Patent Description:
Modern fenestration units typically comprise a frame assembly, into which a panel, such as a glass pane, or a sealed double glazing unit, is inserted in a direction generally normal to the plane of the panel. Typically, such frame assemblies are pre-assembled prior to the panel being inserted. A glazing bead is then secured to the frame assembly after the panel has been inserted into the frame assembly, along with a gasket, for securing and sealing said panel within the frame assembly.

The frame assembly is commonly a moveable sash, which can rotate and translate within an outer frame of the fenestration unit. The sash can be fitted into the outer frame via a hinge mechanism. Correct positioning and alignment of the hinge mechanism within the outer frame is essential to the functionality of the fenestration unit. Misalignment of the hinge mechanism may result in gaps between the sash and the outer frame when the outer frame is in a closed position, and allow airflow and moisture through the fenestration unit.

In order to fasten the hinge mechanism to the outer frame, the sash must be in an open position to prevent obstruction of the fastening process. This means the installer, or installers, must support some of the weight of the sash, whilst holding the hinge mechanism in the correct positioning and fastening the hinge mechanism within the outer frame. For large fenestration units, the sash may be too heavy to be supported by one installer, meaning additional labour is required. Even in the case of small fenestration units, additional installers may be required if one installer cannot support the sash and hold the hinge mechanism in position, whilst fastening the hinge mechanism into place. This is a cumbersome and labour inefficient process.

Beadless window frames require the glazing unit to be installed within the sash prior to installation within the outer frame. The additional weight of the glazing unit will makes the sash heavy, and additional labour may again be required to support the extra weight of the glazing unit whilst installing the sash in the correct position. <CIT> discloses a stay including a hinge mechanism and a track. <CIT> discloses a friction stay with an anti-tampering device. It also comprises a body with a ramped surface arranged to ensure that, as the vent arm is moved towards its closed position, the vent arm is lifted to a position that ensures that the vent frame does not abut part of the fixed window frame in such a manner as to prevent closure of the vent.

<CIT> discloses a window, e.g. swivel window, with a frame side locking part that engages a leaf sided locking part, in a locking position of leaf, where locking parts and closing piece are constructed in the same manner.

The present invention seeks to overcome or at least mitigate the problems of the prior art through a hinge locator assembly according to claim <NUM>.

A first aspect of the present invention provides a hinge locator assembly of a sash window configured to be located within an outer frame of a fenestration unit, the hinge locator assembly comprising;.

Advantageously, this retains the base of the hinge mechanism within the retaining formation in the correct alignment within the outer frame. In order to fasten the hinge mechanism, it must be in its open position, meaning the weight of the sash window cannot be fully supported by the outer frame and the fitter must support some of the weight. The hinge locator assists in locating the fixed part of the hinge mechanism within the outer frame for fastening into place, therefore minimising user intervention. The configuration minimises the number of extra parts needed to be manufactured, as the ramp member and the first guiding formation are integral, and minimises the labour required to install the fenestration unit. Advantageously, this configuration enables the ramp member to serve the function of guiding the glazing unit into the correct alignment, whilst the retaining formation is in the correct configuration to receive the hinge mechanism.

Advantageously, the recess is a simple way of configuring the retaining formation to receive the hinge mechanism, whilst using a part that is be required for to aid closing of the sash regardless. The shape of the recess can be altered based on the shape of the end of the part it receives.

The retaining formation may be located on a side surface of the ramp portion and extend from a top surface of the ramp portion to a base surface of the ramp portion.

The hinge locator may be configured to be fitted within the outer frame of the fenestration unit prior to the fixing of the hinge mechanism within the retaining formation.

The ramp portion and the retaining formation may be integral.

The retaining formation is a recess that may comprise two parallel sides and one perpendicular side.

According to the invention, the shape of recess complements the common shape of the end of the fixed part of the hinge mechanism. This has functional advantages because the end of the fixed part is more likely to be correctly aligned, and additionally makes the hinge locator applicable to a wide range of hinge mechanisms currently on the market.

The hinge locator may comprise a bore configured to receive a fastener. Advantageously, this is a simple way of securing the hinge locator within the outer frame.

The bore may be located on a top surface of the hinge locator extending from a top edge of the ramp portion. Advantageously, having the hole in the top surface makes it easily accessible to the fitter installing the fastening mechanism, for example a screw.

The hinge locator may comprise an at least partially planar bottom surface configured to sit within the outer frame, and a mutually parallel top surface extending from the ramp portion.

Advantageously, the bottom surface of the hinge locator being planar allows it to sit flush to the outer surface upon installation. The planar top surface is advantageous because it provides a region for the sash to sit upon when it is in the closed position.

A second aspect of the present invention provides a hinge locator system for installing a hinge mechanism within a fenestration unit comprising;.

Advantageously, having a second locator retains the hinge mechanism at a second location, and therefore restricts its movement in an axis that is running between the hinge locator and the second locator, and decreases the likelihood of misalignment.

The second locator may be configured to be located at a corner of the outer frame remote from the hinge locator.

Advantageously, this may be a space efficient configuration, and inhibits the second locator being an obstacle to the movable parts of the hinge mechanism upon assembly, and to the installation process. Additionally, the corner is a suitable datum to retain the hinge mechanism in the correct position in two directions.

The body of the second hinge locator may be configured to engage a first surface of the outer frame and an adjacent second surface of the outer frame.

Advantageously, this configuration is a compact way of seating the second locator within the corner.

The second locator may comprise a ramped surface.

Advantageously, this aids the glazing unit being in the correct position when it is in its closed position.

The second locator may comprise a hole configured to receive a fastener.

Advantageously, this is a simple way of securing the hinge locator within the outer frame.

A third aspect of the present invention provides a fenestration unit assembly for installation within an opening comprising;.

Advantageously, this assembly requires a lower level of user intervention than traditional methods. Additionally, if the sash is beadless the glazing unit must be installed prior to fitting within the outer frame, which makes the sash heavier. The hinge locator system is particularly advantageous in this case because the fitter does not have to hold the entire weight of the frame in position.

The hinge mechanism may be further configured to move the sash to translate relative to the outer frame.

A second hinge locator system may be mounted within the outer frame on an opposing side to the first hinge locator system.

Advantageously, this further simplifies the fitting of the sash by enabling hinges on both sides of the sash to be more easily secured.

A fourth aspect of the present invention provides a method of installing a glazing unit within an outer frame of a fenestration unit comprising the steps of;.

The method may comprise a further step d) after step a) of fitting the second locator of the hinge locator system of the second aspect within the outer frame.

The method may comprise a further step e) after step b) of retaining a second end of the fixed part of the hinge mechanism in the second retaining formation of the second locator.

<FIG> shows a fenestration unit of an embodiment of the present invention generally indicated at <NUM>, comprising an outer frame <NUM> with a hinge locator <NUM>, illustrated in <FIG>, mounted thereto. The fenestration unit <NUM> of this embodiment is suitable for a window, door or other type of fenestration, such as a vent or cladding panel. A sash <NUM> is moveably mounted within the outer frame <NUM>.

The term "closed position" refers to the position of the sash <NUM> when it is substantially coplanar with the outer frame <NUM>. The open position refers to the position of the sash <NUM> when it is in any other position within the outer frame <NUM>.

The term "vertical" in this context refers to the direction perpendicular to the side of the outer frame <NUM> in contact with the hinge locator <NUM>. The term "horizontal" refers to the direction parallel to the side of the outer frame <NUM> in contact with the hinge locator <NUM>. The sash <NUM> comprises an inner frame <NUM> and a glazing unit <NUM>. In this embodiment the sash <NUM> is beadless. That is, the glazing unit <NUM> is received within a fixed channel of the inner frame <NUM>, and is fitted into the channel when three sides of the inner frame <NUM> are assembled. A fourth side of the inner frame <NUM> is then secured across the opening so the glazing unit <NUM> is held in place on all sides and cannot readily be removed from the inner frame <NUM>. In other embodiments the inner frame may be beaded, and the glazing unite <NUM> may be fitted transverse to the plane of the inner frame, before a bead is fitted to hold it in place.

The sash <NUM> is connected to the outer frame <NUM> via a hinge mechanism <NUM>, so that the sash is retained within the outer frame <NUM> whilst being moveable relative to the outer frame <NUM>. It shall be appreciated that although the glazing unit <NUM> in this embodiment is a double glazing unit, alternative glazing units, for example triple glazing or opaque panels, for example for doors, may be used.

Fenestration units <NUM> of this type are typically used in external walls of domestic and commercial buildings. It is therefore necessary that the fenestration unit meets requirements for thermal insulation, sealing against water ingress, draughts etc..

Typically, the sash <NUM> and the outer frame <NUM> are metallic frames constructed from four members connected by mitre joints. A metallic sash as described here may include features or components of some non-metallic or composite material, such as plastics material or wood. In particular, the sash <NUM> may comprise external and internal aluminium profiles, which provide structural strength to the inner frame, with a thermal break of plastics or foam material sandwiched therebetween.

Typically, the sash <NUM> and the outer frame <NUM> are aluminium. The sash <NUM> and the outer frame <NUM> of this embodiment comprise a 6063T6 aluminium alloy. However, it shall be appreciated that any other suitable material may be used. In one alternative, the sash and the outer frame are of some other suitable material, such as some other <NUM> series aluminium alloy, or a <NUM> series aluminium alloy.

<FIG> is an isometric view of the fenestration unit <NUM> having a hinge locator system configured to position the hinge mechanism <NUM>. In this embodiment, the outer frame <NUM> comprises a first surface <NUM>, configured to receive the hinge locator <NUM>. The first surface <NUM> and a second surface <NUM> normal to the first are configured to receive a second locator <NUM> of the hinge locator system. The first surface <NUM> of the outer frame <NUM> is substantially horizontal in this embodiment. In this embodiment a relatively narrow groove or channel 17a is provided on the surface <NUM>, and an aligned groove or channel (not visible) is provided on the second surface <NUM>.

The first groove 17a complements a corresponding mounting formation <NUM> on the hinge locator <NUM>, and a corresponding mounting formation <NUM> on the second locator <NUM>.

<FIG> is an enlarged view of the hinge locator <NUM> illustrated in <FIG>. The hinge locator <NUM> comprises a body <NUM>, a ramp portion <NUM> formed from the body and a first retaining formation <NUM>, to receive the hinge mechanism <NUM>. The body <NUM>, the ramp portion <NUM> and the first retaining formation <NUM> are integral and the retaining formation is a recess. This reduces the number of parts necessary for manufacture and installation, and is also space efficient.

The hinge locator <NUM> is manufactured from a plastics material, but in other embodiments may be metallic or another suitable material. The hinge locator <NUM> is manufactured using injection moulding, however any suitable manufacturing technique may be used.

The ramp portion <NUM> of the hinge locator <NUM> comprises a first ramp section <NUM> and a second ramp section <NUM>. The ramped surface of the first ramp section <NUM> is configured to be steeper in gradient than the ramped surface of the second ramp section <NUM>, to aid the run-up process of the sash <NUM> into the closed position. The base surface of the first ramp section <NUM> is mounted within the first groove 17a upon assembly. This assists with its correct alignment and retention.

The second ramp section <NUM> comprises a planar bottom surface configured to sit within the outer frame <NUM> on the surface <NUM>. The first retaining formation <NUM> and a hole <NUM> extend from the top surface of the ramp section <NUM> to the base surface of the ramp section <NUM>. The hole <NUM> is configured to receive a fastener. In this embodiment, the hole <NUM> is countersunk to receive the head of a screw in a flush manner, as illustrated in <FIG>. The first retaining formation <NUM> is located on a side surface of the hinge locator <NUM> that is adjacent to an inclined edge of the ramp portion <NUM>. A second retaining formation <NUM> is located on the opposing side of the ramp portion <NUM> in the same equivalent position. The second retaining formation <NUM> makes the hinge locator <NUM> suitable for use on either side of the hinge mechanism <NUM>, and therefore increases its versatility for both right hand and left hand opening sashes.

The retaining formations <NUM>, <NUM> are both recesses, each comprising two parallel sides, and a side perpendicular to the parallel sides that extend the full depth of the hinge locator. This arrangement is suitable for receiving the hinge mechanism <NUM> of <FIG>, because the two ends of the hinge mechanism <NUM> are rectangular. The width of the retaining formation <NUM> is configured to be slightly wider than the width of the end of the hinge mechanism <NUM>, to ensure the hinge mechanism <NUM> fits within the retaining formation <NUM>, but that the movement of the hinge mechanism <NUM> within the retaining formation <NUM> is restricted. The two parallel sides restrict the movement of the hinge mechanism in a first axis extending between the parallel sides, the perpendicular side restricts the movement in an axis running perpendicular to the first axis, and the outer frame restricts the movement downwardly. Thus, the hinge mechanism <NUM> is correctly aligned in three directions when fitted therein.

The body <NUM> of the hinge locator <NUM> comprises a planar top surface <NUM> that extends from a top edge of the ramp portion <NUM>, parallel to the base surface that is mounted to the surface <NUM> of the outer frame <NUM>. This configuration enables the sash <NUM> to sit upon the planar top surface <NUM> of the hinge locator <NUM> when the window is in its closed position, in the correct alignment.

<FIG> shows a perspective view of the second locator <NUM>. The hinge locator <NUM> and the second locator <NUM> together make up the hinge locator system.

The second locator <NUM> comprises a body <NUM> configured to be mounted to the outer frame <NUM>, a third retaining formation <NUM> and a second ramp portion <NUM>. Upon assembly, the second locator <NUM> engages with the end of the hinge mechanism <NUM> remote from the hinge locator <NUM>. The second locator <NUM> is configured to be mounted to the outer frame <NUM> at a corner. The corner acts as a datum point and positions the second locator <NUM> correctly in two directions, which consequently aids the correct positioning of the hinge mechanism <NUM>.

The second locator <NUM> is manufactured from a plastics material, however it shall be appreciated that the second locator <NUM> may be manufactured using any suitable material, for example a metallic material. The second locator <NUM> is manufactured using injection moulding, however any suitable manufacturing technique may be used.

In this embodiment, the second locator <NUM> extends in two perpendicular directions to form a substantially L-shaped cross-section. A vertically extending section of the L-shape is longer than a horizontally extending section of the L-shape. This arrangement enables the second locator <NUM> to receive the end of the hinge mechanism <NUM> that has a vertical protrusion <NUM>.

The third retaining formation <NUM> extends in two perpendicular directions to form an L-shaped recess in the body <NUM> of the second locator <NUM>. The third retaining formation <NUM> comprises two sets of parallel sides that are perpendicular to one another, and a side that is perpendicular to both sets of parallel lines to form an L-shape. This configuration restricts the movement and aids the correct positioning of the hinge mechanism <NUM> in three directions. Having the hinge locator <NUM> and the second locator <NUM> fixes the position of the hinge mechanism <NUM> and prevents it from sliding out of the retaining formation <NUM>.

The second locator <NUM> comprises a second mounting formation <NUM> to mount into the non-visible groove of the second surface <NUM> to aid retention and alignment of the second locator.

The second ramp portion <NUM> extends from the horizontally extending section of the second locator <NUM>. In this embodiment, the horizontally extending section and the second ramp portion <NUM> are shorter than the total length of the first ramp portion <NUM> and the body <NUM>. This is because there is more space available both at the location of the hinge locator <NUM> and in the orientation of the hinge locator <NUM>. The second ramp portion <NUM> aids the correct positioning of the sash <NUM> by providing a run up.

The second locator <NUM> comprises a countersunk bore <NUM> extending through the vertical section of the second locator <NUM> to receive a screw.

The hinge mechanism <NUM> comprises a fixed component and at least one moveable arm. The fixed component of the hinge mechanism <NUM> of this embodiment is a track <NUM>. A slidable member <NUM> allows the sash <NUM> to translate through the linear movement of the slidable member <NUM> within the track <NUM>. The hinge mechanism <NUM> of this embodiment comprises a first, second and third arm 13a, 13b, and 13c. The arms 13a-c are configured in such a way as to allow a simultaneous pivoting and translational movement of the sash <NUM> as is known per se.

To fit the sash <NUM> within the outer frame <NUM>, firstly the hinge locator <NUM> of the above embodiment is fitted within the outer frame <NUM> by mounting the mounting formation <NUM> within the first groove 17a of the outer frame <NUM> and securing it with the screw. This ensures the hinge locator <NUM> is correctly aligned within the outer frame <NUM>. The hinge mechanism <NUM>, which is mounted to the sash <NUM>, is subsequently offered up to the outer frame <NUM> such that an end of the track <NUM> of the hinge mechanism <NUM> is located in the retaining formation <NUM>. In this embodiment, the second locator <NUM> is fitted to the corner of the sash <NUM> prior to the installation of the sash <NUM>, so that the base surface of the second locator <NUM> and the base surface of the hinge locator <NUM> are positioned on the first surface <NUM> of the outer frame <NUM>. The second end of the hinge mechanism <NUM> is retained in the third retaining formation <NUM>. This provides positive location and support for the track <NUM> and for the sash <NUM>.

The hinge mechanism <NUM> is then fastened to the outer frame <NUM>; in this embodiment using a screwdriver and screw. This permanent mounting is facilitated by the hinge locator system already aligning the track <NUM> in the correct location.

In preferred embodiments, a corresponding locating formation is provided on the opposing outer frame member so that a second hinge on a second side of the sash <NUM> may be located within that corresponding formation.

In alternative embodiments, the retaining formation may be a separate part that clips onto the body of the hinge locator. The retaining formation may be any suitable shape, for example triangular or rounded. The retaining formation may be any suitable means of retaining the hinge mechanism, for example a clamp.

In alternative embodiments, the hole in the ramp section of the hinge locator may be located in any position, for example extending from the top surface to the bottom surface of the body <NUM>. The hole may be configured to receive any suitable form of fastener, for example a rivet. Alternatively, the hinge locator <NUM> may be mechanically fastened to the other frame <NUM> via a clip fit mechanism between the base surface of the hinge locator <NUM> and the outer frame <NUM>. Any suitable non-mechanical fastening means may also be used, for example an adhesive.

In alternative embodiments, the second locator may comprise any suitable cross-section configured to position the second locator in a corner of the outer frame <NUM>. Alternatively, the second locator <NUM> may be configured to sit at any suitable location within the outer frame, for example displaced from the corner. The second locator may be identical to the hinge locator and positioned at a remote end of the hinge mechanism.

Although described in relation to a side hung sash that pivots about a vertical axis, the hinge locator may also be used for mounting hinges of top hung windows that pivot about a horizontal axis.

Claim 1:
A hinge locator assembly of a sash window (<NUM>) configured to be located within an outer frame (<NUM>) of a fenestration unit (<NUM>), the hinge locator assembly comprising;
a hinge mechanism (<NUM>) comprising a fixed component (<NUM>) and an arm (13a) pivotable relative to the fixed component (<NUM>); and
a hinge locator (<NUM>) for installing the hinge mechanism (<NUM>), comprising:
a body (<NUM>) defining a ramp portion (<NUM>) configured to be mounted within the outer frame (<NUM>) of the fenestration unit (<NUM>) so as to guide the window sash (<NUM>) into a desired position during the closure thereof,
a retaining formation (<NUM>, <NUM>) for receiving a first end of the fixed component (<NUM>) of the hinge mechanism (<NUM>) formed from the body (<NUM>), and
characterised in that the retaining formation (<NUM>, <NUM>) is a recess (<NUM>, <NUM>) located on a side surface of the hinge locator (<NUM>) that is adjacent to an inclined edge of the ramp portion (<NUM>), and wherein a shape of the recess (<NUM>, <NUM>) complements a shape of the first end of the fixed component (<NUM>) of the hinge mechanism (<NUM>).