Thermal composite window

Abstract

A composite window includes an exterior frame having a metal portion. An interior frame is spaced apart from the exterior frame and has a wooden portion. A thermal barrier interconnecting the exterior frame and the interior frame has an uninterrupted wall defining a cavity in cross-section to restrict the flow of heat between the exterior frame and the interior frame.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of GB Application No. 0702958.0, filed Feb. 15, 2007. The disclosure of the above application is incorporated herein by reference.

BACKGROUND

The present disclosure relates to composite windows.

There is an increasing demand for windows made from materials other than plastic. Timber is often a preferred option visually but typically requires maintenance and can deteriorate when exposed to moisture. Metal windows, especially those clad with timber on the inside, may provide an acceptable solution. However, with increasing pressure on suppliers to produce very insulative products to avoid heat escaping from buildings, a thermally superior window profile may be required.

Demands also come from architects, suppliers, end users and conservation teams from local councils, all often having different remits. Some users request one or more feature including slim sections, heavier sections, low maintenance, wood and high insulation values. UPVC is often restrictive due to its properties and mass market status. When timber is used, it may have to be made in heavier sections to support the weight of double glazed or even triple glazed units. Aluminum may be more versatile with virtually any color option and is up to 28 times stronger than UPVC. The aluminum material may be slimmer and may be joined together to make thicker profiles. However, aluminum allows greater heat transfer and is a very poor insulator, possibly resulting in great heat loss and condensation on inside faces.

SUMMARY

A thermal composite window includes an exterior frame having a metal portion. An interior frame is spaced apart from the exterior frame and has a wooden portion. A thermal barrier interconnecting the exterior frame and the interior frame has an uninterrupted wall defining a cavity in cross-section to restrict the flow of heat between the exterior frame and the interior frame.

Also disclosed is a composite window comprising an exterior frame and an interior frame spaced apart from the exterior frame. A thermal barrier interconnecting the exterior frame and the interior frame has an internal cavity positioned between the exterior frame and the interior frame to restrict the flow of heat or cold between the exterior frame and the interior frame. A glass unit is positioned within a recess formed by the exterior frame, the thermal barrier and the interior frame.

Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

FIG. 1 is a fragmentary cross-sectional view through a composite window;

FIG. 2 is a fragmentary top view of a miter joint interconnecting portions of the window depicted in FIG. 1;

FIG. 3 is a cross-sectional view of a key used to interconnect frame portions of the window;

FIG. 4 is a fragmentary cross-sectional view taken through the miter joint shown in FIG. 2;

FIG. 5 is a fragmentary cross-sectional view of another window according to the present disclosure; and

FIG. 6 is a fragmentary cross-sectional view taken through a window assembly having one portion moveable relative to another portion.

DETAILED DESCRIPTION

FIG. 1 depicts a composite window 8 having a frame assembly 10 with at least part of an exterior frame 12 formed of metal and at least part of an interior frame 14 formed from wood or a similar material. A thermal barrier 16 with a hollow section interconnects the interior and exterior frames, 12, 14. For environmental reasons, thermal barrier 16 may be constructed from 100% recycled plastic.

Window thermal performance can be measured in the same way that light bulbs and appliances are rated using the BRFC (British Rating Federation Council or similar rating body) by banding the products A-G, the best being A. It is proposed that the window frame of the present disclosure may achieve ratings ranging from A-C. A very energy efficient window results because less heat is escaping from the building fitted with the windows. Furthermore, the present window is environmentally friendly from a manufacturing point of view because of the use of recycled products.

A double glazed glass unit 18 is positioned in communication with a portion of interior frame 14 and a portion of exterior frame 12. Glass unit 18 forms a thermal break at this point as most glass unit manufacturers produce thermally efficient units with these issues in mind. If glass unit 18 is surrounded by a frame having less thermally efficient characteristics, the thermal efficiency of the window is compromised. Therefore, a thermally efficient frame assembly 10 is described below.

Exterior frame 12 may be formed as an aluminum extrusion. It should be appreciated that exterior frame 12 may be cut to various lengths to form any number of differently sized and shaped frame assemblies 10. It is contemplated that the cross-section shown in FIG. 1 may define the top, bottom or either side of a given frame assembly 10. Furthermore, while rectangularly-shaped composite windows 8 are contemplated, other external shapes, including curved sections, may also be formed within the scope of the present disclosure.

Exterior frame 12 includes an outer wall 20 spaced apart from an inner wall 22. An upper wall 24 interconnects outer wall 20 and inner wall 22 at a first location. A bottom wall 26 extends substantially parallel to and spaced apart from upper wall 24. Bottom wall 26 also interconnects outer wall 20 with inner wall 22. Walls 20, 22, 24 and 26 form a closed polygonal shape defining a cavity 28. Cavity 28 functions as a thermal break defined by a hollow section surrounded by contiguous and uninterrupted walls 20, 22, 24 and 26. The thermal efficiency or resistance to heat transfer may be increased even if the material used to construct exterior frame 12 is a very poor insulator. Cavity 28 may be filled with air or some other insulating material to increase thermal efficiency of the box section formed by walls 20, 22, 24 and 26.

A first support 30 is integrally formed with inner wall 22 and spaced apart from upper wall 24. A second support 32 is integrally formed with upper wall 24 and includes a transversely extending first peg 34 spaced apart from upper wall 24 to define a pocket 36. A third support 38 is integrally formed with outer wall 20 and includes a second peg 40. Second peg 40 extends substantially parallel to and spaced apart from upper wall 24 to define a recess 42. A first projection 43 transversely extends from first support 30. A second projection 44 transversely extends from inner wall 22 spaced apart from first projection 43 to define a first groove 46. First projection 43 and second projection 44 each include tapered side walls to cause first groove 46 to have a substantially triangular or trapezoidal shaped cross-section. Second and third transversely extending projections 48, 50 are integrally formed with inner wall 22 and are spaced apart from one another to define a second groove 52. Second and third projections 48, 50 have tapered walls to define second groove 52 as at least a partial triangle or trapezoid. Outer wall 20 extends beyond bottom wall 26 and terminates at an end face 54. Upper and lower hooks 56, 58 transversely inwardly extend from outer wall 20.

Thermal barrier 16 includes an outer wall 60 and an inner wall 62 extending substantially parallel to and spaced apart from outer wall 60. A top wall 64 interconnects inner wall 62 and outer wall 60 which completely covers the timber face. A bottom wall 66 extends substantially parallel to and spaced apart from top wall 64. Bottom wall 66 also interconnects outer wall 60 with inner wall 62. Walls 60, 62, 64 and 66 are integrally formed with one another to define a contiguous and uninterrupted box structure enclosing a cavity 68. Cavity 68 may be filled with air or another insulator, such as foam, to act as a thermal barrier.

A first nipple 70 is integrally formed with and transversely inwardly extends from top wall 64 and inner wall 62. First nipple 70 is triangularly or trapezoidally shaped to substantially match the shape of first groove 46. A second nipple 72 is integrally formed with and transversely inwardly extends from bottom wall 66 and inner wall 62. Second nipple 72 is shaped substantially similarly to first nipple 70 and complements the shape of second groove 52. Thermal barrier 16 may be coupled to exterior frame 12 by sliding or pressing the two components together. A clearance may be provided to allow for an adhesive if desired. The adhesive bonding agent may expand as it dries to produce an even tighter fitting joint. It should be understood that first projection 43 may be pressed down to secure nipple 70 and third projection 50 may be pressed up to secure nipple 72.

A plurality of connectors 74 are integrally formed with and transversely outwardly extend from outer wall 60. Connectors 74 may be substantially cylindrically shaped or may alternatively be elongated members extending along a portion or substantially the entire length of thermal barriers 16. Corresponding apertures shaped as pockets or grooves 76 are formed within interior frame 14. If cylindrically shaped connectors 74 are to be used, substantially cylindrically shaped pockets 76 may be formed in inner frame 14. If elongated connectors 74 are utilized, elongated grooves 76 may extend through interior frame 14. Apertures 76 are in communication with a recessed surface 78 of interior frame 14. An outer surface 80 of outer wall 60 covers recessed surface 78 when connectors 74 are positioned within apertures 76. Outer surface 80 extends along substantially the entire exposed surface 78 of interior frame 14. As such, moisture is prevented from contacting wooden surface 78 of interior frame 14 to extend the useful life of composite window 8. A forced or press fit exists between connectors 74 and apertures 76 to couple thermal barrier 16 to interior frame 14. The connectors 74 may include flexible barbs 81 that deflect upon insertion within apertures 76 but resist removal therefrom. After assembly, outer surface 80 may engage or be slightly spaced apart from recessed surface 78.

Third and fourth hooks 82, 83 transversely inwardly extend from outer wall 60. Insulating foam 84 fills a cavity 86 defined by thermal barrier 16 and exterior frame 12. Foam 84 is restricted from movement by hooks 56, 58, 82 and 83. Foam 84 includes a bottom surface 88 extending substantially co-planar with end face 54 of exterior frame 12. A bottom surface 90 of interior frame 14 is also substantially co-planar with bottom surface 88 and end face 54.

It is contemplated that frame assembly 10 is now complete and manufacturing processes may be optimized to create substantially long lengths of frame assembly 10. Depending on the specific geometry of the window to be formed, desired lengths of frame assembly 10 will be cut accordingly.

FIGS. 2 and 3 depict a first frame assembly 100 and a second frame assembly 102 having cross-sections as shown in FIG. 1 coupled to one another at a miter joint 104. A key 106 has a dual inverted cone cross-sectional shape. A complementary dual inverted cone cross-sectional passageway 108 is machined into the ends of first frame assembly 100 and second frame assembly 102. As depicted in FIG. 4, key 106 is inserted within passageway 108 to fix first frame assembly 100 to second frame assembly 102. It should be noted that the dual cone shaped passageway 108 is cut into portions of connectors 74 as well. Accordingly, key 106 engages connectors 74 to form a reinforced miter joint. Other connecting items can also be inserted into chamber 28 and into hook 56, 68, 82 and 83 to further secure the miter joint.

Composite window 8 may be completed by adhering a double sided foam adhesive strip 110 to a face 111 formed on interior frame 14. Seal 110 also engages thermal barrier 16 to further restrict moisture from contacting the wooden surfaces of interior frame 14. Double glazed glass unit 18 is positioned within the recess formed by exterior frame 12, thermal barrier 16 and interior frame 14 having a first pane 112 in sealing engagement with foam adhesive strip 110. Double glazed glass unit 18 also includes a second pane 114 spaced apart from and extending substantially parallel to first pane 112. Primary and secondary desiccant seals 116, 118 seal the perimeter of double glazed glass unit 18 and extend between first pane 112 and second pane 114. A glazing packer 120 extends along the outer circumference of first pane 112, second pane 114 and secondary desiccant seal 118. Glazing packer 120 is placed in engagement with first support 30 and second support 32.

A glazing bead 122 may be an extruded structure having a first wall 124, a second wall 126 and a third wall 128 interconnecting first and second walls 124, 126. First wall 124 terminates at a bifurcated end 130 in receipt of a flexible seal 132. Flexible seal 132 is in engagement with second pane 114. Second wall 126 terminates at a male lug 134. To complete assembly of composite window 8, male lug 134 is inserted within pocket 36. Subsequently, a tab 136 downwardly extending from second wall 126 is placed in snap-fit engagement with second peg 40. Tab 136 enters recess 42. At this time, glazing bead 122 is fixed to exterior frame 12 and flexible seal 132 is biasedly engaged with second pane 114.

FIG. 5 depicts another composite window 200. Composite window 200 is substantially similar to composite window 8. Accordingly, like elements will retain their previously introduced reference numerals. A top edge of thermal barrier 16 is exposed to a glazing chamber 202. Glazing chamber 202 is exposed to any moisture that may enter in from the outside. As such, it is preferable that thermal barrier 16 also function helps to take the moisture back to the outside and therefore protect the wood and prevent moisture entering the inside of a building. An additional drainage groove 203 is formed on top wall 64 to trap water before it can continue toward the wood surface. When water enters groove 203 it is taken away by drainage holes 206 that extend through thermal barrier 16. To drain water that may have accumulated within glazing chamber 202, a thermal barrier 204 includes a first aperture 206 extending through a first portion 208. Similarly, second aperture 210 extends through a second portion 212 of thermal barrier 204 to allow water that may possibly accumulate within glazing chamber 202 to exit via drainage apertures 206 and 210.

FIG. 6 depicts another composite window 300. Composite window is substantially similar to composite window 8. Accordingly, like elements will retain their previously introduced reference numerals including a prime suffix. Composite window 300 includes an opening light assembly 302 moveably coupled to a fixed frame assembly 304. Opening light subassembly 302 is substantially similar to composite window 8 other than the shape of an outer wall 306 and an inner wall 308 of exterior frame 12′. Outer wall 306 has a curved or similar bottom portion 309 intersecting an outwardly offset and vertically oriented portion 310 of inner wall 308. A transversely extending section 312 interconnects an inwardly offset portion 314 of inner wall 308 with portion 310. Inner wall 308 includes another portion 316 vertically oriented but offset from portion 314. Outer wall 306, inner wall 308 and upper wall 24′ form a contiguous uninterrupted perimeter about cavity 28′. Due to the offset nature of wall portions 314 and 316, thermal barrier 16′ includes first and second nipples 70′, 72′ transversely offset from one another to mate with transversely offset first groove 46′ and second groove 52′.

Fixed frame assembly 304 is substantially similar to frame assembly 10. Accordingly, similar elements will be identified with like reference numerals including a double prime suffix. Fixed frame assembly 304 includes an interior frame 14″, an exterior frame 12″ and a thermal barrier 16″. Thermal barrier 16″ interconnects interior frame 14″ and exterior frame 12″ as previously described in relation to composite window 8. Foam 84″ fills a cavity 86″ defined by thermal barrier 16″ and exterior frame 12″. Fixed frame assembly 304 may be attached to a building or other structure via fasteners not shown. A hinge housing 320 is fixed to exterior frame 12″. A hinge (not shown) pivotally interconnects opening light assembly 302 and fixed frame assembly 304 at hinge housing 320. An inner seal 322 is attached to interior frame 14″. Seal 322 also sealingly engages thermal barrier 16″. Accordingly, moisture is restricted from contacting the wooden surfaces of interior frame 14″ due to thermal barrier 16″ extending along substantially the entire surface of interior frame 14″ as well as being in contact with seal 322. An exterior seal 324 is fixed to exterior frame 12′. When opening light assembly 302 is in the closed position depicted in FIG. 6, exterior seal 324 engages exterior frame 12″ while interior frame 14′ engages seal 322.

Furthermore, the foregoing discussion discloses and describes merely exemplary embodiments of the present disclosure. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications and variations may be made therein without departing from the spirit and scope of the disclosure as defined in the following claims.

Claims

1. A composite window comprising:

an exterior frame having a metal portion;

an interior frame spaced apart from the exterior frame and having a wooden portion; and

a thermal barrier interconnecting the exterior frame and the interior frame as well as having an uninterrupted wall defining a cavity in cross-section to restrict the flow of heat between the exterior frame and the interior frame.

2. The composite window of claim 1 further including a glass unit having a first pane of glass extending substantially parallel to and offset from a second pane of glass, a portion of the thermal barrier cavity and a portion of the exterior frame being positioned between planes in which the first and second panes of glass lie.

3. The composite window of claim 2 wherein the exterior frame includes two spaced apart supports engaging the glass unit.

4. The composite window of claim 3 wherein one of the supports includes a detent in receipt of a glazing bead in engagement with the glass unit.

5. The composite window of claim 4 wherein an innermost of the first and second panes of glass is positioned in communication with a glazing cavity formed by the interior frame, the exterior frame, the thermal barrier and the glass unit.

6. The composite window of claim 5 wherein the thermal barrier includes an aperture extending therethrough to allow passage of moisture out of the glazing cavity.

7. The composite window of claim 2 wherein the glass unit includes a glazing packer extending along edges of each of the first and second panes, the glazing packer being supported by the exterior frame.

8. The composite window of claim 1 wherein the thermal barrier includes one of a projection and a pocket and the exterior frame includes the other of the projection and the pocket, the projection being positioned within the pocket to restrict relative motion between the thermal barrier and the exterior frame.

9. The composite window of claim 8 wherein a portion of the pocket is deformed to engage the projection and further restrict relative motion between the exterior frame and the thermal barrier.

10. The composite window of claim 1 wherein the thermal barrier includes integrally formed fasteners engaging the wooden portion.

11. The composite window of claim 1 wherein the exterior frame includes an uninterrupted wall defining a cavity in cross-section.

12. The composite window of claim 1 further including a fixed frame rotatably supporting the exterior frame.

13. The composite window of claim 1 wherein the thermal barrier restricts moisture from contacting the wooden portion of the interior frame.

14. A composite window comprising:

an exterior frame;

an interior frame spaced apart from the exterior frame;

a thermal barrier interconnecting the exterior frame and the interior frame, the thermal barrier having an internal cavity positioned between the exterior frame and the interior frame to restrict the flow of heat between the exterior frame and the interior frame; and

a glass unit positioned within a recess formed by the exterior frame, the thermal barrier and the interior frame.

15. The composite window of claim 14 wherein the glass unit is supported by the exterior frame.

16. The composite window of claim 15 wherein the glass unit is spaced apart from the thermal barrier.

17. The composite window of claim 16 wherein the exterior frame includes an internal cavity.

18. The composite window of claim 17 wherein the external frame includes grooves in receipt of projections extending from the thermal barrier to restrict relative movement therebetween.

19. The composite window of claim 18 wherein the thermal barrier includes fasteners engaging the interior frame to restrict relative movement therebetween.

20. The composite window of claim 14 further including a glazing bead coupled to the exterior frame and retaining the glass unit within the recess.

21. The composite window of claim 14 further including a fixed frame having a fixed exterior frame, a fixed interior frame and a fixed thermal barrier interconnecting the fixed exterior and fixed interior frames, the fixed thermal barrier having an internal cavity, the exterior frame being coupled for rotation with the fixed frame.

22. The composite window of claim 14 wherein the thermal barrier restricts moisture from contacting the wooden portion of the interior frame.