higher) end 28. The terms lower and higher are to be understood as "closer" to the mounting base 22 and higher as "more distant".

[0018] The guide tube 26 or the through hole 29 respectively exhibit a plurality of consecutive sections 31, 32, 33 arranged lengthwise along axis 25. Seen from the lower end / first end 27 a first, short section 31 is followed by a longer section 32. The first section's diameter D1 is larger than the second section's 32 diameter D2. This way a screw to be inserted along axis 25 can use section 31 as a countersunk recess or stop 23 for a screw's head. The screw may have a core diameter D_C and a thread diameter D_T depending on the geometry of the screw, e.g. Dc ≤ D2 < D_T a thread can be cut into the inner surface of the guiding tube 26 by said screw.

[0019] A third section 33 is being shown of a length L3 < L2. This section can be used to allow a dowel attached to the tip of the screw to be retracted into the section 3 which might be helpful when aligning the building component / frame to the wall. The length of guiding tube 26 and the length of respective sections 31, 32, 33 will be chosen and optimized depending on the frame size, the load and the base material the fastener shall be screwed in. L1, L2, L3 designate the lengths of respective sections 31-33.

[0020] Figure 4 is a perspective view onto an installation spacer 20 from the "lower" end (first end 27) onto the guiding tube 26. The wedge element 24 here has been formed from two vertically arranged bars or plates for improved stability. The mounting base 22 is shown as a broad base plate to make room for fixtures to a frame's surface.

[0021] Figure 5 to 8 show various types of fasteners, screws 60, 70, 80, 90 to be advantageously used with an installation spacer 20 as shown in figure 3. The term D_T means "diameter thread" and D_C "diameter core". The additional reference number refers to the respective section of the screw, the numbering starts at the tip towards the head. The screws each exhibit different sections with and without threads. The diameter of the sections may vary. The geometry of the tip shall not be limiting, a man skilled in the art will choose a tip-type known in the art to screw the fastener into bricks, wood, predrilled holes with or without a plastic wall plug.

[0022] Figure 5 shows a common screw with a threaded shaft 61 and a head 69, useful to screw an installation spacer to a wall segment. If thread diameter D_{T 60} is being chosen smaller than D2 of section 32 (cf. figure 3), the screw will be easily inserted through section 32. That way the frame will be pressed to the wall segment as soon as the screw gains grip in the wall and the head hits the recess/stop 23 between section 31 and 32.

[0023] If the diameter D_{T 60} is being chosen larger than D2, then screw 60 will cut a thread into the inner surface of section 32. This way screw 60 will gain grip via section 32 and not necessarily via the stop / recess 23. In this case the screw will be able to withstand both push- and pull-forces, because it is being anchored independently via two different sections. The frame does not need to forcedly contact the wall to be in its final position. The screw in this case acts as a spacer bolt.

[0024] Figure 6 shows a screw 70 with a threaded section 71 including a tip and an unthreaded section 72. Diameter D_{C 70} is the diameter in section 72 as well as core diameter in section 71. If thread diameter D_{T 70} is being chosen smaller than D2 of section 32 (cf. figure 3), the screw will be easily inserted through section 32. If the condition D_{C 70} < D2 < D_{T 70} is met, then section 71 of screw 70 will cut a thread into section 32, but the unthreaded section 72 will not be affected. The connection between frame and wall will be dominated by tensile forces.

[0025] Figure 7 shows a so called stepped screw 80 with three sections 81-83, where the diameter is increasing from section 81 (incl. tip) to 83. A special feature is the headless design with a recessed force application point. The diameters of the individual sections (D_C core diameter, D_T thread diameter) are as follows: D_{C 81} < D_{T 81} < D_{C 82} < D_{C 83} < D_{T 83}. The pitch of the threads in section 81 and 81 is the same.
Diameter D2 of section 32 is preferably chosen to D_{C 82} < D2 < D_{C 83}. This way the stepped screw can be inserted through the guiding tube 26 up and including section 82. Handling is simplified compared to screw 60, because only section 83 will cut a thread into section 32 of the installation spacer.

[0026] A further variant of mounting can be achieved by screw 90 of figure 8. Here, in analogy to figure 7, is valid for the diameters: D_{C 91} < D_{T 91} < D_{C 92} < D_{C 93} < D_{T 93}. Screw 90 has a head 99; the pitches in section 91 and 93 are different. Thus, the screw 90 can be used as spacer bolt as described for figure 60. However, due to the difference in pitches between section 91 and 93, the forward feed per turn is different for section 91 and 93. This results in a fine-tuning possibility of the distance between frame (installation spacer) and wall.

[0027] As stated, all four screws can be advantageously be used with the inventive installation spacer, depending on the choice of diameters.

[0028] Figure 9 shows a completed mounting situation of a window (building component 40) at a wall opening 44. Inside in this drawing is on the left, outside on the right. The window area is being shown in reduced scale as indicated by the bent line. The window is attached to a rigid wall segment 45, on the inside an insulation layer 46 has been affixed covered again by an inner lining 48 (plaster, gypsum board or alike). A cover 42 bridges the gap between window and inner lining 48 thus hiding the space used for the installation spacer 20.

[0029] Installation spacer 20 have been attached to the outer frame surface of said window, here shown on opposing sides of the frame. The number of installation spacer used will depend on the weight and size of the window (building component 40) and will be chosen by the man skilled in the art based on building regulations or specifications of the window manufacturer. The window will be fixedly attached to the wall 45 with the aid of screws 50 via the installation spacer 20. A seal or dampening layer 49 may help to avoid any leak of air between inside and outside.

[0030] The specific angle α (as described above) effects the screws 50 to be tilted outwardly, away from the building component 40. This results in an increase of the effective anchoring length of screw 50 in the wall compared to a rectangular setting. The screw shown does not require a plastic wall plug.

[0031] For the ease of understanding essential parts of installation spacer 20 have been again shown in lower figure 9: installation layer 20 comprising an essentially flat mounting base 22, the wedge element 24 and guiding tube 26 with its first end 27 and second end 28.

Claims

1. Installation spacer (20) for guiding a fastener (50) when fixing a building component (40) such as a door or a window frame to a wall (45), comprising:

- an essentially flat mounting base (22) defining a base plane (21),

- a guiding tube (26) with a central through hole (29) around its longitudinal axis (25) and a first end (27) and a second end (28)

- and a wedge element (24) fixedly connecting said guide tube (26) with the mounting base (22)

characterized in that
the wedge element is construed to define an acute angle α between the axis (25) and the base plane (21) such that the first end (28) is located closer to the base plane (21) than the second end (28).

2. Installation spacer (20) according to claim 1, characterized in that α is being chosen from a value between 5° to 30° including both values.

3. Installation spacer (20) according to claim 1-2, characterized in that α is being chosen from a value between 5° to 12° including both values.

4. Installation spacer (20) according to claim 1 -3, characterized in that α is being chosen to be 6°.

5. Installation spacer (20) according to claims 1-4, characterized in that the installation spacer (20) is made from plastic such as PE, PP, PA, PC, PVC preferably by injection moulding.

6. Installation spacer (20) according to claims 1-5, characterized in that the through hole (29) has at least 2 sections, a first section (31) with a first diameter D1 and a length L1 starting off at the first end (27) and an adjacent second section (32) with a second diameter D2 and a length L2, for which is valid D1 > D2.

7. Installation spacer (20) according to claim 6, characterized in that through hole (29) has a third section (33) with a third diameter D3 and a length L3, starting off at the second end (28), for which is valid D3 > D2.

8. Installation spacer (20) according to claim 6, characterized in that through hole (29) has a third section (33) with a third diameter D3 and a length L3, starting off at the second end (28), for which is valid D3 < D2.

9. Fastening arrangement comprising an installation spacer (20) according to claims 1-8 and a fastener (50), characterized in that the fastener is a screw with a core diameter D_C and thread diameter D_T for which is valid Dc ≤ D2 < D_T.

10. Method for installing a building component (40) such as a door or a window to a wall (45), the method comprising:

- providing a building component (40) with an outer, frame-like structure

- mounting a plurality of installation spacers (20) according to claims 1 - 6 to the outer frame surface to be oriented rectangular to said wall, such that the guiding tube (26) is facing the wall with its second end (28)

- placing the building component (40) adjacent to a wall opening

- aligning the building component (40) in its target position

- screwing in a screw (50) through the installation spacer's (20) guiding tube (26) into a section to the wall.

11. Method according to claim 10, characterized in that before screwing in the screw (50) a pre-drilling takes place, wherein a drill uses guiding tube (26) as drilling jig.

12. Method according to claims 10-11, characterized in that the screw (50) has a core diameter D_C and thread diameter D_T for which is valid Dc ≤ D2 < D_T resulting in a thread being cut into the inner surface of the guiding tube (26).

Drawing