Frame Construction Method

Abstract

The invention is a method, an apparatus and a kit of parts for assembling a universal frame with at least two jambs, a lintel and a sill. The resulting frame is suitable for any size of opening and any size of door, with the option to include single doors or double doors as well as side screens and/or side lights. The frame is typically assembled by cutting the jambs (and optionally the sill and/or lintel) to a selected size, attaching keys to each end of each jamb and inserting the keys into keying channels in the sill and lintel.

Claims

1. A method of assembling a frame, the method comprising, providing or forming a sill of a selected length, the sill having at least one keying channel running along at least part of a longitudinal surface of the sill; providing or forming a lintel of a selected length, the lintel having at least one keying channel running along at least part of a longitudinal surface of the lintel; providing or forming at least two jambs of a selected length, each jamb having longitudinally extending keys at either end, said keys shaped to cooperate with and be retained by said keying channels; inserting the keys at one end of each jamb into the at least one keying channel of the lintel; and inserting the keys at the other end of each jamb into the at least one keying channel of the sill, to thereby form the frame.

2. The method according to claim 1 wherein the method comprises cutting one or more jambs to a selected length and subsequently forming a key at at least one end of the or each jamb.

2. The method according to claim 1 wherein the forming of at least two jambs of a selected length, each jamb having longitudinally extending keys at either end comprises the step of attaching a key to each end of each jamb, optionally using a key jig to align the key.

4. The method according to claim 1 wherein forming of at least two jambs of a selected length comprises cutting one or more of the jambs to the selected length and the method further comprises attaching a key to each end of each jamb, optionally using a key jig to align the key.

5. The method according to claim 1 comprising the step of attaching of a key to each end of each jamb, the step of attaching a key to a jamb comprising the steps of, placing at east one key jig against and aligning the at least one key jig with an end of the jamb; aligning a key with the or each key jig; attaching the or each key to the end of the jamb; and removing the or each key jig from the end of the jamb;

6. The method according to claim 1 wherein the forming of the sill of a selected length and/or the lintel of a selected length and/or the at least two jambs of a selected length comprises cutting one or more lengths of material to a selected length.

7. The method according to claim 1 wherein the forming of a sill of a selected length and/or the lintel of a selected length and/or the at least two jambs of a selected length comprises forming the jambs and/or lintels and/or sills to a selected length by cutting through a longer piece of material at the site of use.

8. The method according to claim 1 further comprising the step of separating the at least two jambs by a selected distance to thereby define the width of the frame.

9. The method according to claim 8 wherein the step of separating the at least two jambs comprises the steps of, inserting a first locator into at least one keying channel of the lintel; inserting a second locator into at least one keying channel of the sill; inserting the keys attached to the top of each jamb into the keying channel of the lintel; and inserting the keys attached to the base of each jamb into the keying channel of the sill.

10. The method according to claim 1, further comprising, forming one or more additional jambs and/or one or more mullions each of a selected length, the or each additional jamb and/or the or each mullion having longitudinally extending keys at either end; inserting the keys attached to the top of the or each additional jamb and/or the or each mullion into the at least one keying channel of the lintel; and inserting the keys attached to the base of the or each additional jamb and/or the or each mullion into the at least one keying channel of the sill.

11. The method according to claim 10 wherein the forming of one or more additional jambs and/or one or more mullions each of a selected length, each jamb having longitudinally extending keys at either end comprises attaching a key to each end of each additional jamb and/or each mullion, optionally through the use of a key jig to align the key.

12. The method according o claim 10 wherein the attaching of a key to each end of each additional jamb and/or each mullion comprises the steps of, placing at least one key jig against and aligning the at least one key jig with an end of one or more additional jambs and/or one or more mullions; aligning a key with the or each key jig; attaching the or each key to the end of the or each additional jamb and/or the or each mullion; and removing the or each key jig from the end of each additional jamb and/or the or each mullion;

13. The method according to claim 10 comprising separating the or each additional jamb from the first and second jambs by a selected distance.

14. The method according to claim 10 comprising separating the or each mullion from the first and second jambs.

15. The method according to claim 10 wherein the separating the additional jambs and/or mullions comprises the steps of, inserting an additional locator into at least one keying channel of the lintel; inserting an additional locator into at least one keying channel of the sill; inserting the keys attached to the top of the or each additional jamb and/or the or each mullion into the keying channel of the lintel; and inserting the keys attached to the base of the or each additional jamb and/or the or each mullion into the keying channel of the sill.

16. A frame construction apparatus, the apparatus comprising a plurality of keys and a key jig, the key jig comprising a locating formation and a key retaining formation defining a key space wherein the key space is configured to cooperate with a key in use the key jig and is configured to define the location of the end of a jamb where the key is to be attached.

17. A frame construction kit comprising a sill, the sill having at least one keying channel ruining along at least part of a longitudinal surface of the sill, a lintel, the lintel having at least one keying channel running along at least part of a longitudinal surface of the lintel, a first lamb and a second jamb, at least one key jig and a plurality of keys, said keys shaped to cooperate with said keying channels and the at least one key jig.

18. The kit according to claim 17 further comprising one or more mullions.

19. The kit according to claim 17 wherein the lintel comprises at least one keying channel configured to cooperate with a key in use and/or the sill comprises at least one keying channel configured to cooperate with a key in use.

20. The kit according to claim 17 further comprising one or more locator, each locator configured to cooperate within the at least one keying channel of the lintel and/or within the at least one keying channel of the sill.

21-24. (canceled)

Description

DESCRIPTION OF THE DRAWINGS

[0064] Features described above in respect of any aspect of the invention are optional features of any other aspect of the invention.

[0065] An example embodiment of the present invention will now be illustrated with reference to the following Figures in which:

[0066] FIG. 1 is a perspective view of an example of a frame as constructed;

[0067] FIG. 2 is an exploded perspective view of the components of an example of a frame;

[0068] FIG. 3A is a plan view of a first example of a (door) frame as constructed, including a door;

[0069] FIG. 3B is a plan view of a second e, ample of a (door) frame as constructed, including a door, a side screen, a side light and mullions;

[0070] FIG. 4 is a cross-section of an example embodiment of a sill for a frame;

[0071] FIG. 5 is a cross-section of an example embodiment of a lintel for a frame;

[0072] FIG. 6 is a cross-section of an example embodiment of a jamb for a frame;

[0073] FIG. 7 is a perspective view of an example embodiment of a key in the form of a dovetail;

[0074] FIG. 8 is a perspective view of an example embodiment of a key jig;

[0075] FIG. 9a is a diagram of the positioning of a key jig at the top of a jamb for a frame;

[0076] FIG. 9b is a diagram of the positioning of a key within a key jig at the top of a jamb for a frame;

[0077] FIG. 9c is a diagram of the positioning of a key as attached at the top of a jamb for a frame;

[0078] FIG. 10 is a diagram of a jamb with keys attached to each end, the keys being fitted into a sill and a lintel of a frame; and

[0079] FIG. 11 is a flow chart of an example embodiment of the method as according to the invention.

DETAILED DESCRIPTION OF AN EXAMPLE EMBODIMENT

[0080] With reference to FIG. 1, in one example embodiment of the invention a frame (1) is formed with two jambs (2), a sill (4) and a lintel (6). Each jamb has a key (14) in the form of a dovetail attached to each end. The sill (4) has a dovetail slot (8) (functioning as a keying channel) running along the full length of the aperture-facing surface of the sill (4) and the lintel (6) has a dovetail slot (8) (functioning as a keying channel) running along the full length of the aperture-facing surface of the lintel (6).

[0081] FIG. 2 is an exploded diagram of the same frame (1) as that of the diagram of FIG. 1, indicating the individual components of the frame. Here it can be seen that the keys (14) attached to the upper end of each jamb (2) can be slidably inserted (along an upper axis (17), shown for clarity) into the dovetail slots (8) of the lintel (6). Likewise, the keys (14) attached to the lower end of each jamb (2) can be slidably inserted (along a lower axis (19), shown for clarity) into the dovetail slots (8) of the sill (4). Additionally, spacers (16) can be slidably inserted into the dovetail slots (8) of the sill (4) and the lintel (6). The spacers (16) are used to control the separation distance of the two jambs (2) to thereby define the width of the frame (1).

[0082] Jambs (2), sills (4) and/or lintels (6) can be formed by cutting each to a desired length corresponding to the desired size of frame (1). Keys (14) configured to cooperate with the dovetail slots (8) of the sill (4) and the lintel (6) can then be attached to each end of each jamb (2). The positioning of the keys (14) is guided by a key jig (90) (see FIG. 8) configured to cooperate with the key (14) and to precisely align the key (e.g. in three linear dimensions as well as in at least one rotational degree of freedom) at the end of the jamb (2) such that it can be slidably received by a dovetail slot (8). In this way accurate positioning of each key (14) is ensured and thus the ease of assembly of a frame (1) is enhanced.

[0083] FIG. 3A is a plan view of a first example of a frame (in this instance, a doorframe) as assembled and FIG. 3B is a plan view of a second example of a frame (in this instance, a doorframe) as assembled. The example doorframe in FIG. 3A includes, two jambs (2), a lintel (6) and a sill (4), wherein the keys (14) attached to the upper end of each jamb (2) are retained in the keying channel (8) of the lintel (6) and the keys (14) attached to the lower end of each jamb (2) are retained in the keying channel (8) of the sill (4). The example doorframe in FIG. 3B further includes two mullions (3), each mullion (3) having a key (14) attached to each end. As with the keys (14) attached to the jambs (2), the key (14) attached to the upper end of each mullion (3) is retained in the keying channel (8) of the lintel (6) and the key (14) attached to the lower end of each mullion (3) is retained in the keying channel (8) of the sill (4). The use of mullions (3) allows additional spaces to be defined within the frame (in this instance, two additional spaces are defined by the frame, however one skilled in the art will appreciate that an arbitrary number of additional spaces may be chosen, depending on the frame design required). In this example, the additional spaces retain a sidelight (5) and a side screen (7), respectively.

[0084] FIG. 4 is a diagram of an example cross-section of a sill (4) for a frame. The sill (4) has an upper surface (20), a lower surface (22) a dovetail slot (8), a sealant channel (24) and a drip channel (26). The dovetail slot (8) is configured to slidably receive a key (14) with the same cross-section (in this example, a dovetail); however, the dovetail slot is also configured to slidably receive a spacer (16) in the form of an elongate strut. During construction of a frame (1), a first key (14) that is connected to a first jamb (2) is inserted into the dovetail slot (8) of the sill (4) and is fixed in place. Then, a spacer (16) is inserted into the dovetail slot (8) of the sill (4), followed by a second key (14) that is connected to a second jamb (2) and this second key (14) is also fixed into place. However, it is also possible to insert the spacer (16) into the dovetail slot (8) of the sill (4) first and to subsequently insert the first and second keys (14) before fixing both keys into place. The spacer (16) is of sufficient length that it separates the first and second keys (14) such that the inner surfaces of the first and second jambs (2) define the leftmost and rightmost inner limits of the frame (1).

[0085] FIG. 5 is a diagram of an example cross-section of a lintel (6) for a frame. The lintel (6) has an upper surface (58), a lower surface (50), a front surface (46), a back surface (52), a sealant channel (44) a dovetail slot (8), a gasket channel (42), and a drip channel (40). Each key (14) and each spacer (16) is configured to be slidably received by the dovetail slot (8). During construction of the frame, a first key (14) that is connected to a first jamb (2) is inserted into the dovetail slot (8) of the lintel (6) and is fixed in place. Then, a spacer (16) is inserted into the dovetail slot (8) of the lintel (6), followed by a second key (14) that is connected to a second jamb (2) and this second key (14) is also fixed into place. However, it is also possible to insert the spacer (16) into the dovetail slot (8) of the lintel (6) first and to subsequently insert the first and second keys (14) before fixing both keys (14) into place. The spacer (16) is of sufficient length that it separates the first and second keys (14) such that the in surfaces of the first and second jambs (2) define the leftmost and rightmost inner limits of the frame (1).

[0086] FIG. 6 is a diagram of an example cross-section of a jamb (2) for a frame (2). The jamb (2) has an inner limit surface (66), an outer limit surface (68), an interior surface (64), an exterior surface (62), a sealant channel (76), a gasket channel (72) and a drip channel (74).

[0087] FIG. 7 is a diagram of one example of a key (14). The key (14) in this example has a dovetail cross-section (86) and as such is configured be slidably inserted into a (i.e. dovetail-shaped) key space (92) of a key jig (90), such as the key jig (90) shown in FIG. 8. However, one skilled in the art will appreciate that a range of shapes other than dovetails would also be effective, provided that the key (14) is configured to fit within the key space (92) of the key jig (90) and the keying channels (8). The key (14) also has adhesive channels (84) and through-bores (82) through which screws (or other fastening means) can be inserted in use to thereby fix the key to a jamb (2) or mullion (3). To ensure proper alignment, the dimensions of the key (14) must be known with some precision. In this example, the key has a length (85) of 35 mm, a lower width (81) of 22.2 mm, and an upper width (83) of 1 1.13 mm. One skilled in the art will appreciate that the choice of dimensions is may be decided according to the design requirements of the frame (1), provided that the dimensions of the key are consistent with those of the key jig (90).

[0088] The adhesive channels (84) reduce the frictional forces when the key (14) is inserted into the key space (92) of the key jig (90) and also can be filled with adhesive during construction of a frame (1), increasing the strength of any joint formed.

[0089] FIG. 8 is a diagram of one example of a key jig (90). The key jig (90) has a key space (92) that, in this example, is configured to contain a key with a dovetail cross- section, however one skilled in the art will appreciate that a range of shapes would effective, provided that the key space (92) is configured to contain a key (14) with a matching cross-section. The key jig (90) also has a locating formation in the form of a backing section (96) configured to sit flush against the rear surface of a jamb (2) or mullion (3) and an access hole (94) through which screws (or other fastening means) can be inserted in use to thereby fix the key to the jamb. To ensure proper alignment, the dimensions of the key jig (90) must be known with some precision.

[0090] In this example, the key jig (90) has a length (85) chosen to correspond with the length of the key (90) and as such is 35 mm. Including the height of the backing piece (96), the key jig (90) in this example has a total height (91) of 47 mm, and excluding the height of the backing piece a height (97) of 22 mm. The key jig (90) in this example has a depth (97) of 45 mm. One skilled in the art will appreciate that the choice of dimensions is may be decided according to the design requirements of the frame (1), provided that the dimensions of the key jig (90) and keying channels (8) are consistent with those of the key (14).

[0091] Accordingly, the dimensions of each key (14), spacer (16), key jig (90) and dovetail slot (8) can be selected such that the jamb (2) can be accurately laterally positioned in relation to the sill (4) and the lintel (6) according to the required dimensions of the frame (1).

[0092] FIG. 9a is a diagram of a key jig (90), positioned at the upper end of a jamb (2) (with a door (96) shown for illustrative purposes). In use, the key jig (90) is positioned such that the backing section (96) lies flush against the interior surface (64) of the jamb (2). FIG. 9b is a diagram of a key jig (90), positioned at the upper end of a jamb (2) (door omitted) with a key (14) inserted into the key space (92) of the key jig (90). In use, when the key (14) is correctly positioned it can then be connected to the jamb (2) by inserting screws via the access hole (94) of the key jig (90), into the through-bores (82) of the key (14) and into the jamb (2). The key jig (90) is then slidably removed from the key (14), leaving the key (14) attached to the jamb (2). This process is then repeated for the lower end of the jamb (2) to attach a second key (14), and is further repeated for as many jambs (2) (and/or mullions (3)) as are needed for the desired frame (1). FIG. 9c is a diagram of a key (14) fixed to the upper end of a jamb (2) (door omitted).

[0093] FIG. 10 is a diagram of part of a frame (1) indicating in more detail the positioning of the keys (14) attached to each end of a jamb (2) within the dovetail slot (8) of a sill (4) and a lintel (6) when a frame (1) is constructed.

[0094] It will be understood that in further embodiments of the invention additional jambs (2), mullions (3) (and keys (14) attached to the jambs (2) and/or mullions (3)) may be used to create frames with additional spaces to retain double doors and/or sidelights (5) and/or side screens (7). For example, by inserting an additional spacer into the keying channel of the sill (4) and a further additional spacer (16) into a keying channel of the lintel (6) and subsequently inserting a key (14) attached to the upper end of a mullion (3) into the keying channel of the lintel (6) and a key (14) attached to the lower end of a mullion (3) into the keying channel of the sill (4), an additional space is defined by the resulting frame (see FIG. 3). This additional space can then retain a sidelight (5) or a side screen (7). This process can optionally be repeated as many times as desired to create further additional spaces that can retain further sidelights (5) or side screens (7).

[0095] A further embodiment of the invention provides a method as indicated in FIG. 11 which is a flow chart of the main steps of an example of the method (100) of constructing a frame (1) according to the invention. The method (100) begins with cutting the lintel to the required overall opening length (102) and then cutting the sill to the required overall opening length (104). Next, the first jamb (2) is cut to the required size for fitting between the sill and the lintel (106) and the second jamb (2) is cut to the required size for fitting between the sill and the lintel (108). One skilled in the art will appreciate that the dimensions chosen will depend on the space available. For example, where the frame is a doorframe the dimensions will depend on the space available for a door, the door itself, any excluder that is intended for use with the door and any required clearance space.

[0096] In this example, one key (14) is positioned at a time. When the sill (4), lintel (6) and first and second jambs (2) have been cut to size, the key jig (90) is positioned at the top of the first jamb (110) such that the backing section (96) of the key jig (90) is flush with the interior surface (64) of the first jamb (2). Then, a first key (14) is slidably inserted into the key space of the key jig and is secured (1 12) to the first jamb with screws inserted into the holes (82) of the first key (14) via the access hole (92) of the key jig (90). The next step is to remove the key jig (90) by sliding it off the first key (14) and to move it to the base of the first jamb (114). A second key is inserted into the key space of the key jig and is secured to the first jamb as before (116) and the key jig is then removed and moved to the top of the second jamb (118). Then, a third key is inserted into the key space and secured to the second jamb (120) and the key jig is moved to the base of the second jamb (122). A fourth key is inserted into the key space and secured to the second jamb (124) and the key jig is removed (126). At this point both jambs (2) have keys (14) attached to their upper and lower ends.

[0097] The next step in the method (100) is to insert a first spacer into the keying channel (in the above examples, a keying channel in the form of a dovetail slot) in the lintel (128) and then to insert a second spacer into the keying channel in the sill (in the above examples, a keying channel in the form of a dovetail slot) (130). Then, the keys of the first jamb are inserted into the channels in the lintel and the sill (132). Finally, the keys of the second jamb are inserted into the channels in the lintel and the sill (134) this completing the assembly of the frame. It will be appreciated that, in some examples of the invention, this method may comprise additional steps, and that some steps may be carried out in different orders or simultaneously.