AU2019101066B4

AU2019101066B4 - Screen frame assembly

Info

Publication number: AU2019101066B4
Application number: AU2019101066A
Authority: AU
Inventors: Mile Krstanoski
Original assignee: Securemesh Pty Ltd
Current assignee: Securemesh Pty Ltd
Priority date: 2019-06-11
Filing date: 2019-09-16
Publication date: 2020-01-02
Anticipated expiration: 2027-09-16
Also published as: AU2020100735A4; AU2019226147B1; AU2019101066A4; AU2020100735B4

Abstract

A frame assembly for a screen, comprising at least one frame member that comprises an end wall and opposed first and second side walls that together form a channel for receiving an edge section of the screen. The frame member also comprises first and second channel inserts adapted to be inserted into the channel in turn one before and one after the edge section is inserted into the channel such that the edge section is sandwiched between the channel inserts. The first channel insert comprises a deformable side portion that faces the first side wall when the first channel insert is in the channel. The frame member also comprises one or more protuberances extending from the first side wall inwardly into the channel. Each of the protuberances is adapted to press into and deform the deformable side portion, and thereby form an indentation in the deformable side portion, when the second channel insert is forced into the channel. At least the first and second side walls are made of aluminium.

Description

SCREEN FRAME ASSEMBLY Field

[0001] The present invention relates to a frame assembly for a screen.

Background

[0002] Screen doors are ancillary doors that are mounted in a building's doorway external to the main door. Screen doors are occasionally referred to as security screens and typically comprise an outer metal frame assembly that borders and retains a rectangular screen therein. The screen may comprise a metal mesh screen or similar flat metal structure. In hot climates, screen doors enable the main door of a building to be left open and provide a barrier that stops flying insects and airborne debris from entering into the building while allowing for ventilation. In cold climates, screen doors are used to protect the main door from bad weather.

[0003] Screen doors must be constructed so that they provide a strong and resilient barrier to keep the building secure from intruders when the main door is open. The screen is, therefore, often comprised of heavy gauge woven stainless steel mesh and the frame assembly is often made of tough extruded aluminium.

[0004] To attach the screen within the frame assembly, the edges of the screen may slot into an inwardly-facing channel that extends around the perimeter of the frame assembly. Each edge may be secured in the channel using one or more wedge member inserts that are pushed forcefully into the channel either side of the screen edge after it has been slotted into the channel. This attachment mechanism provides some degree of strength and resistance but is not impervious to intruders. For example, using the right tools the inserts can easily be prised out of the channel. Further, when a sufficiently large force is applied to the screen this may cause one or more of its edge sections to be pulled out of the channel.

[0005] In this context, there is a need for improved screen frame assemblies

Summary

[0006] According to the present invention, there is provided a frame assembly for a screen, the frame assembly comprising at least one frame member comprising: an end wall and opposed first and second side walls that together form a channel for receiving an edge section of the screen; first and second channel inserts adapted to be inserted into the channel in turn one before and one after the edge section is inserted into the channel such that the edge section is sandwiched between the channel inserts, wherein the first channel insert comprises a deformable side portion that faces the first side wall when the first channel insert is in the channel; and one or more protuberances extending from the first side wall inwardly into the channel, wherein each of the protuberances is adapted to press into and deform the deformable side portion, and thereby form an indentation in the deformable side portion, when the second channel insert is forced into the channel, wherein at least the first and second side walls are made of aluminium.

[0007] The first channel insert may further comprise a second side portion that is aligned parallel to the deformable side portion and is made of a material that is harder than the deformable side portion.

[0008] The second side portion may be made of a material that is between 2 and 2.5 times harder than the deformable side portion.

[0009] The deformable side portion may be made of a material having a hardness of between 30 to 50 on the Shore 00 hardness scale and the second side portion may be made of a material having a hardness of between 80 to 100 on the Shore 00 hardness scale.

[0010] The deformable side portion may be elastically deformable.

[0011] Each of the protuberances may comprise a pointed apex adapted to pierce a surface of the deformable side portion when the second channel insert is forced into the channel.

[0012] The channel, protuberances and first channel insert may be dimensioned such that each of the protuberances pierces the surface and protrudes into the deformable side portion to a depth of between approximately 0.5 and 1.4 millimeters.

[0013] The second channel insert and the second side wall may comprise co-operating locking means for locking the second channel insert in the channel.

[0014] The second channel insert and second side wall may comprise one or more interconnecting projections and recesses that together provide the co-operating locking means.

[0015] The interconnecting projections and recesses may be oriented diagonally relative to longitudinal axes of the second channel insert and second side wall.

[0016] The first channel insert may comprise a terminal section extending transversely from a lowermost end of the first channel insert, the terminal section being adapted to fit between a lowermost end of the edge section of the screen and the end wall of the channel.

[0017] The second side wall may comprise a flange member inwardly extending into the channel that defines a cavity together with the end wall of the channel, wherein the cavity is adapted to receive an end of the terminal section when the first channel insert is inserted into the channel.

[0018] The flange member may comprise a lowermost surface that impedes removal of the first channel insert from the channel when the end of the terminal section is in the cavity.

[0019] The lowermost surface of the flange member may extend perpendicularly from the second side wall.

[0020] The cavity and the end of the terminal section may be dimensioned such that the end of the terminal section may be spaced apart from the cavity when inserted into the cavity.

[0021] The first channel insert may comprise a lip member extending transversely from an uppermost end of the first channel insert, wherein the lip member abuts an uppermost end of the first side wall when the first channel insert is inserted fully into the channel.

[0022] The first and second channel inserts may each comprise a plurality of toothed members that project inwardly into the channel and engage the edge section of the screen when the edge section is sandwiched between the channel inserts.

[0023] Each of the toothed members may comprise a tapered uppermost surface.

[0024] The present invention also provides a screen assembly for a doorway, wherein the screen assembly comprises the frame assembly described above and a screen secured within the frame assembly.

[0025] The present invention also provides a process for manufacturing the frame assembly described above, wherein the process comprises forming the deformable side portion and the second side portion of the first channel insert using a co-extrusion process.

Brief Description of Drawings

[0026] Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which: Figure 1 is an isometric view of an individual frame member of a frame assembly according to an example embodiment of the invention;

Figure 2 is a side cross-sectional view of an uppermost section of the frame member of Figure 1, wherein the frame member is shown with a first channel insert disposed therein; Figure 3 is a further side cross-sectional view of the uppermost section of the frame member of Figure 1, wherein the frame member is also shown with a screen edge section and second channel insert disposed therein; Figures 4(a) and 4(b) are isometric views of, respectively, first and second channel inserts of the frame member of Figure 1; Figure 5 is an elevated plan view of an example screen installed in the frame assembly; Figure 6 is an isometric view of an individual frame member of a frame assembly according to a further example embodiment of the invention, wherein the frame member is shown with first and second channel inserts disposed therein; and Figure 7 is a side cross-sectional view of an uppermost section of the frame member of Figure 6 shown with first and second channel inserts.

Description of Embodiments

[0027] Referring to Figures 1 to 5, there is provided a frame assembly 10 for a screen 12. The frame assembly 10 comprises at least one frame member 14 comprising an end wall 16 and opposed first and second side walls 18,20 that together form a channel 22 for receiving an edge section 24 of the screen 12. The frame member 14 also comprises first and second channel inserts 26,28 adapted to be inserted into the channel 22 in turn one before and one after the edge section 24 of the screen 12 is inserted into the channel 22 such that the edge section 24 is sandwiched between the channel inserts 26,28. The first channel insert 26 comprises a deformable side portion 30 that faces the first side wall 18 when the first channel insert 26 is in the channel 22. The frame member 14 also comprises one or more protuberances 32 extending from the first side wall 18 inwardly into the channel 22. Each of the protuberances 32 is adapted to press into and deform the deformable side portion 30, and thereby form an indentation in the deformable side portion 30, when the second channel insert 28 is forced into the channel 22.

[0028] More particularly, each of the protuberances 32 may comprise a pointed apex 34. It will be understood that when the second channel insert 28 is being pushed forcefully into the channel 22 between the screen edge section 24 and the second channel side wall 20, the screen edge section 24 is caused to be urged towards the protuberances 32. Consequently, the first channel insert 26 and deformable side portion 30 are also caused to be urged towards the protuberances 32. The protuberances 32 are dimensioned such that when this happens, the pointed apexes 34 press into the deformable side portion 30. This, in turn, causes each of the protuberances 32 to deform and form an indentation in the deformable side portion 30.

[0029] The frame member 14 may comprise a plurality of the protuberances 32 and in the example depicted a total of three protuberances 32 inwardly extending from the first side wall 18.

[0030] The deformable side portion 30 may be elastically deformable. In such examples, when the protuberances 32 are being pressed into the deformable side portion 30 causing it to be deformed, the elastic qualities of the deformable side portion 30 provide that it offers resistance to the protuberances 32. This resistance may cause the pointed apexes 34 to pierce the surface of the deformable side portion 30 and penetrate into the deformable side portion 30 to a particular depth.

[0031] The relative dimensions of the channel 22, the protuberances 32 and the first channel insert 26 will preferably provide that the protuberances 32 pierce the deformable side portion 30 to a depth that allows the protuberances 32 to engage the first channel insert 26 effectively without adversely affecting its structural strength. That is to say, the apexes 34 of the protuberances 32 obtain a strong hold on the channel insert 26 without damaging its structural integrity. If the apexes 34 were to pierce the deformable side portion 30 to an excessive depth, the structural integrity of the channel insert 26 could be compromised thereby enabling it to be easily picked or pulled out of the channel 22 by an intruder. In one example, the protuberances 32 may pierce the surface of the deformable side portion 30 and protrude into the deformable side portion 30 to a depth of substantially between 0.5 and 1.4 millimeters. More particularly, in preferred embodiments a depth of about 1.4 millimeters provides that the protuberances 32 advantageously engage the deformable side portion 30 and first channel insert 26 effectively without compromising its structural strength.

[0032] The frame member 14 may be dimensioned such that the protuberances 32 deform the deformable side portion 30 without piercing its surface. In such examples, the protuberances 32 may simply occupy the indented spaces that they form in the deformable side portion 30. The deformable side portion 30 may be elastically or plastically deformable in such examples.

[0033] The first and second channel inserts 26,28 may each be made of flexible polyvinyl chloride (PVC) and/or natural or synthetic rubber-based materials. It will be understood that the channel inserts 26,28 may be made of one or more other materials having the requisite firmness that enable them to secure the screen edge section 24 effectively in the channel 22 yet are also suitably deformable, at least in part, such that the protuberances 32 are able to press into the deformable side portion 30.

[0034] The first channel insert 26 may comprise a second side portion 31 that is aligned parallel to the deformable side portion 30 and is made of a material that is harder than the deformable side portion 30. More particularly, the second side portion 31 may be made of a material that is between 2 and 2.5 times harder than the deformable side portion 30. For example, the deformable side portion 30 may be made of a material having a hardness of between 30 to 50 on the Shore 00 hardness scale and the second side portion 31 may be made of a material having a hardness of between 80 to 100 on the Shore 00 hardness scale.

[0035] The deformable side portion 30 may be formed integrally with the second side portion 31, such as via a co-extrusion process, to produce the first channel insert 26. For example, a pair of extruders may be used to melt and deliver a steady volumetric throughput of the respective materials used for the deformable side portion 30 and second side portion 31. The two materials may then be forced through a single extrusion head (die) to extrude the two materials together and form the finished channel insert 26. In other examples, the deformable side portion 30 and second side portion 31 may be manufactured separately and then affixed together using an appropriate attachment means, such as glue.

[0036] The deformable side portion 30 may also comprise a rough or textured surface 35 that faces the protuberances 32. For example, the surface may comprise a series of striations 35 formed therein which have been exaggerated in size in the Figures for the purpose of illustration. The textured surface 35 provides a visual indication of the location of the deformable side portion 30 which may assist the installer.

[0037] The second channel insert 28 and the second side wall 20 may comprise co-operating locking means for locking the second channel insert 28 in the channel 22 once inserted therein. For example, the second channel insert 28 and second side wall 20 may comprise a plurality of interconnecting projections and recesses 36 that, together, provide the co-operating locking means. The interconnecting projections and recesses 36 may be oriented diagonally relative to longitudinal axes of the second channel insert 28 and second side wall 20. In this configuration, the projections and recesses 36 inhibit removal of the second channel insert 28 from the channel 22 when the insert 28 has been forced therein.

[0038] The first channel insert 26 may also comprise an L-shaped terminal section 38 that extends transversely from a lowermost end of the first channel insert 26. The terminal section 38 is adapted to fit underneath a lowermost end of the screen edge section 24 such that it provides a barrier that spaces the edge section 24 apart from the end wall 16. It will be understood that when the screen 12 and frame member 14 are made of two different types of metal (for example, steel and aluminum respectively) galvanic or dissimilar metal corrosion may take place at or near to the boundary between the two metals if they are in abutting contact. The barrier provided by the terminal section 38, therefore, advantageously, avoids such corrosion.

[0039] The second side wall 20 may comprise a flange member 40 that inwardly extends into the channel 22. Together with the end wall 16 of the channel 22, the flange member 40 defines a cavity 42 that is adapted to receive an end part 44 of the terminal section 38 when the first channel insert 26 is inserted into the channel 22. The flange member 40 may comprise a lowermost surface 46 that extends perpendicularly from the second side wall 20 into the channel 22. The flange member 40 impedes removal of the first channel insert 26 from the channel 22 when the end part 44 of the terminal section

38 has been inserted into the cavity 42. The relative dimensions of the cavity 42 and the end part 44 of the terminal section 38 may provide that the end part 44 may be spaced apart from the cavity 42 when inserted therein.

[0040] The first channel insert 26 may comprise a lip member 48 that extends transversely from an uppermost end of the first channel insert 26. The lip member 48 is configured to abut, at least partially, an uppermost end of the first side wall 18 when the first channel insert 26 has been pushed fully into the channel 22.

[0041] The first and second channel inserts 26,28 may also comprise a plurality of toothed members 50,52 that project inwardly into the channel 22 for engaging the edge section 24 of the screen 12. Each of the toothed members 50,52 may comprise a tapered uppermost surface and a flat lowermost surface that projects perpendicularly into the channel 22.

[0042] In use, to install the screen 12 in the frame assembly 10 each edge section 24 of the screen 12 is secured into the channel 22 of an individual frame member 14 of the frame assembly 10. For example, Figure 3 shows an individual frame member 14 in cross section with a single frame edge section 24 secured therein.

[0043] Before the frame edge section 24 is inserted, the first channel insert 26 is slotted into the channel 22, as shown in Figure 2. The channel insert 26 is inserted such that the end part 44 of its L-shaped terminal section 38 enters the cavity 42. The relative sizes and dimensions of the end part 44 and the cavity 42 provide that the end part 44 is spaced apart from the cavity 42 and, therefore, does not form a tight fit in the cavity 42. This advantageously allows the person who is performing the installation to place the insert 26 into the channel 22 and then manipulate the insert 26 until it is in the required position and orientation with ease.

[0044] The flange member 40 provides an obstruction that conveniently inhibits removal of the insert 26 from the channel 22 once the end part 44 has entered the cavity 42 during the installation procedure. For example, it will be understood that if the frame member 14 is located at the top of the frame assembly 10 in a doorway and the channel 22 is facing downwardly, gravity will act downwardly on the insert 26 once it has been inserted into the channel 22. The flange member 40, therefore, stops the insert 26 from falling out of the channel 22. The flange member 40 similarly assists the installer when the frame member 14 is oriented vertically at one of the sides of the frame assembly 10 in the doorway during the installation procedure.

[0045] After the first channel insert 26 has been placed correctly into the channel 22, the screen edge 24 may then be slotted into the channel 22 in the gap formed between the first insert 26 and the second side wall 20. The second channel insert 28 may then be inserted forcefully into the gap between the screen edge 24 and the second side wall 20. When the second insert 28 is forced in, the first and second inserts 26, 28 each apply an inward compressive force on the screen edge 24 causing the toothed members 50,52 to engage the screen edge 24. In examples where the screen 12 is comprised of metal mesh, the toothed members 50,52 may enter directly into the perforations in the mesh. The pressure that is exerted by the second channel insert 28 on the second side wall 20 causes the projections and recesses 36 to mate together thereby locking the second insert 28 in place.

[0046] Further, when the second channel insert 28 is pushed into the channel 22, the pressure exerted by the protuberances 32 on the first channel insert 26 causes each of the protuberances 32 to press into the deformable side portion 30. This causes the protuberances 32 to deform the deformable side portion 30 and thereby form a plurality of indentations therein, as shown in Figure 3. The pointed apexes 34 may also piece a surface of the deformable side portion 30.

[0047] The series of indentations formed by the protuberances 32 in the deformable side portion 30 advantageously provide that the first channel insert 26 is held clamped in the channel 22 in a strong and resilient manner. The resultant connection achieved withstands substantial pulling forces acting on the first channel insert 26. This includes, for example, when an intruder may be attempting to pick the first channel insert 26 out of the channel 22 or when large forces are exerted on the screen 12.

[0048] Prior art screen frames that use channel inserts for retaining screen edges do not comprise protuberances that deformably press into and indent the inserts. These screen frames do not, therefore, provide the strong and resilient clamping action that is provided by the present invention.

[0049] It will also be understood that the protuberances 32 only press into and deform the deformable side portion 30 when the second channel insert 28 is being inserted into the channel 22. This enables the first channel insert 26 to be inserted into the channel 22 with ease.

[0050] Referring to Figures 6 and 7, there is provided an individual frame member 60 of a frame assembly according to a further example embodiment of the invention. The frame member 60 is materially the same as the frame member 14 depicted in Figures 1 to 3 except that the lip member 62 of its first channel insert 64 is dimensioned such that it extends fully across the uppermost end 68 of the first side wall 66 of the frame member 60 flush with its outermost surface 70.

[0051] Further, the second channel insert 72 is comprised of two portions, being an outer portion 74 that engages with the second side wall of the channel and an inner portion 76 that comprises the toothed members that engage with the edge section of the screen. The outer portion 74 may be made of a hard, rigid material, such as a hard PVC-based material, and the inner portion 76 may be made using a softer material, such as a softer PVC-based material. The two portions 74,76 may be formed using a co-extrusion process or separately and then fixed together.

[0052] For the purpose of this specification, the word "comprising" means "including but not limited to", and the word "comprises" has a corresponding meaning.

[0053] The above embodiments have been described by way of example only and modifications are possible within the scope of the claims that follow.

Claims

1. A frame assembly for a screen, the frame assembly comprising at least one frame member comprising: opposed first and second side walls that together form a channel for receiving an edge section of the screen; one or more protuberances extending from the first side wall inwardly into the channel; and first and second channel inserts adapted to be inserted into the channel in turn one before and one after the edge section is inserted into the channel such that the edge section is sandwiched between the channel inserts, wherein the first channel insert comprises at least first and second side portions arranged on respective sides of the first channel insert, wherein the first side portion is deformable such that the protuberances press into and deform the first side portion to form indentations therein when the second channel insert is forced into the channel, and wherein the second side portion is harder than the first side portion and bears against the edge section when the edge section is sandwiched between the channel inserts, wherein the first and second side walls are made of aluminium.

2. The frame assembly according to claim 1, wherein the second side portion is made of a material that is between 2 and 2.5 times harder than the first side portion.

3. The frame assembly according to claim 1 or 2, wherein the first side portion is made of a material having a hardness of between 30 to 50 on the Shore 00 hardness scale and the second side portion is made of a material having a hardness of between 80 to 100 on the Shore 00 hardness scale.

4. The frame assembly according to any one of the preceding claims, wherein the first side portion is elastically deformable.

5. The frame assembly according to any one of the preceding claims, wherein each of the protuberances comprises a pointed apex adapted to pierce a surface of the first side portion when the second channel insert is forced into the channel.