Joint structure and method of manufacture

• US 5,603,585 A
• Filed: 10/19/1994
• Issued: 02/18/1997
• Est. Priority Date: 05/17/1994
• Status: Expired due to Term

• Current Assignee: Andersen Corporation
• Original Assignee: Andersen Corporation
• Inventors: Bruchu, Todd W., Beske, Scott R.
• Primary Examiner(s): Canfield, Robert
• Application Number:
  US08/325,696
• Time in Patent Office: 853 Days
• Field of Search: 52/656.9, 52/656.5, 52/656.4, 52/204.1, 52/204.5, 52/780, 52/781, 49/524, 403/401, 403/402, 403/403, 403/382, 403/384, 403/387
• US Class Current: 403/382
• CPC Class Codes: B29C 65/20 with direct contact, e.g. using "mirror"
• CPC Class Codes: B29C 65/2007 characterised by the type of welding mirror
• CPC Class Codes: B29C 65/2015 being a single welding mirror comprising several separate heating surfaces in different planes, e.g. said heating surfaces having different temperatures
• CPC Class Codes: B29C 66/0044 using a separating sheet, e.g. fixed on the joining tool
• CPC Class Codes: B29C 66/02241 Cutting, e.g. by using waterjets, or sawing using heat B29C66/0246; cutting-off or cutting-out a part of a strip-like or sheet-like material, transferring that part and fixing it to an article B29C69/005
• CPC Class Codes: B29C 66/1162 Single bevel to bevel joints, e.g. mitre joints
• CPC Class Codes: B29C 66/1282 comprising at least one overlap joint-segment
• CPC Class Codes: B29C 66/12841 comprising at least two butt joint-segments
• CPC Class Codes: B29C 66/52431 with a right angle, e.g. for making L-shaped pieces
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/7212 characterised by the composition of the fibres
• CPC Class Codes: B29C 66/723 being multi-layered B29C66/7292, B29C66/72941 take precedence
• CPC Class Codes: B29C 66/72523 multi-channelled or multi-tubular B29C66/438, B29C66/5227 take precedence
• CPC Class Codes: B29C 66/7392 characterised by the material of at least one of the parts being a thermoplastic
• CPC Class Codes: B29C 66/73921 characterised by the materials of both parts being thermoplastics
• CPC Class Codes: B29C 66/8122 characterised by the composition of the material constituting the pressing elements, e.g. constituting the welding jaws or clamps
• CPC Class Codes: B29C 66/81431 comprising a single cavity, e.g. a groove
• CPC Class Codes: B29C 66/843 Machines for making separate joints at the same time in different planes; Machines for making separate joints at the same time mounted in parallel or in series
• CPC Class Codes: B29K 2027/06 PVC, i.e. polyvinylchloride
• CPC Class Codes: B29K 2311/14 Wood, e.g. woodboard or fibreboard
• CPC Class Codes: B29K 2905/02 : Aluminium
• CPC Class Codes: B29L 2009/005 : coated
• CPC Class Codes: B29L 2031/005 : for making window frames windows B29L2031/778
• CPC Class Codes: B29L 2031/778 : Windows profiled elements for making window frames B29L2031/005, windscreens B29L2031/3052
• CPC Class Codes: E06B 3/9604 : Welded or soldered joints E06B3/988, E06B3/99 take precedence; welding of plastics B29C65/00, soldering or welding of metals B23K
• CPC Class Codes: E06B 3/9608 : Mitre joints
• CPC Class Codes: E06B 3/9628 : Mitre joints concealed to look like butt joints
• CPC Class Codes: E06B 3/9845 : Mitre joints
• CPC Class Codes: F16B 2200/65 : Miter joints
• CPC Class Codes: F16B 2200/67 : Rigid angle couplings
• CPC Class Codes: Y10T 156/1744 : Means bringing discrete articles into assembled relationship
• CPC Class Codes: Y10T 403/7117 : Flanged or grooved rod

Abstract

A joint structure for connecting framing components such as sash members for a window is disclosed having separate functional and decorative junctions between adjacent framing components. The functional junction between components may be formed between opposing and abutting mitered mating surfaces defined at adjacent ends of the component, and a separate squared flange and cooperative recess may be formed on interior surfaces of the components for overlapping the mating surfaces and providing a decorative junction, for example, having the appearance of a mortise and tenon joint. The joint structure is particularly suited for use in custom or replacement applications whereby lineal extruded members formed of a heat weldable material may be cut to size having the aforementioned surfaces, and then heat welded together to form a custom sized framing structures such as a sash or frame for a window or door.

Claims

1. A window, comprising:

(a) a window glass assembly having interior and exterior sides;

(b) first, second, third and fourth members coupled to form a frame, each member having a substantially identical cross-sectional profile, wherein each member includes a glass receiving channel formed between interior and exterior sides of the member, the glass receiving channel for supporting the interior and exterior sides of the window glass assembly; and

(c) a joint structure interconnecting adjacent ends of the first and second members, the joint structure including;

(i) a flange disposed at the end of the first member on the interior side thereof, the flange having a first squared end surface extending substantially orthogonal to the longitudinal axis of the first member;

(ii) a first mitered portion disposed at the end of the first member, the first mitered portion spanning from the flange to the exterior side of the first member and having a first mating surface defined thereon, wherein the first mitered portion has a width defined along a direction extending between the interior and exterior sides of the first member;

(iii) a second mitered portion disposed at the end of the second member, the second mitered portion having a width substantially the same as the width of the first mitered portion, and the second mitered portion spanning from the exterior side of the second member toward the interior side thereof, wherein the second mitered portion has a second mating surface defined thereon for abutting the first mating surface on the first mitered portion, and wherein the second mitered portion defines a recessed surface proximate the interior side of the second member;

(iv) a second squared end surface extending substantially orthogonal to the longitudinal axis of the second member between the interior side of the second member and the recessed surface of the second mitered portion, wherein a recess is defined by the recessed surface and the second squared end surface; and

(v) connecting means for connecting the first and second members through the first and second mating surfaces, with the flange on the first member received in the recess defined on the second member;

whereby the flange and the second squared end surface define a squared edge on the interior side of the members, the squared edge giving the appearance of a mortise and tenon joint structure between the members.

2. The window of claim 1, wherein each member comprises a composite material including wood fiber disposed in a thermoplastic polymer.

3. The window of claim 2, wherein each member further comprises a polymer coating disposed over the interior and exterior sides thereof.

4. The window of claim 1, wherein the glass receiving channel of each member is defined by opposing channel surfaces, wherein at least one of the channel surfaces includes flexible members extending into the glass receiving channel for forcing the window glass assembly against the opposing channel surface.

5. The window of claim 4, further comprising a silicone sealant interposed in the glass receiving channel between the exterior side of the window glass assembly and the channel surface proximate the exterior side of each member.

6. The window of claim 1, further comprising a silicone sealant filler material disposed at a plurality of points along the glass receiving channel of each member.

7. The window of claim 1, wherein the window glass assembly is an insulated glass unit comprising opposing interior and exterior glass panes sealed by a spacer interposed therebetween.

8. The window of claim 1, wherein each member further comprises an outer hardware mounting channel formed opposite the glass receiving channel.

9. The window of claim 1, wherein the first and second mating surfaces are planar surfaces angled at about 45 degrees with respect to the longitudinal axis of the first and second members, respectively.

10. The window of claim 1, wherein portions of the first and second mating surfaces are disposed proximate interior and exterior sides of the glass receiving channels of the first and second members, respectively.

11. The window of claim 1, wherein each member is formed of a heat weldable material, and wherein the connecting means comprises means for heat welding the first and second mitered portions through the first and second mating surfaces.

12. The window of claim 11, wherein the first and second mitered portions include flashing portions disposed at the first and second mating surfaces, and wherein the flashing portions compress to form flashing about edges of the first and second mating surfaces during heat welding.

13. The window of claim 12, wherein the first and second members include a non-heat weldable decorative coating disposed on sides thereof, and wherein the flashing portions are sized such that the decorative coatings on the first and second members abut one another after compression of the flashing portions during heat welding.

14. The window of claim 13, wherein the decorative coating comprises a wood veneer.

15. A joint structure for interconnecting adjacent ends of first and second framing members, each having opposing first and second sides, and each including a glass receiving channel formed between the first and second sides thereof, the glass receiving channel for supporting interior and exterior sides of a window glass assembly, the joint structure comprising:

(a) a first mating portion disposed at the end of the first framing member, the first mating portion having a first mating surface defined thereon, wherein the first mating portion has a width defined along a direction extending between the first and second sides of the first framing member;

(b) a flange disposed at the end of the first framing member on the first side thereof;

(c) a second mating portion disposed at the end of the second framing member and having a width substantially the same as the width of the first mating portion, the second mating portion having a second mating surface defined thereon for abutting the first mating surface on the first mating portion, and wherein the second mating portion defines a recessed surface proximate the first side of the second framing member; and

(d) connecting means for connecting the first and second mating portions through the first and second mating surfaces with the flange overlapping the recessed surface on the second mating portion.

16. The joint structure of claim 15, wherein portions of the first and second mating surfaces are disposed proximate interior and exterior sides of the glass receiving channels.

17. The joint structure of claim 15, wherein the flange has a squared end surface extending substantially orthogonal to the longitudinal axis of the first framing member.

18. The joint structure of claim 17, further comprising a second squared end surface extending substantially orthogonal to the longitudinal axis of the second framing member between the first side of the second framing member and the recessed surface of the second mating portion, wherein a recess is defined by the recessed surface and the second squared end surface, the recess for receiving the flange therein.

19. The joint structure of claim 15, wherein the first and second mating surfaces are planar surfaces angled at about 45 degrees with respect to the longitudinal axis of the first and second framing members, respectively.

20. The joint structure of claim 15, wherein the first side of the framing members is an interior side and the second side of the framing members is an exterior side;

whereby the flange is disposed on the interior side of the first framing member.

21. The joint structure of claim 20, wherein the first and second mating portions are disposed proximate the exterior sides of the first and second framing members, respectively.

22. The joint structure of claim 15, wherein each framing member is formed of a heat weldable material, and wherein the connecting means comprises means for heat welding the first and second mating portions through the first and second mating surfaces.

23. The joint structure of claim 22, wherein the first and second mating portions include flashing portions disposed at the first and second mating surfaces, and wherein the flashing portions compress to form flashing about edges of the first and second mating surfaces during heat welding.

24. The joint structure of claim 23, wherein the flange substantially overlaps the mating surfaces proximate the first sides of the framing members, and wherein the flashing formed along the mating surfaces is diverted away from the first sides of the framing members.

25. The joint structure of claim 15, wherein the flange has a decorative surface formed on an end thereof, at least a portion of which is substantially non-coplanar with the mating surfaces.

26. A joint structure for interconnecting first and second framing members, each member having opposing first and second sides, the joint structure comprising:

(a) a mating portion disposed at the end of each framing member, wherein each mating portion is formed of a heat weldable material and includes a mating surface defined thereon for mating with a mating surface defined on the other mating portion;

(b) a flange disposed at the end of the first framing member, the flange spanning between the mating portion and the first side of the first framing member;

(c) a recess defined on the first side of the second framing member at the end thereof, the recess for receiving the flange on the first framing member; and

(d) means for heat welding the first and second members through the mating surfaces thereof, wherein the flange is received in the recess and substantially covers the mating surfaces proximate the first sides of the framing members, and wherein flashing formed along the mating surfaces during heat welding is diverted away from the first sides of the framing members.

27. The joint structure of claim 26, wherein each framing member is a sash member including a glass receiving channel formed between the first and second sides thereof, the glass receiving channel for supporting interior and exterior sides of a window glass assembly.

28. The joint structure of claim 27, wherein portions of the first and second mating surfaces are disposed proximate interior and exterior sides of the glass receiving channels.

29. The joint structure of claim 26, wherein the flange has a squared end surface extending substantially orthogonal to the longitudinal axis of the first framing member.

30. The joint structure of claim 29, further comprising a second squared end surface extending substantially orthogonal to the longitudinal axis of the second framing member between the first side of the second framing member and the mating portion thereof.

31. The joint structure of claim 26, wherein the mating surfaces on the first and second framing members are planar surfaces angled at about 45 degrees with respect to the longitudinal axis of the first and second framing members, respectively.

32. The joint structure of claim 26, wherein the first side of the framing members is an interior side and the second side of the framing members is an exterior side;

whereby the flange is disposed on the interior side of the first framing member.

33. The joint structure of claim 32, wherein the mating portions are disposed proximate the exterior sides of the first and second framing members, respectively.

34. The joint structure of claim 26, wherein the flange has a decorative surface formed on an end thereof, at least a portion of which is substantially non-coplanar with the mating surfaces.

35. A joint structure for interconnecting adjacent ends of first and second framing members, each having opposing first and second sides, and each formed of a heat weldable material, the joint structure comprising:

(a) a first mating portion disposed at the end of the first framing member, the first mating portion having a first mating surface defined thereon, wherein the first mating portion has a width defined along a direction extending between the first and second sides of the first framing member;

(b) a flange disposed at the end of the first framing member on the first side thereof; and

(c) a second mating portion disposed at the end of the second framing member and having a width substantially the same as the width of the first mating portion, the second mating portion having a second mating surface defined thereon for abutting the first mating surface on the first mating portion, and wherein the second mating portion defines a recessed surface proximate the first side of the second framing member;

wherein the first and second mating portions are connected through a heat welded connection between the first and second mating surfaces with the flange overlapping the recessed surface on the second mating portion.

36. The joint structure of claim 35, wherein each framing member is a sash member including a glass receiving channel formed between the first and second sides thereof, the glass receiving channel for supporting interior and exterior sides of a window glass assembly.

37. The joint structure of claim 36, wherein portions of the first and second mating surfaces are disposed proximate interior and exterior sides of the glass receiving channels.

38. The joint structure of claim 35, wherein the flange has a squared end surface extending substantially orthogonal to the longitudinal axis of the first framing member, wherein the joint structure further comprises a second squared end surface extending substantially orthogonal to the longitudinal axis of the second framing member between the first side of the second framing member and the recessed surface of the second mating portion, and wherein a recess is defined by the recessed surface and the second squared end surface, the recess for receiving the flange therein.

39. The joint structure of claim 35, wherein the first and second mating surfaces are planar surfaces angled at about 45 degrees with respect to the longitudinal axis of the first and second framing members, respectively.

40. The joint structure of claim 35, wherein the first side of the framing members is an interior side and the second side of the framing members is an exterior side;

whereby the flange is disposed on the interior side of the first framing member; and

wherein the first and second mating portions are disposed proximate the exterior sides of the first and second framing members, respectively.

41. The joint structure of claim 35, wherein the first and second mating portions include flashing portions disposed at the first and second mating surfaces, and wherein the flashing portions compress to form flashing about edges of the first and second mating surfaces during heat welding.

42. The joint structure of claim 41, wherein the flange substantially overlaps the mating surfaces proximate the first sides of the framing members, and wherein the flashing formed along the mating surfaces is diverted away from the first sides of the framing members.