Lineal corner block

• US 6,047,507 A
• Filed: 06/19/1998
• Issued: 04/11/2000
• Est. Priority Date: 06/19/1998
• Status: Expired due to Term

• Current Assignee: PLY GEM Pacific Windows Corporation (Cornerstone Building Brands, Inc.)
• Original Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Inventors: Long, Robert, Lappin, Rick
• Primary Examiner(s): Kent, Christopher T.
• Application Number:
  US09/100,552
• Time in Patent Office: 662 Days
• Field of Search: 52/212, 52/311.1, 52/656.2, 52/656.4, 52/656.5, 52/656.9, 52/657, 52/717.01, 52/745.16, 52/302.1
• US Class Current: 52/212
• CPC Class Codes: E06B 3/9641 part of which remains visible E06B3/9647 takes precedence

Abstract

A frame for a door or window includes a plurality of frame portions, which may be lineals, and a plurality of corner blocks. For a door frame, three frame portions and two corner blocks are used. For a window frame, four frame portions and four corner portions are used. Each corner block comprises first and second mounting flange portions for attaching the corner block to a surface, such as an exterior wall of a building. First and second channel portions are each attached to a respective mounting flange portion. Each of the first and second channel portions is shaped to engage a respective one of a first and a second frame portions. A cover portion is attached to both of the first and second channel portions. The cover portion has first and second overlap portions which overlap the first and second frame portions, respectively, when the first and second channel portions engage the first and second frame portions. An ornamental "rosette" may be attached to the cover portion of the corner block.

Claims

1. A corner block, comprising:

first and second mounting flange portions for attaching the corner block to a surface;

first and second channel portions, each attached to a respective mounting flange portion, each of the first and second channel portions being shaped to engage a respective one of a first and a second frame portions; and

a cover portion attached to both of the first and second channel portions, the cover portion having first and second overlap portions which overlap the first and second frame portions, respectively, when the first and second channel portions engage the first and second frame portions, wherein the first and second channel portions are inclined relative to a first outer edge and a second outer edge, respectively, of the cover portion.

2. A corner block according to claim 1, wherein the first and second channel portions are inclined so that, if one of the first or second channel portions is facing substantially upward, the inclination of that one upward facing channel portion diverts a fluid away from the frame portion to which that one upward facing channel portion is attached.

3. A corner block according to claim 1, wherein the first and second channel portions meet at an angle that is greater than 90 degrees.

4. A corner block according to claim 1, said corner block being formed from a single piece of a vinyl material.

5. A corner block according to claim 1, wherein:

the first and second mounting flange portions form an L-shaped mounting flange;

the first and second channel portions are inclined and meet each other at an angle greater than 90 degrees, so that, if one of the first or second channel portions is facing substantially upward, the inclination of that one upward facing channel portion diverts a fluid away from the frame portion to which that one upward facing channel portion is attached;

the first and second channel portions engage the first and second frame portions, so that the ends of the first and second frame portions are hidden; and

the cover portion includes means for fastening an ornament to the corner block.

6. A corner block according to claim 1, wherein an interior U-shaped concavity is formed between the cover portion and each channel portion, the concavity shaped to receive an edge of one of the frame portions.

7. A corner block according to claim 6, further comprising an edge between the cover and each channel portion, wherein the cover, one of the edges and the channel portion adjacent to the one edge form an "S" shape.

8. A corner block, comprising:

first and second mounting flange portions for attaching the corner block to a surface;

first and second channel portions, each attached to a respective mounting flange portion, each of the first and second channel portions being shaped to engage a respective one of a first and a second frame portions; and

a cover portion attached to both of the first and second channel portions, the cover portion having first and second overlap portions which overlap the first and second frame portions, respectively, when the first and second channel portions engage the first and second frame portions, said cover portion including means for fastening an ornament to the corner block.

12. A frame assembly according to claim 8, wherein the assembly includes four frame portions and four corner blocks alternately arranged to form a rectangular frame.

13. A frame assembly according to claim 12, wherein:

each of the frame members has a channel, and

the channels of the frame portions and channel portions of the corner blocks are connected to each other to form a twelve-sided polygon.

14. A frame assembly according to claim 8, wherein the first and second channel portions meet at an angle that is greater than 90 degrees.

15. A frame assembly according to claim 8, said corner block being formed from a single piece of a vinyl material.

16. A frame assembly according to claim 8, wherein the cover portion includes means for fastening an ornament to the corner block.

17. A frame assembly according to claim 8, wherein each frame portion has a channel portion, and the channel portion of each frame portion is sized to be received by the channel portion of any one of the corner blocks.

18. A frame assembly according to claim 8, wherein:

the assembly includes four frame portions and four corner blocks alternately arranged to form a rectangular frame;

each of the frame members has a channel, and

the channels of the frame portions and channel portions of the corner blocks are connected to each other to form a rectangle.

9. A frame assembly comprising:

at least three frame portions and at least two corner blocks alternately arranged to form a frame, wherein each of the corner blocks comprises;

(a) first and second mounting flange portions for attaching the corner block to a surface;

(b) first and second channel portions, each attached to a respective mounting flange portion, each of the first and second channel portions being shaped to engage a respective one of a first and a second one of the frame portions, the first and second channel portions being inclined relative to the first and second ones of the frame portions; and

(c) a cover portion attached to both of the first and second channel portions, the cover portion having first and second overlap portions which overlap the first and second ones of the frame portions, respectively.

10. A frame assembly according to claim 9, wherein one of the frame members is a top frame member, and a top one of the channel portions of each corner block is inclined downward from the top frame member, so that the inclination of each of the top channel portions diverts a fluid away from the top frame portion.

11. A frame assembly according to claim 10, wherein at least two of the frame members are side-facing members, and a side-facing channel portion of each corner block is received within a channel portion of a respective one of the side-facing members, so that the fluid is diverted outward beyond a top end of each of the side-facing members.

19. A corner block, comprising:

a mounting flange having first and second mounting flange portions for attaching the corner block to a surface;

first and second U-shaped channel portions, each attached to a respective mounting flange portion, each of the first and second channel portions being shaped to engage a respective one of a first and a second frame portions;

a cover portion attached to both of the first and second channel portions, the cover portion having first and second overlap portions which overlap the first and second frame portions, respectively, when the first and second channel portions engage the first and second frame portions, so that the ends of the first and second frame portions are hidden; and

first and second slots between the cover and the first and second channel portions, respectively,

wherein an interior U-shaped concavity is formed between the cover portion and each channel portion, the concavity shaped to receive an edge of one of the frame portions.

20. A corner block according to claim 19, further comprising an edge between the cover and each channel portion, wherein the cover, one of the edges and the channel portion adjacent to the one edge form an "S" shape.

21. A method for forming a frame assembly, comprising the steps of:

(a) providing at least three frame portions, each frame portion having a channel portion,

(b) providing at least two corner blocks, each corner block having first and second channel portions, a cover, and first and second slots between the cover and the first and second channel portions, respectively;

(c) alternately arranging the frame portions and corner blocks around an opening in a wall, to form a frame;

(d) inserting an end of the channel portion of each frame portion into one of the first and second channel portions of the corner block nearest to that frame portion, with an end of each frame member inside a slot of the corner block nearest to that frame portion.

22. A method according to claim 21, further comprising the step of:

(e) inserting fasteners into the mounting flanges of the frame portions and the mounting flange portions of the corner blocks to secure the frame members and corner blocks to the wall.

23. A method according to claim 21, wherein each cover block includes a cover portion having first and second overlap portions, and step (d) includes concealing ends of the frame members behind the overlap portions.

24. A method according to claim 21, further comprising, before step (c), the step of fastening a rosette onto a cover portion of each of the corner blocks.

25. A method according to claim 21, further comprising the steps of:

cutting slits in the channel portions of one of the frame members, to form a strip at a bottom of the channel portion;

inserting the strip inside one of the channel portions of the corner block if the one frame member is a top frame member; and

inserting the strip behind one of the channel portions of the corner block if the one frame member is a side frame member.