Patent Description:
When installing windows in a roof it is vital to ensure that both the roof window itself and the joint between the roof window and the roof structure is properly weather proofed. This is ensured by the use of coverings and flashing, which covers the roof window and the joint, respectively. Covering members and flashing members are usually made from sheet metal, which combines the advantages of low weight and high weather resistances, but which is sensitive to damages caused by deformation and scratching. Flashing members are typically provided in a separate packaging, but at least some of the covering members are typically pre-attached to the roof window. To protects these and other sensitive components, such as the pane of the roof window, blocks of expanded polystyrene or similar shock absorbing material are arranged inside the cardboard box. These blocks may prevent deformation of the cardboard box, thereby preventing that excessive loads affect the roof window, and/or keep components of the roof window in their intended positions within the box. One example of a packed roof window, where these principles are used, is known from <CIT>.

While this packaging has worked very well, there is an ever-increasing demand for delivering products that are more environmentally friendly.

With this background, it is an object of the invention to provide a packed roof window, which has a smaller climate footprint, while maintaining a good protection of the roof window during transportation.

This and further objects are achieved with a packed roof window product with a frame-side ventilation flap retainer as defined in claim <NUM>.

Ventilation flap retainers have previously been made from expanded polystyrene (EPS), which is cheap, light-weight, and sufficiently soft to not course abrasive damage to other components of the roof window during handling and transportation in the packed state. The use of EPS, however, requires that the packaging material will have to be separated in different fractions for recycling. The paper-based ventilation flap retainer on the other hand belongs to the same fraction as the cardboard box, which considerably increases the likelihood of the packaging material being recycled instead of just being disposed of as combustible waste and reduces the risk of recycled material being polluted by other materials.

Roof windows are often delivered with the ventilation flap in a disengaged state where it has been swung away from the frame and/or sash of the window towards the pane in order to make it take up less space, thereby allowing the use of a smaller cardboard box. The frame-side ventilation flap retainer arranged between the ventilation flap and a sash or frame of the roof window keeps the ventilation flap in this position, preventing it from moving towards the sash or frame during handling and transportation of the packed roof window. In this way damage to the roof window, which might be caused by uncontrolled movement of the ventilation flap is prevented.

Some paper-based materials may have poorer properties than EPS when it comes to abrasion, but this may be compensated for by arranging a paper-based slip sheet between the ventilation flap retainer and potentially sensitive components of the roof window, such as the pane or a painted surface of the sash. Likewise, smudging should be avoided, either by testing the material chosen for the ventilation flap retainer or by using a slip sheet.

Another potential advantage of using a ventilation flap retainer made from a paper-based material is that it may be biologically degradable. Light-weight packaging items, such as plastic wrappings, films, and EPS, are easily caught by wind when installing a roof window product on a roof of building and may easily end up in nature or other places where it cannot be collected by the installer. While it is of course not the intention to leave packaging material behind, a biodegradable ventilation flap retainer does little harm.

A ventilation flap typically form part of a roof window further comprising a sash carrying a pane, a frame, a set of hinges allowing the sash to swing or rotated in relation to the frame, and a locking assembly for locking the sash in relation to the frame, where the locking assembly is operable by moving the ventilation flap, where in the first and second positions, the sash is locked in relation to the frame, and in a third position of the ventilation flap, the sash is moveable in relation to the frame. Such a window will typically be centre-hung, and the ventilation flap will be located at a top sash member intended to be at the top of the roof window in the mounted state.

The ventilation flap may be connected to a sash or frame of the roof window by means of one or more hinges.

The ventilation flap may be an elongate member extending along a member of the sash or frame, in parallel therewith, and may extend over substantially the entire width or height of the roof window.

A handle may be provided on the ventilation flap for ease of operation. If the ventilation flap is an elongate member, the handle may be in the form of a rail or bar extending in parallel therewith and having substantially the same length as the ventilation flap.

In one embodiment, the frame-side ventilation flap retainer extends into the ventilation passage. If the section(s) of the frame-side ventilation flap retainer, which extend into the ventilation passage, is/are of slightly larger dimensions than the ventilation passage, the engagement between them may contribute to keeping the frame-side ventilation flap retainer in the intended position. In some roof windows the ventilation passage is provided with a grate-like structure dividing the ventilation passage into a series of openings. The frame-side ventilation flap retainer is configured for engagement with the grate-like structure or an opening therein.

Another frame-side ventilation flap retainer comprises a centre section configured for engagement with the ventilation flap and two wing sections configured for being inserted into the ventilation passage. The shape and size of the frame-side ventilation flap retainer will depend on the design of the roof window. Particularly the shape and position of the wing sections may have to be adapted to the shape and position of the ventilation passage in a given roof window.

In one embodiment, a pane-side ventilation flap retainer is arranged between the ventilation flap and a pane of the roof window. Such a ventilation flap retainer prevents a ventilation flap provided in a disengaged state from moving further towards the pane than intended, thus for example preventing it from pounding at the pane and potentially coursing damage during handling and transportation of the packed roof window.

In one embodiment, the pane-side ventilation flap retainer is further arranged between the ventilation flap and the cardboard box. This too will contribute to keeping the ventilation flap in the intended position during handling and transportation of the packed roof window.

One ventilation flap retainer may extend from the pane to the cardboard box.

In one embodiment the roof window comprises a handle on the ventilation flap and the ventilation flap retainer is attached to the handle. This arrangement of the ventilation flap retainer is particularly advantageous in a pane-side ventilation flap retainer and may provide for easy and reliable attachment and detachment of the ventilation flap retainer as will be described in further detail below.

In the following, whenever reference it made to "a ventilation flap retainer" or "the ventilation flap retainer" it is to be understood that the description applies to both a pane-side ventilation flap retainer and to a frame-side ventilation flap retainer.

A ventilation flap retainer(s) may for example be made from a material chosen from the group consisting of: moulded pulp, folded cardboard, folded corrugated cardboard, multi-layer corrugated cardboard, cardboard profile, and honeycomb material, preferably a having a cell size of <NUM> and being made from paper with a weight of <NUM>/m<NUM> and having a height of <NUM>-<NUM>. The present frame-side ventilation flap retainer is made from folded cardboard or folded corrugated cardboard.

A present moulded pulp, folded cardboard, or folded corrugated cardboard is considered advantageous as the strength requirement for the ventilation flap retainer(s) is usually limited and as it allows the use of the ventilation flap retainer for other purposes.

Moulded pulp can be given virtually any desired shape but has limited strength. It is thus advantageous for applications, where the ventilation flap retainer needs to a have complex three-dimensional shape, but items made from moulded pulp are generally characterized by large dimensionally tolerances. Folded cardboard and folded corrugated cardboard on the other hand can be given less complex shapes but may have higher strength and smaller tolerances. They are therefore preferred for roof windows, where the ventilation flap has been made extra heavy to balance the sash. Furthermore, folded cardboard and folded corrugated cardboard can easily be reshaped by folding, unfolding and possibly refolding in another configuration.

In one embodiment the pane-side ventilation flap retainer is a carton made from folded cardboard or folded corrugated cardboard and containing components for use when installing or operating the roof window. Examples of such components are sensitive components, such as electronic components, for example wires, photovoltaic elements, sensors, batteries, or remote controls; components, which are likely to cause damage to other components, such as mounting brackets for connecting a roof window to a roof structure and screws, nails, clamps or like fasteners; and components, which are advantageously kept in a folded and/or compressed state, such as wires, cables, sealing strips, insulating components, underroof collars, and vapour barrier.

It is presently considered particularly advantageous to provide components, which are to be used on the interior side of the roof window, in a carton used as pane-side ventilation flap retainer, examples of such components being a remote control for operating the window once installed, and a vapour barrier, which is used to seal the joint between the roof window and the roof structure, wall or sealing on the interior side.

It is also, or alternatively, possible to attach items to a ventilation flap retainer, for example using a glue, an adhesive, a paper tape or a paper ribbon. Small items such as fasteners may be arranged in a paper bag, which is attached to the ventilation flap retainer. Screws may even be attached to a ventilation flap retainer by simply being screwed into it.

Attachment of the pane-side ventilation flap retainer may be achieved by providing it with a physical structure allowing it to engage with the handle, such as one or more hook-shaped projections. These may be formed by folding the material of the ventilation flap retainer.

A shock absorbing material may be provided on the ventilation flap retainer(s). Such a shock absorbing material is preferably also made from a paper-based material.

In one embodiment, a ventilation flap retainer is configured for serving a secondary purpose after having been removed from the ventilation flap or handle. One example of such a secondary purpose is that the ventilation flap retainer is configured for being attached to a corner of a sash of the roof window after being removed from the ventilation flap. The sash of a roof window is often removed before mounting the window frame in an opening in a roof structure, and the sash then needs to be put down, for example on a floor. When doing so, particularly the corners of the sash are in danger of being scratched or smudged. As substantially the entire sash may be visible in the use state of the roof window, the possibility for protecting it without increasing the material consumption is clearly advantageous. The ventilation flap retainer is preferably attached to a corner of the sash before detaching the sash from the window frame.

The attachment to the corner of the sash may for example be achieved by inserting the corner of the sash or a projection thereon into a recess in the ventilation flap retainer or vice versa.

A ventilation flap retainer made from folded cardboard or folded corrugated cardboard may be foldable into two different configurations, one suited for retaining the ventilation flap and one suitable for sash corner protection. For this purpose, the ventilation flap retainer may have matching flaps and recesses allowing it to be retained in one or more folded states.

When a ventilation flap retainer is made from moulded pulp, it may be re-shaped by being compressible or by being provided with one or more weak zones allowing a section of the ventilation flap retainer to be broken off.

Information about the intended use of the ventilation flap retainer, about the installation of the roof window, or about items contained in or attached to the ventilation flap retainer may be printed on the ventilation flap retainer. Alternatively, at a sticker with such information may be attached to the ventilation flap retainer.

It is to be understood that while paper and cardboard are usually made from wood-fibres, other plant fibres including fibres originating from straw, bamboo, bagasse, esparto, other grasses, hemp, flax, and cotton may also be used, including combinations of different types of fibres. In Europe, up to <NUM>% of alternative materials, such as the glue or adhesive used for example in the formation of a corrugated cardboard or a honeycomb structure, is acceptable, but a maximum of <NUM>% is recommended.

Referring initially to <FIG>, a centre-hung roof window <NUM> comprising a frame <NUM> and a sash <NUM> carrying a pane <NUM> is shown. The roof window can be opened and closed and brought into an intermediate ventilation position by operating a handle bar <NUM> connected to ventilation flap <NUM>, which is in turn connected to a locking assembly (not visible in <FIG>) configured for locking the sash in relation to the frame. In the state shown in <FIG>, the handle bar and the ventilation flap are, however, shown in a state, where they are disengaged from the locking assembly to make the roof window take up less room during storage and transportation. To prevent the disengaged handle bar and ventilation flap from moving too much during handling and transportation, ventilation flap retainers are attached to the handle bar <NUM>, of which only pane-side ventilation flap retainers <NUM>, <NUM> are visible in <FIG>.

A set of blocks <NUM>-<NUM> of shock absorbing material are arranged around a frame <NUM> of the roof window and on the pane <NUM>. These blocks of shock absorbing material are intended to protect the roof window when it is arranged in a cardboard box before being delivered to a customer and will not be described in further detail here.

In the following the same reference numbers will be used for elements having substantially the same function, even if not identical.

Turning now to <FIG>, which corresponds to a cross-section along the line A-A in <FIG>, only without the frame-side ventilation flap retainer <NUM>, the roof window <NUM> has been arranged in a cardboard box <NUM>. As may be seen, the frame-side ventilation flap retainer <NUM> hooks over the handle bar <NUM> and extends from the interior side <NUM> of the pane <NUM> to the section <NUM> of the cardboard box extending in parallel therewith. In this way the frame-side ventilation flap retainer not only retains the handle bar and the ventilation flap to which the handle bar is connected but also contributes to preventing deformation of the cardboard box, thus protecting the window as such. In a similar manner the block <NUM> of insulating material provided on the exterior side <NUM> of the pane <NUM> keeps a distance between the pane and the section <NUM> of the cardboard box extending along it.

A frame-side ventilation flap retainer <NUM> is seen between the ventilation flap <NUM> and the top frame member <NUM> of the roof window <NUM> in <FIG>, extending into the ventilation passage <NUM>. This frame-side ventilation flap retainer may both retain the ventilation flap and support the top sash member <NUM> of the roof window.

Turning now to <FIG>, which a perspective view corresponding to the detail marked B in <FIG> but taken from the interior side of a roof window <NUM> and showing a carton <NUM> instead of the pane-side ventilation flap retainer <NUM> made from moulded pulp. Here it is seen that both the handle bar <NUM> and the ventilation flap <NUM> are elongate extending in parallel with the top sash member <NUM> and extending over substantially the entire width of the roof window. This need not be the case, but the ventilation flap should be able to cover the entire opening of the ventilation passage <NUM>, which in this case is divided into a series of openings by a grate-like structure <NUM>.

As may be seen the pane-side ventilation flap retainers <NUM>, <NUM>, which were shown in <FIG>, are both made from folded cardboard and the carton <NUM> attached to the handle bar <NUM> also serves as a pane-side ventilation flap retainer. Whereas the ventilation flap retainers <NUM>, <NUM> are made from recycled unbleached cardboard, the carton <NUM>, which contains items to be used in the installation or operation of the roof window, is made from white cardboard to make draw attention to it, ensuring the items inside are not unintentionally discarded.

The pane-side ventilation flap retainer <NUM> is shown in more detail in <FIG> showing the ventilation flap retainer in an unfolded state and <FIG> showing it in the folded state also seen in <FIG>. A bone-shaped cut-out <NUM> is configured for attachment of the handle bar <NUM> of the roof window, and fold lines <NUM> extend perpendicular to the longest dimension of the cut-out. As shown in <FIG> the pane-side ventilation flap retainer <NUM> is attached to the handle bar <NUM> by first arranging the unfolded or slightly folded ventilation flap retainer on top of the handle bar so that the straight section <NUM> of the cut-out extends in parallel with the handle bar. When then folding the ventilation flap retainer <NUM> along the fold lines <NUM>, the straight sections <NUM> pass over the handle bar, which becomes arranged in the wider end sections <NUM> of the cut-out <NUM>. The slight elasticity of the cardboard at the fold lines <NUM>, which urges the pane-side ventilation flap retainer <NUM> back towards the unfolded state, now presses the ends of the cut-out <NUM> against the handle bar <NUM>, as may also be seen in <FIG>, keeping it in place.

When the roof window has been unpacked, the pane-side ventilation flap retainer <NUM> is no longer needed and may be removed. At the same time the sash of the roof window often needs to be removed to facilitate installation of the frame in the roof structure, and the pane-side ventilation flap retainer may then be folded further and used for protecting the sash. The further folded pane-side ventilation flap retainer is shown in <FIG>, and the further folded ventilation flap retainer attached to a corner of the sash is seen in <FIG>. As is best seen in <FIG>, the ventilation flap retainer <NUM> remains folded at the original fold lines <NUM> and is further folded along a secondary folding line <NUM>, which is located at the indentation <NUM> seen in <FIG> and extending in parallel with the original fold lines <NUM>. The ventilation flap retainer is fixated in the further folded state by folding the V-shaped sections <NUM>, and the cut-out <NUM> now fits over a projecting edge <NUM> of the sash of the roof window as shown in <FIG>. The cut-out <NUM> is preferably slightly smaller than the projecting edge <NUM> of the sash, so that the further folded ventilation flap retainer <NUM> is kept in place on the sash by friction.

In this embodiment the V-shaped sections <NUM> are delimited by pre-made cuts in the material, but it is also possible to use weak zones, which can be interrupted when the V-shaped sections are to be used, or printed lines indicating where to cut the cardboard.

Furthermore, information <NUM> about the intended use of the pane-side ventilation flap retainer <NUM> is printed on its surface as seen in <FIG>.

Two alternative pane-side ventilation flap retainers <NUM> are shown in <FIG>. In <FIG> the pane-side ventilation flap retainer <NUM> is pre-folded with a pipe-shape cross-sectional shape instead of the U-shape resulting from the folding shown in <FIG>, and in <FIG> the pane-side ventilation flap retainer <NUM> is made from a honeycomb material. Both of these ventilation flap retainers are stronger and more stable than the one in <FIG>, but not immediately useable for sash corner protection.

Turning now to <FIG>, the frame-side ventilation flap retainer <NUM> arranged between the ventilation flap <NUM> and the top frame member of the roof window <NUM> and extending into the ventilation passage <NUM> is shown in more detail. Two fold lines <NUM> separate two wing sections <NUM> from a centre section <NUM>. The wing sections are configured for being inserted into the ventilation passage <NUM> as shown in <FIG> and the centre section is configured for abutting the ventilation flap <NUM> as shown in <FIG>.

The shape and size of the frame-side ventilation flap retainer <NUM> will depend on the design of the roof window. Particularly the shape of the ventilation passage <NUM> and hence the shape and position of the wing sections <NUM> may therefore need to be different from what is shown in <FIG>.

An alternative to the frame-side ventilation flap retainer <NUM> shown in <FIG> is shown in <FIG> which show a frame-side ventilation flap retainer <NUM>' according to the invention. This frame-side ventilation flap retainer <NUM>' is folded along fold lines <NUM> so that the cut-out <NUM> at the centre gets a T-shape fitting over the bracket assembly <NUM> connecting the ventilation flap <NUM> to the locking assembly <NUM> (only visible in <FIG>) of the roof window. At the same time other cut-outs <NUM> and recesses <NUM>, which overlap in the folded state, fit over the grate-like structure <NUM> at the entrance to the ventilation passage <NUM>, and the elasticity resulting from the folding keeps the frame-side ventilation flap retainer <NUM>' in place. A further recess <NUM> allows the frame-side ventilation flap retainer to also be used with an electrically operated window comprising a further bracket <NUM> attached to the ventilation flap as shown in <FIG>.

The shape and size of this frame-side ventilation flap retainer <NUM>' too will depend on the design of the roof window. Particularly the shape of the cut-outs <NUM> and recesses <NUM>, <NUM> may need to be different from what is shown.

Compared to the frame-side ventilation flap retainer <NUM> in <FIG>, the embodiment in <FIG> has proven to be stronger and more stable in use.

Turning now to <FIG>, a series of perspective views show how a cardboard blank is folded into a carton <NUM> and attached to the handle bar <NUM> of a roof window. This carton may serve both to hold items for use in the installation or operation of the window and as a pane-side ventilation flap retainer. It corresponds to the one shown in <FIG>, except for being provided with information of its content and having a slightly different shape. The perspective view in <FIG> is seen from the interior side of the roof window, whereas the perspective views in <FIG> are seen for the exterior side of the roof window.

As is best seen in <FIG>, the carton <NUM> engages with the interior side of the pane <NUM>, but does not project above the handle bar in the opposite direction. It is, however, possible to make the carton bigger so that it could potentially extend out to the cardboard box <NUM> in the same way as the pane-side ventilation flap retainer <NUM> in <FIG>. An example of such a bigger carton <NUM>' is shown in <FIG>.

Turning now to <FIG>, a further development of the frame-side ventilation flap retainer <NUM> in <FIG> is shown.

Each of the two wing sections <NUM> are here formed by folding a first sub-section 233a onto a second sub-section 233b before folding along the two fold lines <NUM>, and likewise the centre section <NUM> is formed by folding a first sub-section 234a onto a second sub-section 234b. Flaps <NUM> help the frame-side ventilation flap retainer <NUM> to remain in the folded state shown in <FIG>.

In this embodiment the centre section <NUM> further comprises a third sub-section 234c, which is angled in relation to the first and second subsections 234a, 234b in the folded state shown in <FIG> and extending between the wing sections <NUM>. As will be understood by comparing to <FIG>, the wing sections <NUM> of this embodiment too extend into the ventilation passage <NUM> and the third sub-section 234c will extend over ventilation passage <NUM>. In this way the wing sections will be kept from moving towards each other, thus contributing to keeping them in engagement with the ventilation passage. Further, since both the centre section <NUM> and the wing sections <NUM> are made by folding, they are in themselves stronger than in the embodiment in <FIG>, and hence the entire frame-side ventilation flap retainer <NUM> is stronger. This embodiment may therefore be preferred if the ventilation flap itself is very heavy, or if having weight is attached to it, for example in the form of cartons as shown in <FIG>.

As mentioned above with reference to <FIG>, the shape and size of the frame-side ventilation flap retainer <NUM> will depend on the design of the roof window. Particularly the shape of the ventilation passage <NUM> and hence the shape and position of the wing sections <NUM>, and sub-section 234c may therefore need to be different from what is shown in <FIG>.

Claim 1:
A packed roof window, said window (<NUM>) comprising a ventilation passage (<NUM>) and a ventilation flap (<NUM>), said ventilation passage (<NUM>) extending from an interior side (<NUM>) of the window to an exterior side (<NUM>) of the window, said ventilation flap (<NUM>) being provided on the interior side (<NUM>) of the window and being moveable between a first position, where the ventilation passage (<NUM>) is open, and a second position, where it covers the ventilation passage (<NUM>), where said roof window (<NUM>) is contained in a cardboard box (<NUM>), where blocks of shock absorbing materials (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>) are arranged inside the cardboard box (<NUM>) to protect the roof window (<NUM>), and where a frame-side ventilation flap retainer (<NUM>, <NUM>') is provided on or at the ventilation flap (<NUM>) to prevent it from unintentional movement, said frame-side ventilation flap retainer (<NUM>, <NUM>') being arranged between the ventilation flap (<NUM>) and a sash (<NUM>),
characterised in that
the frame-side ventilation flap retainer (<NUM>, <NUM>') is made from paper-based folded cardboard or folded corrugated cardboard, and that the frame-side ventilation flap retainer (<NUM>') is folded along fold lines (<NUM>) so that a cut-out (<NUM>) at the centre gets a shape fitting over a bracket assembly (<NUM>) connecting the ventilation flap (<NUM>) to a locking assembly (<NUM>) of the roof window (<NUM>), and the frame-side ventilation flap retainer (<NUM>') comprises other cut-outs (<NUM>) and recesses (<NUM>) overlapping in the folded state, which are fitted over a grate-like structure (<NUM>) at the entrance of the ventilation passage (<NUM>), wherein the cut-out (<NUM>) at the centre gets a T-shape.