METAL FRAME ARRANGEMENT AND PROCESS FOR PRODUCING SAME

Abstract: A metal frame arrangement (20, 21), for use as or in door frames, window frames (22), window casements (23) or the like, comprises a frame made of concave metal profile. The frame (20, 21) comprises two pairs of mutually opposite frame portions which are angled at right angles relative to the adjacent neighbouring frame portion. The frame (20, 21) is made into a coherent piece in a longitudinal continuous and sectionally angled contour, by means of local cavities (31, 35) in the metal profile and longitudinal deformation of locally uncovered portions (32, 36, 37) of the metal profile, the deformation by means of the material of the metal profile forming angle reinforcing and angle bracing means (32', 38) just by the apex of the angle between two neighbouring frame portions. A process for the production of the metal frame (20, 21) comprises that cavities (31, 35) in a side portion or side portions of the profile are removed, after which a section of web portion (20c) or one web portion (21f) of the profile uncovered by the cavity (31, 35) is finished to form an angle bracing and angle reinforcing means (32', 38) for establishing frame portions angled at right angles relative to each other. The angle bracing is effected simul­ taneously with the undertaking of the angle bending of the frame plate.

Description: The present invention relates to a metal frame arrangement for use as or in a door frame, window frame, window casement or the like, according to the peamble of claim 1. The invention is not limited to specific metal profiles but can generally be employed for relatively simple profiles as well as for more complex profiles, that is to say for simple profiles with a side portion and two web portions (essentially C-shaped profile) or with two opposite side portions and an intermediate web portion (essentially H-shaped profile), as well as for profiles with a greater number of flanges or similar projections and for closed (pipe-shaped), concave profiles. By the expression "side portion" herein is meant, in general, a portion which forms a side of the frame parallel to the main plane of the frame, while by the expression "web portion" herein is generally meant a portion which passes across the main plane of the frame. The invention relates further to a method for producing the metal frame as indicated above. Hitherto, it has been usual in the manufacture of metal frames which are to be used for door frames, window frames, window casements or the like, to fabricate the frame members in sections and to join together the frame members at the four corners of the frame by means of special mountings, for example corner angles and/or by means of special fastening devices, including fastening screws and fastening means for these. In addition to the operations of cutting off the frame members and special finishing of the frame member ends individually, significant work and extra materials are required for the production and finishing of mountings, fastening means, and the like, together with laborious mounting of these between each pair of mutually adjacent frame members, together with intermediate storage of members, which demands space and storage in a precise system. Simple frames of L-shape, C-shape or T-shape profile are also known, where cavities have been made in the profile portion or one pair of profile portions of the profile in connection with a bending of a remaining profile portion. In such cases, one obtains rather limited bracing of corners of the frame and a significant weakening of the profile at the corner portions. Such simple frames are little suited for use in window casements, wndow frames, door frames, and the like. From United Kingdom Patent Specification No. 1,394,578 it is known to brace and join together separate frame members of a profile of a synthetic plastics material, at each of the corners of the frame, with the aid of separately made reinforcing members of metal profile which are bent into a V shape after cavities have been made in side portions of the profile. In AT Patent Specification No. 333,016 there are shown reinforcing strips which are separately fastened to separate frame components. After assembling the frame components at right angles relative to each other, an extension of the reinforcing strips on the two frame components is bent into supporting abutment against the neighbouring frame component. GB-2,146,752 discloses an annular frame consisting of two jambs and an upper part which are bent into a reversed U shape and connected in ring shape with a lower part. The U-shaped frame portion is made of a largely C-shaped profile having a flat web, opposite transverse flange portions and parallel, flat flange portions. Cavities are cut in the transverse flange portions. The remaining, uncovered web and the remaining, flat flange portions are each separately folded and put together in V shape into a closely clamped state. A rigid, but not very elastic connection can be obtained between the jambs and the upper part of the U shape. According to GB-2,148,752, three separate cavities are to be made at each corner of the U shape. In addition, in each corner three different portions must be separately folded and put together. A sharp bending at the apex of each of the folded portions is shown. The sharply bent apices tend to weaken the joint connection in each corner. In addition, the joint connection is not very elastic, and it is not possible to obtain an elastically yielding clamping force in the joint connection to clamp the sections of the U shape together in an accurate manner by simple means. On the contrary, great accuracy is necessary to obtain an accurately adapted folding and putting together of the different portions in each corner and to obtain the intended accurate angles in each corner. In practice, it is still not possible to guarantee a self-regulating mutual repulsion between the abutting edges of the U shape as a result of insufficient possibilities of elastic adaptation between the different portions. The present invention aims at solving this problem by simple means. The mode of manufacture and the mode of mounting of window casements, window frames, door frames, and the like, such as has been effected hitherto, is little suited for economic mechanical production or for mass production, as a consequence of the general design of the metal profiles employed. With the new arrangement, there can be obtained a continuous production and with this a production which is substantially simpler to automatise. With the present invention the aim is a frame construction which is well suited for the manufacture of frames of metal profile for doors, windows and the like, in moderate quantities as well as for mass production. In particular, the aim is a solution where the mounting operations can be avoided or at least limited to a minimum, at the same time as there is obtained an accurately designed, stable and solid frame With the present invention, the aim is to produce a metal frame which is sufficiently rigid and strong to take up the stresses which arise in practice, without being dependent on extra rigidity and strength from other components. In this way, there is a possibility, if this is preferred, of employing, for example, separate wooden frame members which are fastened separately to the metal frame but which must not necessarily, form in themselves a coherent wooden frame. With the present invention, one has particularly in mind a frame construction which is made up of a metal frame facing towards the outside air and a wooden frame facing towards a room within. In such frame constructions, the metal frame is included as the bracing and reinforcing element of the frame construction, while the wooden frame mainly serves as a covering means and insulation on the inwardly facing side of the frame construction, that is to say on the side which faces inwards into the room present inside. The metal frame arrangement according to the invention is characterised by the features contained in the characterizing part of claim 1. By the solution according to the invention, there is achieved, with the aid of simple means, an effective bracing and extra locking of each corner portion of the frame. In that this bracing and locking can be effected with the material of the frame profile itself by means of relatively simple finishing operations, it is possible to arrive at an automatised mass production of such frames at the same time as making oneself independent of separate fastening means. A method according to the invention for producing a frame according to the invention is characterised by the steps contained in the characterizing part of claim 5. In the afore-mentioned solution, the metal frame can be produced in an especially simple and ready manner in one piece, for example, by an introductory stamping operation which is followed by a combined bending and deformation operation, effected in a coherent metal profile of a length suitable for this. This production can take place during employment of a single metal profile piece which in itself can constitute all the necessary material in the finished metal frame. More specifically, by the aid of relatively simple operations one can obtain the length of metal profile finally fashioned into a coherent, closed annular form and, in the end, obtain the finally fabricated metal frame by a simple coupling together of the ends of the length of metal profile bent towards each other. For joining together the said ends bent towards each other, there can be employed especially simple joint means as a consequence of the remaining bending of the frame. Preferably, the joint means can be formed in opposite ends of the metal profile itself, that is to say designed in the frame material itself. In this way, there is a possibility also of automatising the manufacture mechanically as regards the final fabrication of the frame and effecting the whole manufacture of the frame without being dependent on extra fastening members or remaining fastening means. Consequently there can then be avoided any usual mounting operation in the manufacture of the frame, and the fabrication can be effected in a more or less coherent sequence of working operations directly in the metal profile. According to the invention one can control the bending in a simple bending operation by accurately fashioning the support surfaces so that corners of the frame are similarly accurately designed and set precisely at a 90° angle. Further features of the invention will be evident from the following description having regard to the accompanying drawings, in which: Fig. 1 shows a vertical section centrally through a window according to the invention, with the section disposed parallel to the main plane of the window, there being illustrated metal frames (window frame and window casement) of the window, Fig. 2 shows, in part, a corner portion of the window according to the invention, illustrated in a vertical section across the main plane of the window, where there is shown the connection between metal frames of the window and wooden frames of the window, Fig. 3 shows, in part, a portion of a first profile blank which forms a part of the frame which constitutes a main component, that is to say a metal frame in a window frame according to the invention. Fig. 4-6 show different consecutive steps of forming the profile blank according to Fig. 3, Fig. 7 shows in a section corresponding to Fig. 2, the cross-section of the profile blank which constitutes a main component, that is to say a metal frame in a window casement according to the invention. Fig. 8-10 show different steps of forming the profile blank according to Fig. 7. Fig. 11 shows, in part, a fourth corner portion of a profile frame as shown correspondingly in Fig. 3 after the three remaining corner portions are formed such as shown in Fig. 6, Fig. 12-13 show different consecutive design steps for forming the profile blank according to Fig. 11. In Fig. 1, there are shown two different frames 20 and 21, which form a part of a window according to the invention, that is to say a first frame 20, which constitutes a main component of a window frame 22 as shown in Fig. 2, and a second frame 21, which constitutes a main component of a window casement 23 as illustrated in Fig. 2. More specifically, the window frame 22 comprises a main component 20 made of aluminium profile which constitutes the one of the components of the window frame which faces outwards towards the outside air. Further, the window frame comprises a facing component 24 of wood which faces towards a room present within. The aluminium profile component or frame 20 is fastened by means of screws 24a to the facing component 24. Similarly, the window casement 23 comprises a main component 21 made of aluminium profile which constitutes the one of the components of the window casement which faces outwards towards the outside air. Further, the window casement 23 comprises a facing component 25 of wood which faces towards the room present within. The aluminium profile component or frame 21 is fastened with screws 25a to the facing component 25. The facing components 24 and 25 can, in certain instances, be fastened in the form of separate members directly and separately to the frame 20 and 21 respectively. In other instances, the facing components 24 and 25 can, in themselves, constitute a wooden frame which is fastened to its respective frame 20 and 21. As regards the window casement 23, a window pane 26 (in the illustrated embodiment a three-layered insulating glass pane) is fastened by means of cover pieces 27 in a rebate 28 between the main component 21 and the facing component 25. The window pane 26 forms lateral abutments against the facing component 25 and against the cover piece 27 via usual sealing strips 29, 30. The case frame 20, which forms a part of the window frame, has a profile as shown separately in Fig. 3 and is in the form of an aluminium profile known per se , more specifically an essentially H-shaped profile. There is illustrated in Fig. 1-3, a first outer side portion 20a and a second outer side portion 20b which project outwardly on their respective sides of a transverse web portion 20c. A distance within the first outer side portion 20a, there is shown a third, outer side portion 20d present inside. At the opposite side of the profile, there is shown an inner side portion 20e which is connected to the web portion 20c via a transition portion 20f extending in a zig-zag with an associated inner flange 20g. In Fig. 4, there is shown a side view of the aluminium profile according to Fig. 3, after there is effected a finishing of the profile, that is to say a stamping of a cavity 31 in opposite side portions of the profile as shown at the side portion 20e. Without being shown in the drawing, there is taken out an equivalent cavity also in the side portion 20a, 20b, 20d which lies opposite the side portion 20e. The cavities are made just inwardly of the straight portion of web portion 20c of the profile. In other words, two sections of aluminium profile length are connected longitudinally to each other only by means of the web portion 20c, remaining portions of the profile being removed at the cavities 31. As shown in Fig. 4, the cavity 31 has essentially the form of a right angled, isosceles triangle, where equal legs 31a and 31b of the triangle form lateral limits for each frame member or each section in the length of the aluminium profile. At the bottom of the triangle, that is to say at the longest side of the triangle, there is a maximum distance between the legs 31a and 31b while legs of the profile at the top angle of the triangle are mutually separated by a narrow gap 31c. If there is a need for it, the length of the gap can be increased, as required. The web portion 20c is, as shown in Fig. 4, uncovered above a section 32. The length of the gap 31c can be adapted according to the desired length of the section 32. Instead of a triangular cavity, there can be employed another multi-sided shape, that is to say a trapezoidal cavity. In Fig. 5, there is shown the profile with an introductory bending of the uncovered section 32 of the web portion 20c. By the arrow A, there is shown a lower support abutment against the central portion 32a of the uncovered section 32 (for example, by means of a convexly curved support means). By the arrows B and C, there are indicated tapered pressure means which are adapted to form abutments against the web portion 20c, more specifically with abutments in each respective limited region 32b and 32c of the uncovered section 32 at the respective transition port in the cavity 31. In Fig. 6, the profile is shown with a further bending of the uncovered section 32 of the web portion 20c between two neighbouring frame members. In Fig. 6, the support abutment is removed, as shown by the arrow A in Fig. 5. In this fabrication phase, the pressure means form, as shown by the arrows B and C, by way of introduction in this phase, support abutments in the regions 32b and 32c, while additional clamp means, as indicated by the arrows D and E, form abutments against and exert pressure against certain side portions 32d and 32e of central portion 32a of the section 32. Finally, the pressure means are removed, as indicated at B and C, and by further clamping action from the clamp means, as indicated by D and E, there is ensured a stretching effect in the central portion 32a, including the portions 32d, 32e, while there is correspondingly ensured a pressure effect in the portions 32f and 32g. The portions 32f and 32g have together a substantially shorter dimension than the central portion 32a so that the portions 32f and 32g can be pressed endways, tightly together, by the clamping effect from the clamp means D and E against the portions 32d and 32e. Simultaneously with the tight pressing together of the portions 32f and 32g, one ensures that the limiting edges, as illustrted by edges 31a and 31b of the cavity, are pressed correspondingly tightly together for limiting a precise 90° angle between the bent neighbouring frame members. By means of the bent section 32 of the web portion 20c, there is formed a combined bracing means and locking means 32' between the neighbouring frame members, that is to say a means 32' formed by the web portion 20c itself in the profile of the frame 20. The means 32', which forms bracing and locking means for said neighbouring frame members, constitutes consequently a unitary portion of the frame iself and forms a thickened (folded together) and through-going connection between the neighbouring frame members. As is shown in Fig. 1, the means 32' between the pairs of neighbouring frame members are arranged outside the web portion, that is to say in the space which is defined between web portion 20c of the profile and side portion 20d together with side portions 20e and 20f, while the concave space of the frame along the web portion 20c is shown completely level and smooth. In Fig. 7, there is shown the cross-section of the metal frame component 21 of the window casement, the profile being illustrated in the form of an aluminium profile known per se with an approximately C-shaped cross-section. The profile is shown with a central, level side portion 21a. From the side portion 21a, there projects laterally outwards an outer web portion 21b with an outwardly angled flange 21c and an inwardly angled transition portion 21d to a laterally directed flange 21e. From the side portion 21a, there projects additionally laterally outwards an inner web portion 21f which is provided outermost with a U-shaped hook portion 21g. The afore-mentioned cover member 27 is fastened in place on inner web portion 21f of the profile 21 in that an L-shaped locking member portion 27a is received in hook portion part 21g of the profile 21, while a support lug 27b forms support against flange 21e (see Fig. 2) of the outer web portion 21b. As shown in Fig. 8, the profile 21 in the starting position is straight. Provision is made to form a first smaller cavity (not shown) in the hook portion part 21g of the profile and in the portions 21c, 21d, 21e and to form in the side portion 21a, another right angled, isosceles, triangle-shaped cavity 35, that is to say a cavity 35 flush with the said first smaller cavity. The cavity 35 uncovers outer web portion 21b of the profile over a section 36 of minimum dimension at the top of the triangle 35a of the cavity 35 and uncovers inner web portion 21f of the profile over a substantially larger section 37 at the bottom of the triangle of the cavity 35. The said first cavity uncovers the profile correspondingly as shown by the sections 36 and 37. By this, the profile can be bent, as is shown in Figs. 9 and 10, there being fashioned gradually stops and support abutments between isosceles triangle legs 35b and 35c of the cavity 35. Also in the construction according to Fig. 7-10, there can be employed instead of a triangular shape another multi-edged shape, such as a trapezoidal shape. It is evident from Figs. 9 and 10 that outer web portion 21b of the profile 21, as shown by the section 36, is bent to a 90° angle, by means of an inner support abutment as shown by arrow F and outer pressure means, as illustrated by the arrows G and H, while the legs 35b and 35c of the triangle form support abutments against each other. Similarly, it is evident from Fig. 9 and 10 that inner web portion 21f of the profile 21 at the section 37, is bent in an equivalent manner as shown and described for web portion 20c of the profile 20, by means of an inner support abutment, as shown by an arrow A. and outer pressure means, as shown by arrows B and C and clamp means as shown by the arrows D and E. Consequently, there is formed, in the section 37, a bracing and locking means 38 which secures frame members of the profile 21 in the position shown in Fig. 10. Consequenty, the outer web portion 21b will pass continusously at the outer periphery of the frame, while the inner web portion 21f will extend pressed together, but continuously at the inner periphery of the frame. By this, there is achieved an effectively braced, solid frame. frame members of the profile between the formed sections 36 and 37 (Fig. 8) forming support abutments towards each other along the edges 35b, 35c of the cavity 35 in associated side portion 21a of the profile. In addition, there can be obtained a similar support abutment in corresponding bevelled edges at the outwardly opening side of the profile. It is clear that the frames 20 and 21, which are described above and shown in Fig. 1-10, can be fashioned separately in the same sequence with three frame corners in a manner corresponding to that shown in Fig. 4-6 and 8-10. In the same sequence, the fourth corner of the frame 20 can also be fashioned with a bracing and locking connection 40 and the fourth corner of the frame 21 with a bracing and locking connection 41. In Fig. 11-13, there are shown subsequent production steps during the fashioning of the connection 40 in the frame 20, the connection 41 in the frame 21 being able to be fashioned in a manner corresponding to that for the connection 40, without this being shown specifically in detail. In Fig. 11, the frame 20 is shown at the said fourth corner, after the three remaining corners are finally bent such as shown in Fig. 6. The two neighbouring frame members in the fourth corner are provided with their respective obliquely cut off side edges 20h and 20i. The one of the frame members is provided with an uncovered section 42 of the web portion 20c, while the adjacent second frame member in the fourth corner is provided with a transverse slot 43 in the web portion 20c. The uncovered section 42 of the one frame member forms an endways, outwardly projecting locking tongue which is to be connected to the locking member-forming slot 43 in the second frame member. In Fig. 12, the locking tongue 42 is shown in a partially folded condition, that is to say with three successive portions 42a, 42b and 42c bent mutually and relative to the web 20c with outer portion 42c of the locking tongue arranged just by the inlet to the slot 43. In Fig. 13, the locking tongue is shown after the portion 42a is threaded into place through the slot 43 and is clamped into abutment against the one side of the web portion on the said second frame member, while the outer portion 42c is clamped into abutment against the opposite side of the web portion, and the intermediate portion 42b is received in the slot 43. In this way, locking means 42, 43 have been fashioned out of the material of web portion 20c, and these locking means have been joined into an effective locking engagement immediately after the three remaining corners of the frame are set separately at a 90° angle. The locking means 42, 43 correspondingly lock the fourth corner at a 90° angle. By this, there is obtained an effective locking up of each of four corners of the frame with the aid of locking means made of material of the aluminium material itself and directly connected to the aluminium profile.

Claims: Metal frame arrangement (20, 21) for use as or in a door frame, window frame (22), window casement (23) or the like, which frame is made of a single longitudinal concave metal profile with a longitudinally continuous and sectionally angled contour and and comprising local sections of a portion (32, 37) of said longitudinal profile and mutually supporting profile edge portions (31a, 31b; 35b, 35c), said arrangement constituting a rectangular, annular frame with two pairs of mutually opposite frame portions which are angled relative to adjacent frame portions, characterised in that said local sections of a portion (32, 37) of said longitudinal profile provide kidney-shaped angle-reinforcing and angle-bracing components (32', 38) at the apex of the angle between each pair of mutually supporting profile edge portions, which components constitute deformations of said local sections of a portion of said longitudinal metal profile, whereas said profile edge portions (31a, 31b; 35b, 35c) are mutually supported by said angle-reinforcing and angle-bracing components (32', 38). Metal frame according to claim 1, characterised in that the deformably bent kidney-shaped web portion (32', 38) has a convexly bowed outer surface (at 32a) and a concavely bowed inner surface (at 32f and 32g) having a central portion at each corner. Metal frame according to claim 1, characterised in that the kidney shape defines a pair of short pressure-absorbing inner bow portions (32f, 32g) and an outer intermediate stress-absorbing bow portion (32a) having a longitudinal dimension considerably larger than the combined length of said inner bow portions. Metal frame according to claim 3, characterised in that the inner bow portions (32f, 32g) are of substantially rectilinear form while the outer bow portion (32a) is of arcuate form. Method for producing a metal frame arrangement according to any one of claims 1-5 for use as or in a door frame, window frame, window casement or the like, comprising the steps of providing a single longitudinal concave metal profile with a longitudinally continuous and sectionally angled contour; forming local cavities in the metal profile, which cavities uncover local sections of a portion of said longitudinal profile; forming a rectangular, annular frame with two pairs of mutually opposite frame portions, which are angled relative to their adjacent frame portions, by local bending of the metal profile at the local cavities; characterised by the steps, during said forming of a rectangular, annular frame, of deforming the uncovered local sections longitudinally and/or laterally to form the kidney-shaped angle-reinforcing and angle-bracing components at the apex of the angle between each pair of mutually supporting profile edge portions, and simultaneously establishing a predetermined angle between said frame portions. Method according to claim 5, characterised in that said step of forming a rectangular, annular frame comprises bending the opposite ends of the profile in a direction towards each other and joining together mutually engageable locking elements formed at said opposite ends from the material of said profile. Method according to claim 5 or 6, wherein the profile is essentially C-shaped and web portions of the profile extend across a main plane of the frame and a side portion extends parallel to said main plane, characterised in that after removal of the cavity (35) in the side portion (21a) the profile is bent about a transverse axis substantially at one uncovered section (36) of an external web portion (21b) of said cavity, and another uncovered section (37) of an internal web portion (21f) is simultaneously fashioned into the angle-reinforcing and angle-bracing component (38). Method according to claim 5, characterised in that the forming of local cavities comprises forming of an isosceles polygon, and that the establishing of a predetermined angle between said frame portions comprises the step of pressing two legs of the polygon tightly together for limiting a precise 90° angle between neighbouring frame portions.

Inventors: KARLSSON, ARNE
Applicants: A/S SPILKA INCO LTD.
Application year: 1988
Main classification: E06B3
IPC codes: E06B3