Extruded metal construction element
United States Patent 91 [111 3,874,135 Craven Apr. 1, 1975 EXTRUDED METAL CONSTRUCTION 3,566,561 10/1968 Tozer 52/720 X ELEMENT Inventor: Eugene J. Craven, Rt. 1, Box 207,  
 Moreland, Ga. 30259 Filed: Apr. 22, 1974 Appl. No.: 462,802  
 Related US. Application Data Continuation of Ser/No. 283,082, Aug. 23, 1972, abandoned.  
 US. Cl. 52/98, 52/720 Int. Cl. E04c 3/06 Field of Search 52/720, 730, 731,735,  
 References Cited UNITED STATES PATENTS 3/1962 Mucssel 52/720 Primary Examiner-Price C. Faw, Jr. Attorney, Agent, or Firm-Donald L. Johnson; John F. Sieberth; Paul H. Leonard [57] ABSTRACT An integral elongated extruded metal construction element of hollow tubular construction having a set of channels located in oppsite sides thereof joined together by an elongated member integral therewith which is adapted to have a portion thereof readily re moved or knocked out.  
 6 Claims, 2 Drawing Figures EXTRUDED METAL CONSTRUCTION ELEMENT This is a continuation division of application Ser. No. 283,082, filed on Aug. 23, 1972; and now abandoned.  
 BACKGROUND OF THE INVENTION The present invention relates to building construction elements and more particularly to a new and improved elongated metal construction element of low cost construction which may be used for many different structural purposes in fabricating building and window frames.  
  The invention is especially related to an improved elongated vertical mullion of hollow tubular construction having a set of glazing channels located in opposite sides thereof. Prior art metal construction elements or mullions of the type of this invention are exemplified by U.S. Pat. No. 3,023,859.  
  Hollow structural shapes are often made of metal, especially aluminum and aluminum alloys, and formed by extrusion of these metals. In the building construction industry. hollow structural shapes are used in making windows and window frames. These elements or pieces are employed as sills, vertical members, headers, mullions, etc.  
  In extruding hollow structural shapes or metal con struction elements, mullions, etc. of the type disclosed in U.S. Pat. No. 3,023,859 and exemplified in FIG. 2 thereof, considerable difficulty is found in constructing dies for the extrusion and in getting the shape to run through the extrusion equipment without the longer widths or sides being concave or convex. Ordinarily, the sides tend to cave in during manufacture, making it difficult to produce a mullion or element requiring sufficiently close tolerances for the subsequent installation of glass and vinyl or plastic splines.  
  The present invention provides a metal extrusion which overcomes these prior art difficulties, improves manufacturing, eliminates twisting and permits thinner extrusions.  
  It is known that double hollow shapes may be joined together as an integral extrusion, but such a shape would be unsatisfactory and unsuitable for most uses.  
  It is therefore an important object of the present invention to provide a new and improved structural shape which can be readily manufactured by extrusion and which can easily be used for its subsequent purpose.  
  It is a particular object of the invention to provide a novel double hollow construction shape in which the double hollows are integrally joined together and in which a desirable portion ofthe integrally joining member may be readily removed.  
  Other objects and advantages of the instant invention will be readily apparent from the drawings and description hereinafter.  
 SUMMARY OF THE INVENTION The present invention comprises an elongated metal construction element of hollow tubular construction having a set of double hollows or channels located in opposite sides thereof. Each of the channels or hollows are joined together by a joining member integrally formed therewith. The joining member is so constructed or shaped that a portion thereof may be quickly and easily removed. The joining member is of sufficient strength to provide a desired stability during extrusion of the metal construction element, but sufficiently small or narrow so as not to interfere with the construction purpose for which the element is intended.  
  The invention is especially suitable for vertical mullions having opposed channels therein for receiving glass panes and for the construction of windows and window frames.  
  In the preferred form of the invention, the mullion or element is extruded from aluminum or an aluminum alloy, and the integrally joining member is of a wider dimension in the center thereof as compared to the width where it joins each of the channels or hollows.  
 BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a cross-sectional and perspective view of a section of a vertical mullion embodying an elongated extruded metal construction element characterized by the novel features of the invention; and,  
  FIG. 2 is a cross-sectional view of an enlarged portion of FIG. 1, illustrating the joining member which integrally joins the opposing channels of the extruded metal construction element or mullion.  
 DESCRIPTION OF THE PREFERRED EMBODIMENT In the preferred form of the invention, the metal construction element is formed by the extrusion of aluminum or aluminum alloy. For purposes of this application, the term aluminum as used hereinafter and in the claims includes aluminum and aluminum alloys customarily used or which may be used in the construction industry.  
  The mullion is so extruded or constructed that it provides opposing hollow members or channels which are integrally joined together by a joining member. The joining member is located between the sides of the opposing hollows facing each other and preferably at a central area of each of the facing or opposing sides. The hollows may be of various configurations and be the same or of different sizes or dimensions. For use as mullions for receiving glass panes, vinyl splines and the like, the opposing hollows are preferably channel members. The sides of the channels may be vertical as illustrated in the drawings or may extend outwardly or inwardly as desired.  
  The joining member is integrally formed with the metal construction element and extends longitudinally therewith. The mid-portion or central part of the member is thicker than the portions joining each of the facing sides of the hollows. The joining member may be of any desired configuration, but should be of sufficient strength to retain the extruded shape of the hollows and so constructed that a desired portion on an end of the element can be readily removed. The portion to be removed can be knocked out with a hammer or torn out with pliers or may be removed by any suitable means.  
  The invention provides an element which can be transported to a work site in its extruded form thus retaining the hollows or channels in their desired positions until installation of the glass or other desired time. A workman on the job site can then knock out or remove a desired portion of the joining member on the ends of the element thus readying it for its immediate ultimate use.  
  Referring now to the drawings, and more particularly to FIG. 1 thereof, there is shown an elongated vertical mullion of hollow tubular structure having respectively located in opposite sides thereof a set of glazing channels, hollows or internal U-shaped parts 11 and 12. It will be noted that while the channel 12 is similar to the channel 11, i.e., it is provided with grooves in the side walls thereof, and it is appreciably more shallow than the channel 11. It can be appreciated that the channels 11 and 12 can be constructed in various sizes and shapes and may be the same or different. They merely need to be of such size and shape to effectively receive a panel element, e.g., a glass pane.  
  The channels 11 and 12 are preferably provided with grooves 11a and 11b, and 120 and 12b, respectively. The grooves are adapted to receive resilient gaskets.  
  The channels 11 and 12 are integrallyjoined together by an elongated joining member 13 running longitudinally therewith.  
  In using the vertical mullion 10 in a flush glazing arrangement in which a plurality of adjacent windows or panels are provided, the mullions 10 are spaced along the wall of a building and are so oriented that the deep channels 11 all face in the same direction, i.e., for each window there are provided opposing deep and shallow glazing channels. A desired portion of the integrally joining member 13 on the end of each of the mullions 10 is knocked out or removed at any time prior to the installation of the mullions. As much of the member 13 may be removed as desired, but in most applications only one or two inches will need to be removed at each end.  
  The vertical mullions may all be installed before the glass panes are mounted in the unit. In order to mount the panes in the frames, the panes are each slidably moved at any angle into the bottom of the deep channel and then swung into place opposite opposing channel 12, resilient gaskets having previously been mounted in the grooves 11a and 12a of the channels 11 and 12, respectively. Thereafter, the pane is slidably moved into the bottom of the shallow channel 12 and resilient gaskets are forced into place in the grooves 11b and 12b to complete the unit. By providing both a shallow and a deep glazing channel in each mullion 10, and removing a portion of the joining member 13, sufficient space is provided between the opposing channels 11 and 12 to accommodate suitable reinforcement, if required, while at the same time minimizing the overall width of the mullion in a flush glazing design.  
  More specifically, and as shown in FIG. 1, there is shown an elongated, extruded vertical mullion 10 of hollow tubular construction having a generally rectangular hollow section made up of two external U-shaped parts, hollows or channels, 14 and 15, and two internal U-shaped parts 11 and 12 which are disposed within the section and are provided with base parts 110 and 120 which are disposed in substantially parallel spaced apart relationship. The external U-shaped parts 14 and 15 are respectively provided with legs 14a, 14b and 15a, 15b, which extend toward each other in spaced apart parallel planes and have spaced apart ends adapted to receive the edges of panel elements therebetween on opposite sides of the section. Thus, the legs 14a and 15a extend toward each other in the same plane and are provided with spaced apart ends or edges 14c and 15c which are spaced apart as shown to receive the edge of a panel element therebetween. Similarly, the legs 14b and 15b extend toward each other in another plane which is parallel to the plane occupied by the legs 14a and 15a and are provided with spaced apart ends or edges 14d and 15d to receive the edge of a second panel element therebetween.  
  As illustrated, the legs of the internal U-shaped parts or hollows 11 and 12 extend toward but are displaced from the adjacent leg ends of the external U-shaped parts. Thus, the internal U-shaped part 11 is provided with legs 11d and lle which extend toward the legs 11b and 15b, respectively, and are respectively provided with feet 11f and 11g which are displaced from the leg ends 14b and 15b. Somewhat similarly, the internal U- shaped part 12 is provided with legs 12d and 122 which extend toward the leg ends 14c and 15c, respectively, of the legs 14a and 15a, and are respectively provided with ends 12fand 12g which are displaced from the leg ends and 15c. As will be noted, the end surfaces of the legs 14c and 14d are substantially coplanar with the inner surfaces of the legs 12d and 11d and the end surfaces of the leg ends and 15d are substantially coplaner with the inner surfaces of the legs 12e and lle. By virtue of this coplaner relationship, coupled with the displacing of the ends of the legs of the internal U- shaped parts from the ends of the legs of the external U-shaped parts, it becomes feasible to form the grooves 11a, 11b, 12a and 12b for receiving resilient-securing strips by providing connecting parts 17, 18, 19 and 20 integrally to join the leg ends of the internal U-shaped parts with the legs of the external U-shaped parts at points spaced back from the ends of the last-mentioned legs. More specifically, the connecting part 17 is formed to extend at right angles to the legs 14a and 12d and integrally joins the leg 12d with the leg 14a at a point spaced back from the leg end 140 to define the groove 12a between the leg ends 140 and 12f. Similarly, the connecting part 18 is formed to extend at right angles to the leg 15a and 12e, and integrally joins the leg l2e with the leg 15a at a point spaced back from the leg end 15c to define the groove 12b between the leg ends 150 and 12g. Somewhat similarly, the connecting part 19 is an extension of the leg 11d and is formed to extend at a right angle to the leg 14b, and integrally joins the leg 11d with the leg 14b at a point spaced back from the leg end 14d to define the groove 11a between the leg end 14d and foot 11f. The connecting part 20 is an extension of the leg lle and is formed to extend at a right angle to the leg 15b, and integrally joins the leg 15b with the leg lle at a point spaced back from the leg end 15d, thereby to define the groove 1117 between the leg end 15d and foot 11g.  
  The integrally joining or connecting member 13 can be seen in more detail in FIG. 2. The member 13 runs longitudinally with the mullion 10 and is integrally formed therewith and connects the base parts 11c and 120 of the opposed channels 11 and 12 together. The legs or portions 13a and 13b of the member 13 extend at right angles to the base parts 11c and 120, respectively. The legs 13a and 13b are joined together by an enlarged or central portion 13c which is conveniently of a substantially octagonal shape, having six exterior sides, sides 13d and l3e which extend outwardly and downwardly from leg 13a, sides 13f and 13g which extend outwardly and upwardly from leg 13b, and sides 1311 and 13i which connect sides 13d, 13fand 13a, 13g, respectively, and are parallel to each other. The bottom portion 13] of the leg 13a forms the seventh side of the member 13, and the top portion 13k of the leg 13b forms the eighth side of the member 13, thus forming a substantially octagonally shaped (in cross-section) central part 130.  
  It can be appreciated that the member 13 can be of any desired shape, but it should be of a shape which readily lends itself to being formed in an extrusion operation, and which a portion thereof can readily be removed from the base parts 110 and 12c and from the member 13.  
  The foregoing disclosure and description of the invention is illustrative and explanatory thereof and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made within the scope of the appended claims without departing from the spirit of the invention.  
 What is claimed is:  
  1. An integral elongated metal construction element having a generally rectangular hollow section comprising two external U-shaped parts, the legs of which extend toward each other in two spaced apart planes and are provided with spaced apart ends adapted to receive the edges of panel elements therebetween on opposite sides of said section, two oppositely facing internal U- shaped parts disposed within said section between said planes substantially at right angles to said external U shaped parts and spanning the spaces between the legs of said external U-shaped parts to receive the edges of the panel elements therewithin, the legs of each of said internal U-shaped parts extending toward but being displaced from the adjacent leg ends of said external U- shaped parts, and a joining member connecting said two oppositely facing internal U-shaped parts integrally formed and extending longitudinally therewith, said joining member having a portion thereof adjacent each of said internal U-shaped parts which are of sufficient strength to retain the structural integrity or shape of said U-shaped parts and which portions are sufficiently weak that they may be readily removed from said construction element.  
  2. The construction element of claim 1, wherein said joining member is of a wider dimension in the center thereof than in the area immediately adjacent and joining each of said oppositely facing internal U-shaped parts.  
  3. The construction element of claim 1, wherein said joining member has a central portion of a substantially octagonal shape in cross-section and legs extending from said central portion in opposite directions therefrom and connecting said oppositely facing internal U- shaped parts to each other.  
  4. An integral elongated construction element formed by an extrusion process, comprising a generally hollow section comprising two internal hollows located in opposite sides thereof and facing each other, each of said hollows being joined together by a joining member integrally formed and extending longitudinally therewith, said joining member being so constructed and shaped that a portion thereof adjacent each of said hollows may be quickly and easily removed therefrom, and said portions of said joining member being of sufficient strength to provide a desired stability during extrusion of the construction element.  
  5. The construction element of claim 4, wherein said joining member is of a wider dimension in the center thereof than in the area immediately adjacent and joining each of said oppositely facing internal hollows.  
  6. The construction element of claim 4, wherein said joining member has a central portion of a substantially octagonal shape in cross-section and legs extending from said central portion in opposite directions therefrom and connecting said oppositely facing internal hollows to each other.  
  UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION PATENT NO. 3,874,135 DATED April 1975 |NVENTOR(S) Eugene J. Craven It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:  
 The Title Page should show the Assignee as being The William L. Bonnell Company, Newnan, Ga.  
 Signed and Scaled this Attest:  
 RUTH C. MASON C. MARSHALL DANN Arresting Officer (ommissiuner oj&#39;ParenIs and Trademarks