REFERENCE TO RELATED APPLICATIONS

This is a US non-provisional patent application, which enters the national stage under 35 U.S.C. § 371 from and claims priority to Patent Treaty Cooperation application number PCT/GB2019/051377 filed on May 17, 2019, which claims priority to GB provisional patent application serial number GB1808161.2 filed on May 18, 2019, each of which are hereby incorporated by this reference in their entireties.

FIELD

The field of the invention relates to joinery and more particularly to structural components for frames intended to accommodate doors or windows, and to methods for assembly of frames and buildings including frames.

BACKGROUND

At the present time, frames for doors have been available in standard sizes and considerable additional effort has been required where a non-standard size of frame is preferred. Frames are designed to only fit doors (and/or side lights and/or side screens) that have been manufactured by the same company. On occasions when either a door or a frame is unavailable from a chosen manufacturer this can lead to delays in building during the period that the items are unavailable, or additional work in order to customize a non-standard door or frame. Necessarily, both of these options are also associated with additional expense.

Typically, frames for doors (and windows) are constructed through the assembly of linear sections including two or more vertically positioned sections (typically known as legs, posts, or jambs), spatially separated to define the length of the frame and two or more horizontally positioned sections, one section arranged to define the upper limit of the frame (typically known as the head or lintel) and one section arranged to define the lower limit of the frame (typically known as the sill or cill). These linear sections are typically fixed in place such that the vertically positioned sections are substantially parallel to each other and substantially perpendicular to the horizontally positioned sections, thus defining a frame with a central space. Typically the frame and the central space are rectangular (typically oblong) and are configured such that a door may fit into the space.

Accordingly, the present invention seeks to remedy these issues with known frames by providing a method, apparatus, and kit of parts with which to build a frame suitable for retaining any size of door. The present invention allows such frames to be built quickly and without excessive waste. Due to the dimensional flexibility of the resulting frames these may also, in some circumstances, be less expensive than existing methods.

SUMMARY

According to a first aspect of the invention there is provided a method of assembling a frame (e.g., a doorframe or a window frame), the method comprising:forming a sill of a selected length (e.g., an overall opening length), the sill having at least one keying channel running along at least part of (or the whole of) a longitudinal surface of the sill;forming a lintel of a selected length (e.g., an overall opening length), the lintel having at least one keying channel running along at least part of (or the whole of) a longitudinal surface of the lintel;forming at least two jambs of a selected length, each jamb having longitudinally extending keys (e.g., dovetails) at either end, said keys shaped to cooperate with and be retained by said keying channels;inserting the keys at one end (e.g., the top end) of each jamb into the at least one keying channel of the lintel; andinserting the keys at the other end (e.g., the base) of each jamb into the at least one keying channel of the sill, to thereby form the frame.

In some embodiments, one or more of the jambs may be supplied with one key pre-formed (e.g., pre-attached) at one end, and the method may comprise cutting the jamb to a selected length and subsequently forming (e.g., attaching) a second key to the other end of the jamb. However, typically the method comprises forming (e.g., attaching) a key (e.g., a dovetail) to each end of each jamb. The method may method comprise cutting one or more jambs to a selected length and subsequently forming or attaching a key at least one end of the or each jamb.

In some embodiments, the at least one keying channel (e.g., a sliding dovetail channel) of the sill tapers towards the surface of the sill, i.e., the at least one keying channel is narrowest at the surface of the sill. In some embodiments, the at least one keying channel of the lintel tapers towards the surface of the lintel. i.e., it is narrowest at the surface of the lintel, for example it may be a sliding dovetail channel with a trapezoidal cross-section (e.g., one skilled in the art will appreciate that three sides of the trapezoid (typically the long base and the trapezoid legs) may be defined by the channel in the longitudinal surface of the sill or lintel while the fourth side of the trapezoid is defined by an open surface).

Typically, the forming of at least two jambs of a selected length, each jamb having longitudinally extending keys (e.g., dovetails) at either end comprises the step of attaching a key to each end of each jamb, optionally (e.g., preferably) through the use of a key jig. By a key jig we refer to a jig for locating a key at a defined location at the end of a jamb. Optionally, the forming of at least two jambs of a selected length comprises cutting (e.g., sawing) one or more (e.g., prefabricated) jambs to the selected length and the method further comprises attaching a key to each end of each jamb, optionally using a key jig to align the key. Typically, the method comprises the step of attaching a key to each end of each jamb, the step of attaching of a key to a jamb comprising the steps of:placing at least one key jig against and aligning the at least one key jig with an end (e.g., an upper end or a lower end) of the jamb;aligning a key with the or each key jig;attaching the or each key to the end of the jamb; andremoving the or each key jig from the end of the jamb.

Typically, the step of attaching a key is repeated as often as needed to attach a key to each end of each jamb.

Typically, the aligning the at least one key jig with an end of a jamb comprises aligning the key jig in at least two dimensions (e.g., two dimensions perpendicular to the longitudinal dimension of the jamb) and restricting at least one rotational degree of freedom of the key jig to thereby correspondingly define the position of a key attached to the end of a jamb. Typically, the forming of the sill of a selected length and/or the lintel of a selected length and/or the at least two jambs of a selected length may comprise cutting (e.g., sawing) one or more lengths of material to a selected length. Optionally, the forming of the sill of a predetermined length and/or the lintel of a selected length and/or the at least two jambs of a selected length may comprise joining together (e.g., through the use of adhesives) of two or more sections of material and/or 3D printing a section of material. In embodiments where the forming comprises cutting the cutting typically comprises cutting (e.g., sawing) completely through an (e.g., elongate) section of material in an orthogonal direction to the longest dimension of the section of material (and thereby producing two sections of material).

Typically, the forming (e.g., cutting) of a sill of a selected length and/or the lintel of a selected length and/or the at least two jambs of a selected length comprises forming the jambs and/or lintels and/or sills to a selected length by cutting (e.g., sawing) through a longer piece of material at the site of use (e.g., on a building site where a building is being constructed, in a building where a frame (e.g., a doorframe, optionally a window frame) is to be assembled or replaced, etc.) as opposed to being formed remotely (e.g., in a remote factory). However, jambs and/or lintels and/or sills may be formed (e.g., cut) to a selected length off-site and supplied as needed, for example for use in a building project for which multiple frames of the same size are required. In some embodiments the lintel and/or the sill may be pre-machined.

Typically, the or each key jig is configured to cooperate with the or each key and the or each jamb and to define the position and/or alignment of the or each key in relation a jamb when it is attached to the jamb. In some embodiments, aligning a key with the or each key jig comprises (e.g., slidably) inserting the key into a key space of the or each key jig.

Typically, the method comprises the step of separating the at least two jambs by a selected distance to thereby define the width of the frame (e.g., the internal surface of a first jamb will define the leftmost inner limit of the frame and the internal surface of a second jamb will define the rightmost inner limit of the frame). Optionally, the step of separating the at least two jambs comprises the steps of:inserting a first locator (e.g., a spacer, typically a strut, optionally an elongate strut) into at least one keying channel of the lintel;inserting a second locator (e.g., a spacer, typically a strut, optionally an elongate strut) into at least one keying channel of the sill; inserting the keys attached to the top of each jamb into the or each keying channel of the lintel; andinserting the keys attached to the base of each jamb into the or each keying channel of the sill.

The or each keying channel of the sill is in the aperture-facing surface of the sill (i.e., the or each keying channel is in a surface that is upwards-facing in use). The or each keying channel of the lintel is in the aperture-facing surface of the lintel (i.e., the or each keying channel is in a surface that is downwards-facing in use).

Typically, the or each spacer is formed (e.g., cut) to a selected size, such that the spacer will be of an appropriate length to define a separation distance of the first and second jambs, the separation distance defining the width of the frame.

The method is universal in that it is compatible with a wide range of frame dimensions. Because the method comprises the step of forming (e.g., cutting, for example) the lintel, the sill and the or each jamb to a selected size (i.e., corresponding to a desired frame size) the method is suitable for the production of any size of frame. Because the method comprises the step of attaching at least one key to each jamb, as opposed to (for example) cutting the shape of a key out of the or each jamb, the method minimizes waste. Because the method comprises the use of a key jig the method is simple, precise, and reliable and minimizes construction errors. Further, the method can be carried out quickly and without the need for specialized tools or equipment, and is thus, inexpensive.

Optionally, the method may further comprise:forming one or more additional jambs and/or one or more mullions each of a selected length, the or each additional jamb and/or the or each mullion having longitudinally extending keys at either end;inserting the keys attached to one end (e.g., the top) of the or each additional jamb and/or the or each mullion into the at least one keying channel of the lintel; andinserting the keys attached to the other end (e.g., the base) of the or each additional jamb and/or the or each mullion into the at least one keying channel of the sill. Typically, the forming of one or more additional jambs and/or one or more mullions each of a selected length. (the or each additional jamb and/or the or each mullion having longitudinally extending keys at either end) comprises attaching a key to each end of the or each additional jamb and/or the or each mullion, optionally (e.g., preferably) using a key jig to align the key. Typically, the step of attaching of a key comprises the steps of:placing at least one key jig against and aligning the at least one key jig with an end (e.g., an upper end or a lower end) of one or more additional jambs and/or one or more mullions;aligning a key with the or each key jig;attaching the or each key to the end of the or each additional jamb and/or the or each mullion (e.g., using fastening means such as screws, bolts, nails and/or adhesives); andremoving the or each key jig from the end of each additional jamb and/or the or each mullion;

Typically, the step of attaching a key is repeated as often as needed to attach a key to each end of the or each additional jamb and/or the or each mullion.

Typically, the method comprises separating the or each additional jamb from the first and second jambs by a selected distance. Optionally, the method comprises separating the or each mullion (where present) from the first and second jambs. Typically, the separating the additional jamb (and/or mullion) comprises the steps of:inserting an additional locator (e.g., a spacer typically a strut, optionally an elongate strut) into at least one keying channel of the lintel;inserting an additional locator (e.g., a spacer typically a strut, optionally an elongate strut) into at least one keying channel of the sill;inserting the keys attached to the top of each jamb (and/or mullion) into the keying channel of the lintel; andinserting the keys attached to the base of each jamb (and/or mullion) into the keying channel of the sill.

As such, the method is suitable for the construction of a frame such as a doorframe that (e.g., typically) retains a door and/or or a frame for double doors (e.g., a double doorframe) that retains two doors and/or or a doorframe comprising one or more side screens and/or sidelights. The method may also be used in the construction of a frame for retaining a window (e.g., a glass window). Optionally, the forming of at least two jambs (and/or the or each additional jamb and/or the or each mullion) of a selected length may comprise a calculation of a required length. Optionally, the forming of at least two jambs (and/or the or each additional jamb and/or the or each mullion) of a selected length may comprise a measurement of an opening space into which a frame will be received. Optionally, the forming of at least two jambs (and/or the or each additional jamb and/or the or each mullion) of a selected length may comprise a subtraction, for example of the length of one or more keys from the total selected length of a frame. It may be that the forming of at least two jambs (and/or the or each additional jamb and/or the or each mullion) of a selected length is carried out at the point of assembly of the frame, for example at a construction site, however this is not essential and it may be that the forming of at least two jambs (and/or the or each additional jamb and/or the or each mullion) of a selected length is carried out elsewhere.

The method may comprise carrying out some or all of the above-mentioned steps substantially in the order presented. Alternatively, the method may comprise carrying out the above-mentioned steps in a different order and/or carrying out (e.g., at least) some of the steps simultaneously.

According to a second aspect of the invention there is provided a frame construction apparatus (as a kit of parts), the apparatus comprising a plurality of keys and a key jig, the key jig comprising a locating formation (e.g., a side plate and/or a backing section) and a key retaining formation defining a key space, the key space configured to cooperate with (e.g., slidably receive) a key in use wherein the key jig and key space are configured to define the location of the end of a jamb where the key is to be attached. In some embodiments the key jig further comprises an access hole through which a key in the key space may be accessed in use, for example to allow screws, nails or bolts to be inserted into a key (optionally via through-bores in the key) and through the key into an end of a jamb to thereby attach the key to the end of the jamb. Where provided, the access hole is typically formed in a surface of the key jig that is parallel to an end surface of a jamb and/or mullion when the key jig is in use. Typically the locating formation comprises one or more walls (e.g., side plates and/or backing sections) which may be fitted level with one or more longitudinal surfaces of a jamb and/or a mullion in use.

In some embodiments, the key retaining formation defining a key space may be shaped such that a key can be slidably inserted into the key space but cannot be pulled vertically (i.e., in an orthogonal direction to the direction in which it is slidably inserted) out of the key space. Typically, the keying channel of the lintel is shaped to cooperate with a key, for example it may be shaped such that a key can be slidably inserted into the keying channel but cannot be pulled vertically (i.e., in an orthogonal direction to the direction in which it is slidably inserted) out of the keying channel. Typically, the keying channel of the sill is shaped to cooperate with a key, for example it may be shaped such that a key can be slidably inserted into the keying channel but cannot be pulled vertically (i.e., in an orthogonal direction to the direction in which it is slidably inserted) out of the keying channel. Optionally, the keying channel of the lintel is shaped to cooperate with a locator (e.g., a spacer), for example it may be shaped such that a locator can be slidably inserted into the keying channel but cannot be pulled vertically (i.e., in an orthogonal direction to the direction in which it is slidably inserted) out of the keying channel. Optionally, the keying channel of the sill is shaped to cooperate with a locator (e.g., a spacer), for example it may be shaped such that a locator can be slidably inserted into the keying channel but cannot be pulled vertically (i.e., in an orthogonal direction to the direction in which it is slidably inserted) out of the keying channel. Typically, the key space of the key jig and the or each keying channel comprise substantially geometrically similar cross-sections.

Optionally, the plurality of keys each comprises adhesive channels in one or more longitudinal surfaces of each key. Where each key has a trapezoidal (e.g., dovetail) cross-section, the adhesive channels are typically in one or more of the sloping surfaces of the key (i.e., surfaces which are not parallel to any of the other surfaces of the key). The adhesive channels reduce the frictional forces when a key is inserted into the key space of a key jig, or into the keying channel of a sill or the keying channel of a lintel. The adhesive channels can be filled with adhesive during construction of a (e.g., door) frame, to thereby increase the strength of any joint formed. Typically, the plurality of keys each comprise one or more (typically at least two) holes through which fastening means (e.g., screws, nails, bolts) can be inserted in use to thereby attach the key to a jamb or mullion.

In some embodiments (for example, where thicker frames are desired), the method may comprise attaching one or more further keys to the top of each jamb and/or to the base of each jamb and optionally inserting each key attached to the top of each jamb into at least one keying channel of the lintel and inserting each key attached to the base of each jamb into at least one keying channel of the sill. In a third aspect, the invention extends to a frame construction kit (a kit of parts) comprising a sill, the sill having at least one keying channel running along at least part of (or the whole length of) a longitudinal surface of the sill, a lintel, the lintel having at least one keying channel running along at least part of (or the whole length of) a longitudinal surface of the lintel, a first jamb and a second jamb, at least one key jig and a plurality of keys (e.g., dovetails), said keys shaped to cooperate with said keying channels and the at least one key jig. Optionally, the kit of parts may further comprise one or more mullions. The kit of parts is suitable for constructing a frame according to the method.

One advantage of the kit of parts according to the invention is that all necessary materials are provided, thus preventing the need to source additional components (which would increase the cost of a frame as well as the total time needed to assemble it).

Typically, the lintel comprises at least one keying channel configured to cooperate with a key in use, for example the keying channel may have the same cross-section as that of the plurality of keys such that one or more key may be slidably inserted into the channel. Typically, the sill comprises at least one keying channel configured to cooperate with a key in use, for example, the keying channel may have the same cross-section as that of the plurality of keys such that one or more key may be slidably inserted into the channel. Typically, the kit of parts further comprises one or more locator (e.g., one or more spacers, possibly in the form of elongate struts), each locator configured to cooperate with (e.g., slidably fit within) the at least one keying channel of the lintel and/or within the at least one keying channel of the sill.

Although typically the keying channel of the lintel and/or the keying channel of the sill will extend across the entire length of the lintel and/or the entire length of the sill, in some embodiments, the keying channel of the lintel and/or the keying channel of the sill may extend only a portion of the length of the lintel and/or sill (i.e., the channel may not extend the complete length of the lintel and/or of the sill), such that it would not be possible to insert a key beyond a predetermined distance into such a keying channel. In some embodiments a locator may comprise a spacer, for example an (e.g., elongate) strut. Alternatively or additionally, a locator may comprise stops or blocks. Typically, the spacer is of sufficient length that it separates the first and second keys such that the inner edges of the first and second jambs define the leftmost and rightmost inner edges of the (e.g., door) frame when the jambs are vertically positioned. Optionally, where more than one spacer is used, the combined total length of the spacers is such that it separates the first and second keys such that the inner edges of the first and second jambs define the leftmost and rightmost inner edges of the (e.g., door) frame when the jambs are vertically positioned.

The method may comprise configuring the kit of parts such that the lintel is arranged to be perpendicular to the first and second jambs and parallel to the sill, (i.e., the sill then also being perpendicular to the at least first and second jambs and parallel to the lintel and the first jamb being substantially parallel to the second jamb). As such, the assembly of the frame results in the first and second jambs being spatially separated to define the width of a frame, the lintel defines the upper limit of the frame and the sill defines the lower limit of the frame.

Typically, the frame (e.g., the sill, the lintel and/or the first and second jambs) comprises (e.g., linear sections of) timber. Optionally, the lintel may be longer than the sill, for example a lintel may have “horns”. Typically, each jamb comprises an interior surface and an exterior surface.

The method typically comprises positioning the key jig at the top and/or at the base of the or each jamb (optionally the or each mullion) such that the locating formation (e.g., a side plate and/or a backing section) of the key jig is flush against the interior surface of the or each jamb (optionally the or each mullion). Typically, the key jig is configured such that, when the locating formation (e.g., a side plate and/or a backing section) of the key jig is positioned flush against the interior surface of the or each jamb (optionally the or each mullion) and a key is inserted, the key will be closer to the interior surface than it is to the exterior surface (e.g., the key may be 5 mm closer to the interior surface than to the exterior surface, or more typically 3 mm closer to the interior surface than to the exterior surface).

Optionally, the method may comprise attaching one or more beading pieces to the frame and thereby concealing joints.

Optionally, the kit of parts further comprises a door, the door configured to fit and typically to be retained by the frame when the frame has been assembled. Optionally, the kit of parts may further comprise one or more side screens, the or each side screen configured to fit and typically be retained by the frame when the frame has been assembled. Optionally, the kit of parts may further comprise one or more windows and/or one or more sidelights (e.g., one or more windows, optionally comprising glass) the or each window and/or the or each sidelight configured to fit and typically be retained by the frame when the frame has been assembled. Optionally, the kit of parts may further comprise one or more mullions suitable for separating the one or more side screens and/or one side lights from the or each other side screen and/or the or each other sidelight and/or the or each door. Optionally, the kit of parts may further comprise beading sections. Optionally, the kit of parts may further comprise fastening means (e.g., one or more screws, nails, bolts, and/or adhesives).

Typically, the or each key comprises a dovetail and the key space of the or each key jig and the keying channel of the lintel and the keying channel of sill will be configured to cooperate with (e.g., slidably receive) the dovetail. By dovetail we mean a prism having a trapezoidal cross-section. Typically, the cross-section of the or each key and/or the or each key space and/or the or each keying channel comprises tapering edges and optionally may have sections cut out of any of its surfaces. However one skilled in the art will appreciate that a range of shapes (e.g., shapes other than dovetails) would be suitable.

In some embodiments the method may be carried out on a factory line, for example with the use of one or more machines or robots. However, the method is more typically carried out by hand.

A fourth aspect of the invention provides a key jig, the key jig having a body comprising a locating formation and a key retaining formation defining a key space, the key space being configured to cooperate with a key in use and the key jig and key space configured to define the location of the end of a jamb where a key is to be attached. The locating formation is configured to locate the key jig relative to the end of a jamb during use. The locating formation may comprise a protrusion, e.g., a side portion, such as a plate, extending longitudinally from the edge of the body to locate the jig relative to an adjacent jamb in use.

In some embodiments, the key jig may further comprise an access hole through which a key located (e.g., demountably, typically slideably retained) in the key space may be accessed in use. For example, the access hole may be used to allow fastening means (e.g., screws, bolts, nails, etc.) to be passed therethrough and inserted through a key and into a jamb to thereby attach the key to the jamb. In some embodiments the key retaining formation of the key jig may have a trapezoidal (e.g., dovetail) cross-section (e.g., with the broader end located away from the jamb end in use).

A fifth aspect of the invention provides a key, the key being suitable for attachment to the end of a jamb and/or a mullion and for being retained by a keying channel (e.g., a keying 5 channel of a lintel and/or a keying channel of a sill) to thereby form a frame. Optionally, the key may be suitable for being retained by a key space of a key jig. In some embodiments, the key may comprise a dovetail (e.g., it may have a trapezoidal cross-section or have a dovetail cross-section). Typically, the cross-section of the key comprises tapering edges and optionally may have sections cut out of any of its surfaces. In some embodiments the key may comprise through-bores, for example holes through which fastening means (e.g., screws, bolts, nails, etc.) can be inserted in use to thereby fix the key to an end of a jamb and/or to an end of a mullion.

A sixth aspect of the invention provides a frame (e.g., a doorframe or a window frame) comprising a lintel, the lintel comprising at least one keying channel running along at least part of a longitudinal surface of the lintel, a sill, the sill comprising at least one keying channel running along at least part of a longitudinal surface of the sill, a first jamb having longitudinally extending keys at either end and a second jamb having longitudinally extending keys at either end the keys shaped to cooperate with said keying channels, wherein each key extending from the upper end of each jamb is retained in the keying channel of the lintel and each key extending from the lower end of each jamb is retained in the keying channel of the sill. Optionally, the frame may further comprise one or more additional jambs, wherein each additional jamb has longitudinally extending keys at either end and/or one or more mullions, wherein the or each mullion has longitudinally extending keys at either end, each key shaped to cooperate with said keying channels and wherein each key extending from the upper end of the or each additional jamb and/or the or each mullion is retained in the keying channel of the lintel and each key extending from the lower end of the or each additional jamb and/or the or each mullion is retained in the keying channel of the sill. Typically, in embodiments comprising one or more mullions, the frame further comprises at least one sidelight and/or at least one side screen. A seventh aspect of the invention provides a building, the building comprising one or more frames (e.g., one or more doorframes and/or one or more window frames) according to the sixth aspect of the invention. Optionally, the building may comprise one or more frames wherein the or each frame further comprises one or more additional jambs, wherein the or each additional jamb has longitudinally extending keys at either end and/or one or more mullions, wherein the or each mullion has longitudinally extending keys at either end, each key shaped to cooperate with said keying channels and wherein each key extending from the upper end of the or each additional jamb and/or the or each mullion is retained in the keying channel of the lintel and each key extending from the lower end of the or each additional jamb and/or the or each mullion is retained in the keying channel of the sill. Typically, in embodiments comprising one or more mullions, the frame further comprises at least one sidelight and/or at least one side screen.

