AU1650699A - Window or door frame - Google Patents

Description

WO 99/32750 PCT/AU98/01042 -1 WINDOW OR DOOR FRAME FIELD OF THE INVENTION The present invention relates generally to a new wall opening surround structure and to an associated method of construction. The invention also relates to 5 improvements in window and door frame elements specifically designed for installation with a wall opening surround structure of this kind. BACKGROUND OF THE INVENTION Hollow extruded aluminium, PVC or steel door and window systems have been in use for many years as a durable, relatively low cost alternatives to their wooden 10 equivalents. However, whilst there are a number of high quality products which are relatively appealing in an aesthetic sense, there is a general perception amongst the public that windows and doors of this kind often look "cheap" because of their small frame cross section sizes compared to those having profiled timber frames. The problem is exacerbated where the window or door is installed in a dwelling 15 clad with plank siding or fibre cement sheeting and the like, since, because of the lack of thickness in the wall which gives more interior room space, it may be difficult to recess the frame into the wall to provide an aesthetically pleasing surround or reveal. Brick clad wall constructions, on the other hand, are particularly suited, due to their thickness, to formation of deep inset external reveals that effectively frame the 20 window or door opening, which is a factor in the perceived aesthetic superiority of masonry dwellings over plank or sheet clad dwellings. While special preformed surround elements may be used in clad dwellings, such componentary is usually expensive and/or labour intensive to install. Furthermore, the preformed surrounds or WO 99/32750 PCT/AU98/01042 -2 trim units are commonly installed such that they simply abut the frame like picture frames fastened to the cladding. Installation of such trim units requires that an appropriate sealant be meticulously applied at the junction between the frame and the surround to ensure an adequate weather seal. These factors add to the time and cost of 5 construction. It is an object of the present invention to provide a new wall opening surround structure, and an optionally associated improved system of window/door frame elements particularly suited for installation with the new surround structure, which overcomes or ameliorates one or more of the above disadvantages of the prior art, or at 10 least offers a useful alternative thereto. In this regard, the term "surround" will be used herein to refer to any structure around a wall opening such as a door or window which includes within its scope an internal or external reveal or surround for the sill, jamb and head elements of the window or door frame. However, the term "surround" as used herein excludes any 15 paneling or structural members of the wall itself. With any window or door structure, it is most important for structural, sealing and aesthetic purposes, that the window or door frame elements be neatly and accurately connected with the opening surround structure. For these reasons, and to minimise the skill level required for installation, a new window/door frame element 20 has been developed. DISCLOSURE OF THE INVENTION Accordingly, the present invention provides a frame element for use in a window or door frame, the frame element including a longitudinal frame portion, and WO 99/32750 PCT/AU98/01042 -3 a longitudinal retaining formation associated therewith, the retaining formation being configured to retain a longitudinal edge of a generally planar building panel such that the edge is disposed between the lateral edges of the frame portion, wherein the building panel forms a surround adjacent the frame element when installed. 5 Preferably, the retaining formation is configured such that, when installed, the building panel forms a reveal which extends generally away from the window or door frame. Desirably, the building panels comprise sheets of fibre reinforced cement (FRC) or steel. However, in some applications the internal reveals may also be made from 10 timber or plasterboard. In some forms, the frame element retaining formation defines a longitudinal channel to retain the longitudinal edge. Preferably, the channel is configured to retain the longitudinal edge by means of a close or sliding fit. In other embodiments, the interior walls of the channel may include one or more raised formations, such as 15 longitudinal ridges, to optionally receive alternative clip in components. In a particularly preferred embodiment, the ridges are configured to allow snap-fit interconnection of the retaining means with another window element. Desirably, for exterior window and door surrounds at least one edge adjacent the channel incorporates a sealing strip which, in use, abuts the building panel to reduce 20 the ingress of moisture or drafts. In one embodiment where the surround is configured to form a sill oriented so as to be generally outwardly and downwardly inclined on installation. The surround is conveniently fabricated by adhering sheets of fibre reinforced cement directly onto a WO 99/32750 PCT/AU98/01042 -4 preformed core element of expanded polystyrene foam or the like. Desirably, the sheets of fibre reinforced cement are adhered to the core element by means of a suitable contact adhesive. Preferably, an epoxy based adhesive is used at the corners to join the fibre reinforced cement sheets, as this is both weather resistant as well as 5 providing a strong joint. Alternatively, the corners may be sealed using a suitable flexible acrylic, silicone or siliconised acrylic or other resilient weather resistant compound. In other embodiments, the building panel is back filled with a suitable filling material such as a formaldehyde based foam, or light weight aggregate concrete etc. 10 It will be appreciated by those skilled in the art, that the novel wall opening surround structure of the invention facilitates a very cost effective means of providing a window, door or other wall opening surround structure, that may be conveniently sealed against wind and rain driven moisture, has the aesthetic appeal of a masonry or full timber structure and yet is completely compatible with most clad dwelling 15 structures as well as brick. In one form the retaining formation is formed integrally with the longitudinal frame portion. However, in other embodiments, the retaining formation is formed separately from the longitudinal frame portion, and in this embodiment, is configured for attachment thereto prior to or during installation. In this embodiment, the retaining 20 formation is preferably attached to the longitudinal frame portion prior to installation, using, for example, rivets, screws, an interlocking clip system or adhesive.

WO 99/32750 PCT/AU98/01042 -5 In one preferred embodiment, a pair of retaining formations are provided to retain internal and external building panels respectively. The building panels, when installed, define corresponding internal and external reveals. In the preferred embodiments of the invention sheets of fibre reinforced cement 5 are used having a thickness of between 3mm and 20mm. BRIEF DESCRIPTION OF THE DRAWINGS Various aspects of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1 is a cross sectional view of the sill portion of a window surround 10 structure according to the present invention; Figure 2 is a cross sectional view of the head portion of a window surround structure according to the present invention; Figure 3 is a cross sectional view of a jamb portion of a window surround structure according to the present invention; 15 Figure 4 is a cross sectional view of a window surround structure in accordance with the invention utilising a window frame element having an integral retaining formation; Figure 5 is a cross sectional view illustrating two alternative embodiment window surround structures in accordance with the invention used in association with 20 two alternative window frame elements; Figure 6 is a sectional view of a further embodiment window surround structure according to the invention in association with a further embodiment of a suitable frame element; WO 99/32750 PCT/AU98/01042 -6 Figure 7 is a perspective view of another window surround structure in accordance with the invention in association with a further embodiment of a suitable frame element; Figure 8 is a transverse sectional view of the assembly shown in figure 7; 5 Figure 9 is a perspective view of another window surround structure in accordance with the invention in association with a further embodiment of a suitable frame element; Figure 10 is a transverse sectional view of the assembly shown in figure 9. Figure 11 is a perspective view of another window surround structure in 10 accordance with the first aspect of the invention in association with a further embodiment frame element in accordance with the second aspect of the invention; and Figure 12 is a transverse sectional view of the assembly shown in figure 11. PREFERRED EMBODIMENT OF THE INVENTION Referring to figure 1 there is shown a transverse sectional view of the sill 15 portion of a window opening including a structural wall support member 1 to which is secured an external surround structure 2 and a window frame element 3. The frame element 3 is fixed to an elongate timber wedge section 8 via fixing elements 7 secured through nailing fin 6. Wooden packing 9 is placed between the timber wedge 8 and the wall support 1 to accurately position the frame element 3. Fixing elements (not 20 shown) extend through the timber wedge 8 into the wall support 1 to secure the frame to the wall. Surround 2 is retained between the timber wedge 8 and the frame element 3 such that its longitudinal edge 15 is positioned between the lateral edges 26, 27 of the frame portion 14 of the frame element 3. Given the normal drainage WO 99/32750 PCT/AU98/01042 -7 characteristics of wind driven rain, by concealing the longitudinal edge 15 between the lateral edges of the frame portion 14 an effective weather seal against the ingress of moisture may be conveniently formed. Furthermore, this configuration allows the surround to be secured to the frame element with fixing elements in a simple and time 5 efficient manner. Obviously, this ultimately reduces the overall construction costs. Construction of the wall may also conveniently include the injection of expanding polyurethane foam into the cavity formed between the frame element 3 and wedge 8 into which is embedded the surround 2. Further sealing is provided by a water proof membrane 5 fitted beneath the sill surround 2 and extending between the 10 sill surround 2 and the external wall panel 11. For aesthetic purposes an outer coating or rendering 4 may be applied to the external surface of the sill surround 2 and external wall panel 11 which in turn conceals a 25 mm concrete render 17 in accordance with the applicant's Australian copending Provisional Patent Application No. PO7347. 15 On the interior of the wall, the frame element 3 is fixed to timber trim 13 through fixing elements (not shown) secured to the nailing fin 6 or wedge 8. The trim 13 includes a rebate formed to receive the interior panel 12 and the join between the interior trim 13 and panel 12 is concealed by architrave 10. Figures 2 and 3 show sectional views of the head and jamb respectively. In 20 these figures, the same reference numeral has been used to indicate corresponding parts. Frame element 3 is fixed to elongate wooden section 18 with fixing elements (not shown) secured through nailing fin 6. This presents a formation in which surround 20 is retained such that its longitudinal edge 15 is concealed between the WO 99/32750 PCT/AU98/01042 -8 lateral sides of the frame portion 14 of the frame element 3. As with the sill shown in figure 1, the cavity between the frame element 3 and the surround 20 may be filled with expanding polyurethane foam 16. Furthermore, the aesthetics of the windows surround may be improved with an external coating 4. Exterior wall panel 11 and 5 interior wall panel 12 are fixed directly to a structural element of the wall 1 and may be provided with insulation 19 sandwiched between them. Again a rebated interior wooden trim 13 abuts the frame element 3 such that the rebate engages the edge of the interior panel 12. Architrave 10 conceals the join between the trim 13 and the panel 12. 10 As with the sill section shown in figure 1, the head and jam sections are also configured such that an effective weather seal may be provided between the frame element 3 and surround 20. Referring to figure 4, there is shown a transverse sectional view of a window opening including a structural wall support member 1 to which has been secured an 15 external surround structure 2 and a window frame element 3 in accordance with the invention and an internal wall facing 4. The surround structure 2 comprises an elongate angle or channel element shown generally at 5 defining a first surface 6 that extends generally away from the plane of the opening 7 and a second surface 8 that is contiguous with a distal edge 9 of the first 20 surface 6, the second surface extending in this particular embodiment in a direction generally parallel to the plane of the opening 7. These first and second surfaces are defined by interconnected sheets of durable sheet material such as fibre reinforced cement (FRC) or steel.

WO 99/32750 PCT/AU98/01042 -9 In the embodiment shown in figure 4, the surround structure 2 also defines a third surface 10 that extends from an edge 11 of the second surface remote from the first surface, so as to return generally inwardly toward the wall surface 12 adjacent the window opening. In this manner the resulting structure is generally channel shaped in 5 cross section with side elements of uneven depth defining externally a rebated surround with a solid appearance resembling that of equivalent masonry or wooden structures. Turning next to the longitudinal frame element 3, it can be seen to have an inner surface 28 adjacent the window, light or sash and an outer surface 14 disposed 10 adjacent the wall structural member 1 partly defining the wall opening. Provided adjacent one or both of the outside and inside edges 26 and 27 are retaining formations 17 and 18. Referring firstly to the outside retaining formation 17, it can be seen that in this preferred form it comprises a channel like structure which is adapted to locate by 15 preferably a sliding fit a longitudinal edge of a generally planar building panel such as that defining the first surface 6 of the window/door surround 2. In this manner, a neat, weatherproof and fast jointing of the frame element to the surrounding structure is readily achieved. In this particular embodiment, the internal retaining formation 18 engages a 20 "clip in" trim element which is adapted to extend from the frame element 3 to the internal wall facing 4. To facilitate the attachment of such "clip in" fixtures, the retaining formation or channels of this particular embodiment include longitudinally extending fastening ridges shown generally at 20.

WO 99/32750 PCT/AU98/01042 -10 Referring next to figure 5, there is shown a vertical section through the upper and lower wall sections of a window opening in a clad dwelling structure, and wherever possible, like reference numerals are used to denote corresponding features. This particular figure illustrates the use of two separate types of frame element, the 5 upper adapted to facilitate construction of a generally horizontally extending generally rectangular sectioned surround structure, of the kind shown in figure 4, whilst the lower frame element is configured to engage directly with a surround structure in the form of a sill, both surround structures being fabricated in accordance with a first aspect of the invention. In the case of the sill, the first surface 6 is inclined generally 10 outwardly and downwardly from the window opening and the second surface 8 extends inwardly and downwardly so as to be inclined back towards the lower wall surface 12. As described above, the upper surround structure and sill structure are preferably fabricated by adhering sheets of fibre reinforced cement directly onto a preformed core 15 element 24 of expanded polystyrene foam or the like. Alternatively, the structure maybe hollow. Where a preformed core element is used, the sheets of fibre reinforced cement are preferably adhered to that core element by means of a suitable contact adhesive. However, an epoxy based adhesive is preferred for use at the corners to join the fibre reinforced cement sheets, as this is both water resistant as well as providing a 20 strong joint. Alternatively, the corners maybe sealed using a suitable flexible acrylic, silicone or siliconised acrylic or other resilient weather resistant compound.

WO 99/32750 PCT/AU98/01042 -11 In other embodiments that are not illustrated herein, the interconnected angle or channel-like outer surround structure is back filled with a suitable filling material such as a formaldehyde based foam or light weight aggregate concrete etc. Turning next to figure 6, there is shown yet a further variation of both the 5 surround structure and the frame element as applied once again to a clad dwelling. In this particular embodiment, the external retaining formation 17 is formed in the frame element 3 by means of separately manufactured frame element 21, in the form of a simple angle section, which is secured to the main frame element 3 by any suitable manner such as riveting as shown. In this case, the frame element 3 is attached to an 10 internal timber reveal 22 which in turn is connected to the structural wall support element 1 which may be a timber or steel stud. Turning next to figures 7 and 8, there is shown yet a further variation on the same theme. In this particular embodiment, the outside retaining formation 17 of the frame element 3 is formed as part of a separate slot in mounting element 23 thereby 15 enabling the same outer frame sill element 3 to be used in numerous applications by substitution of different mounting elements 23. The versatility of such an arrangement is clearly illustrated in the remaining figures 9 to 12 which illustrate how the same basic frame element 3 can be readily adapted for brick veneer structures incorporating a plaster board return 25 (as shown in figures 9 and 10), or brick veneer structures 20 incorporating a timber reveal 22 (as shown in figures 11 and 12). The present invention provides a quick and cost effective way of forming a wall opening surround such as a reveal or sill around a window or door frame, which may relatively inexpensively simulate a solid masonry equivalent and yet maintain a WO 99/32750 PCT/AU98/01042 - 12 configuration that is easily sealable against the ingress of moisture. Further, by coupling this structure with a preferred frame structure in accordance with the second aspect of the invention, accurate and neat interconnection of the window or door frame to the adjacent surround structure is greatly simplified. 5 Although the invention has been described with reference to a number of specific embodiments, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Claims (21)

1. A frame element for use in a window or door frame, the frame element including: a longitudinal frame portion and a longitudinal retaining formation associated 5 therewith, the retaining formation being configured to retain a longitudinal edge of a generally planar building panel such that the edge is disposed between the lateral edges of the frame portion wherein the building panel forms a surround adjacent the frame element when installed.

2. A frame element according to claim 1 wherein the retaining formation defines 10 a longitudinal channel to retain the longitudinal edge of the building panel.

3. A frame element according to claim 2 wherein the channel is configured to retain the longitudinal edge by means of a close or sliding fit.

4. A frame element according to claim 2 or claim 3 wherein the interior walls of the channel include one or more raised formations. 15

5. A frame element according to claim 4 wherein the raised formations are longitudinal ridges adapted to receive complementary clip in components or allow snap fit interconnection of the retaining formation with a complementary window element.

6. A frame element according to any one of claims 2 to 5 wherein at least one 20 edge of the channel incorporates a sealing strip which in use abuts the building panel to reduce the ingress of moisture or drafts. WO 99/32750 PCT/AU98/01042 - 14

7. A frame element according to any one of claims 1 to 6 wherein the retaining formation is configured such that when installed, the building panel forms a reveal which extends generally away from the window or door frame.

8. A frame element according to any one of claims 1 to 7 wherein the surround 5 is configured to form a sill oriented so as to be generally outwardly and downwardly inclined on installation.

9. A frame element according to any one of claims 1 to 8 wherein the surround is fabricated by adhering sheets of fibre reinforced cement directly onto a preformed core element of expanded polystyrene foam.

10 10. A frame element according to claim 9 wherein the sheets of fibre reinforced cement are adhered to the core element by means of a contact adhesive.

11. A frame element according to claim 10 wherein the epoxy based adhesive is used at the corners to join the fibre reinforced cement sheets.

12. A frame element according to any one of claims 9 to 11 wherein the corners 15 are joined and/or sealed using a suitable flexible acrylic, silicone or siliconised acrylic or other resilient weather resistant compound.

13. A frame element according to any one of claims 1 to 12 wherein the retaining formation is at least partially filled with a suitable sealing material.

14. A frame element according to claim 13 wherein the filling material is a 20 formaldehyde based foam or lightweight aggregate concrete.

15. A frame element according to any one of claims 1 to 14 wherein the retaining formation is formed integrally with the longitudinal frame portion. WO 99/32750 PCT/AU98/01042 - 15

16. A frame element according to any one of claims 1 to 14 wherein the retaining formation is formed separately from the longitudinal frame portion.

17. A frame element according to claim 16 wherein the retaining formation is configured for attachment to the frame portion prior to installation. 5

18. A frame element according to claim 17 wherein the retaining formation is attached to the frame portion using rivets, staples, nails, screws, adhesive or a complementary interlocking snap fit system.

19. A frame element according to any one of claims 1 to 18 wherein a pair of retaining formations are provided to retain internal and external generally planar 10 building panels respectively.

20. A frame element according to claim 19 wherein when installed, the generally planar internal and external building panels define corresponding internal and external reveals.

21. A frame element according to claim 20 wherein the generally planar building 15 panels are sheets of fibre reinforced cement between 3 mm and 20 mm thick.