AU2006100650B4 - A Sliding Door or Window Sash Having Square Cut Members and Corner Connectors - Google Patents

Description

A Sliding Door Sash Having Square Cut Members and Corner Connectors Field of the Invention.

This invention is directed to a door sash which can be made of aluminium extrusions I (which is quite conventional), and where the extrusions are "square cut" and are connected to each other using comer connectors which have a particular design and _which contain an opening to accommodate a roller. The invention is not directed to the surround frame which is normally nailed or screwed into a wall opening and 1 0 which supports the sash for sliding movement.

Background Art.

A door sash comprises the "sliding" part of a door assembly.

Typically, the door assembly comprises a surround frame which is fixed into a wall cavity (typically by screws). The frame contains a top and bottom aluminium section.

The top section has a channel and the bottom section (that is the floor section) typically has a rail track or something similar on which the sliding door sash can slide.

The door sash typically contains a sheet of glass. The edges of the glass fit within one or more extrusions which may also contain a weather strip. Thus, the edges of the glass is surrounded by an upper and lower horizontal extrusion and a pair of vertical side extrusions. The extrusions are usually quite small and it is therefore known to fit the extrusions within larger vertical and horizontal extrusions which form part of the door sash.

It is well-known to have a pair of door rollers fitted to the bottom of the door sash and which roll along the rail track. These door rollers fit within cavities on the bottom extrusion of the sash.

The present invention is directed to a better way of assembling the various sections of 2 a door sash together (that is the top wall, bottom wall and sidewalls).

Conventionally, these sections are made of extruded aluminium and each opposed end is machined to provide tabs, extensions, recesses, and the like so that a top section can be screwed to a side wall section with the various machined portions the tabs, extensions etc) overlapping and therefore able to be screwed together.

The reason for this quite complicated attachment system is that the door sash can be quite large and quite heavy and there could be severe consequences if the sash could fall apart by being improperly assembled. For this reason, conventional thinking has been to use fasteners such as screws, rivets and the like together with rather complicated profiles.

The problem with this is that it is quite expensive to machine each end of the top wall, bottom wall and sidewalls of the sash. Also, it results in large inventory costs.

Assembly can be quite time-consuming and require a range of assembly tools.

As well, fitting of the door rollers in the vertical or bottom horizontal extrusion can be somewhat finicky.

It is known to use a simpler system for the surround frame in which the sash slides.

However, the surround frame can be strongly screwed to the wall cavity and therefore the problem of the surround frame coming apart does not occur as the frame can be screwed to the wall studs et cetera. Also, the surround frame itself is not very heavy.

Another problem with many types of door sashes is the need to ensure that water can be properly drained to the outside.

Many conventional sashes also have a quite complicated design that requires the top and bottom extrusions (that support the top and bottom edge of the glass) to be mounted in another extrusion. Again, this increases inventory costs and makes assembly more complicated.

Another problem with some door sashes is that the bottom horizontal extrusion is metal and this can rub on the metal sill of the surround frame causing irritating and annoying levels of noise when sliding the door.

The present invention is directed to a door sash where the sash sections are square cut (by which is meant that the ends are just plain). Then, to attach these square cut sections together, the present invention provides corner connectors that can be made of plastic and which can be pushed into the end of each section to connect the sections together without requiring the sections themselves to have any "fancy" end profile.

The corner connectors contain a cavity which is designed to accept a roller which means that a sash can be supported by rollers in the corner connectors and it is no longer necessary to fit the rollers in the bottom of the vertical or the horizontal extrusion. A single corner connector profile can be used for each corner, and for the top corners, the roller is not fitted and a cavity remains empty.

It should be appreciated that the present invention is directed to a door sash being assembled in this manner, and not to the surround frame.

There are many advantages in assembling the sash in this manner. The invention eliminates the current machining required to "profile" each end such that the ends can be connected to each other. It is much easier to simply cut-off a length of aluminium section to a desired length and then use a corner connector. Thus, the aluminium section can be made to any length simply by cutting off the end to a required length.

No additional "profiling" of the end is required.

The corner connector can be made of plastic and can either be snapped locked or push locked or otherwise attached to a pair of adjacent (and typically right angles) sash members.

Another advantage that comes from this arrangement is that door sashes are provided with bottom door rollers to allow the sash to roll along a track in the surround frame.

These rollers can now be attached to the bottom of the corner connector as opposed to the lower horizontal sash member. This means that the sash member does not need to be cut with openings to accommodate the door roller. Instead, the door roller can be pushed into an opening in the bottom of the corner connector.

Another advantage with the use of corner connectors is that the connector contains a cavity in which are roller can be fitted. However, the roller is not an integral part of the corner connector and therefore when the roller is not fitted, the connector can be used to connect the upper part of the sash where a roller need not be required.

Some attempts have been made to provide a simpler assembly procedure for screen doors. However, screen doors are very lightweight and contain a fly screen infill panel and therefore do not suffer from weight and wind load problems of a sliding glass door. Therefore, these screen doors can be made in a relatively flimsy manner.

Similarly, a simpler assembly design can be achieved for other lightweight doors such as shower screen doors.

There are some designs showing a relatively simple assembly for the surround frame (which can be screwed to the wall cavity) but this is not the same as the relatively heavy door sash which slides along the bottom rail of the surround frame. Also, the surround frame does not need to deal with the issue of positioning of the rollers.

There are some designs which show corner connectors connecting a vertical and horizontal member but where the connector itself forms a significant part of the periphery. That is, the vertical and horizontal members do not meet but instead are spaced some distance apart with the connecting itself forming part of the surround periphery. The disadvantage with this arrangement is that the corner connector needs to be extremely robust and strong and therefore may need to be made of metal or have significant support struts and the like. This makes it difficult for the corner connector to contain a reasonably large cavity to accommodate a roller assembly.

It is also known to use corner connectors for picture framing and the like but again this does not fall within the scope of the present invention which is directed to sliding door sashes.

With sliding (sash) doors, another disadvantage with many conventional designs is that the sashes are quite noisy when moved because of metal to metal contact.

Another disadvantage with many conventional door sashes is that there can be considerable heat transfer due to the metal to metal contact.

It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.

Object of the Invention.

It is an object of the invention to provide a door sash that may overcome at least some of the above-mentioned disadvantages or provide a useful or commercial choice.

In one form, the invention resides in a door sash comprising an infill glass panel opposed vertical frame members and upper and lower horizontal frame members, which are square cut, each opposed vertical frame member comprising a front wall, a rear wall, an outer edge wall and an inner edge, the lower horizontal frame member having a bottom wall and a pair of opposed sidewalls, the said pair of opposed sidewalls extending upwardly from the bottom wall, the upper horizontal frame member having a top wall and a pair of opposed sidewalls, the said pair of opposed sidewalls extending downwardly from the top wall, the inner edge of each vertical frame member comprising means to accommodate an edge portion of said infill glass panel, and comer connectors interconnecting the horizontal frame members with the vertical frame members, the corner connectors containing a cavity between planes defined by opposing sidewalls of the horizontal frame member, said cavity adapted to accommodate a door roller.

It is considered that having corner connectors on square cut frames for a door sash substantially contributes to the working of the invention.

It is considered that having cavities in the corner connectors, which are large enough to accommodate the door roller (by where the door roller is not a permanent part of the comer connector by which is meant that the door roller can be removed if not required without deleterious effect to the corner connector) contribute substantially to the working of the invention.

It is considered that having plastic comer connectors of the above design contribute substantially to the working of the invention.

It is considered that having the vertical and horizontal sash components at least partially abutting or having an internal periphery which abuts or is very close to each other together with the corner connectors substantially contributes to the working of the invention, by minimising the need for the corner connectors to be made very strongly (and therefore allowing the corner connectors to be made of plastic instead of metal).

The door sash may have a width of between 0.5-2 m and a height of between 1.7-2.5 m but it should be appreciated that the sash may have different sizes.

The door sash contains an infill panel which comprises a sheet of glass. The glass may comprise clear glass, opaque glass, frosted glass, tinted glass, toughened glass, safety glass, treated glass, and the like. The sash may contain more than one sheet of glass. The glass may have a thickness of between 4-15 mm. It is envisaged that the glass may comprise noise deadening glass such as two sheets of glass, glass laminates and the like.

The glass panel may have its edges supported by frame members which form part of the sash. These frame members may comprise extrusions. The extrusion may be made of metal or plastic and it is preferred that these extrusions are made of plastic.

Suitable plastic material may comprise homopolymers, copolymers, thermoplastics, thermosetting plastics, ethylene polymers, vinyl chloride polymers such as polyvinyl chloride, block copolymers and the like. The plastic material may comprise filled plastics, plastic laminates and the like.

If the frame members comprise extrusions which are formed of metal, the metal will typically comprise aluminium (aluminum for the USA).

Each extrusion may contain a channel to accommodate the edge of the glass panel.

The size of the channel will depend on the thickness of the panel. Thus, it is envisaged that the channel will have a width of between 4-15 mm, although this can vary to suit. The vertical extrusion may therefore have a somewhat U-shaped crosssection.

The length of the vertical extrusion will depend on the length of the glass panel but will typically be between 1-3 m. It is envisaged that the extrusion can be cut to length.

The width of the extrusion will depend in part on the depth or "thickness" of the door sash but it is envisaged that the extrusion will have a width of between 5-30 mm although this can vary to suit.

It is preferred that the extrusion contains a weather seal which presses up against the edge of the glass panel. The weather seal may comprise a co extrusion seal. This seal can function to prevent rattling of the glass panel and also to function as a weather seal.

The door sash will typically contain a top and bottom horizontal frame member which can cover the top and bottom horizontal edge of the glass panel.

The top and bottom frame member may be made of materials similar to that of the vertical frame members and may therefore comprise plastic/metal extrusions.

These top and bottom extrusions may be tubular and may be substantially rectangular in cross-section except that a channel is provided to accommodate the edge of the glass panel. The channel may have a width depending on the thickness of the glass panel and it is envisaged that the width of the channel will be between 4-20 mm. This can of course vary to suit.

It is preferred that a channel is provided on each opposed face of the extrusion.

Drainage slots or openings may be provided in the extrusion, and typically within the channel such that water can drain from the channel into the interior of the tubular extrusion. It is preferred that any water that passes into the tubular extrusion will drain from one or both ends of the extrusion and this will be explained in greater detail below. Therefore, there is no requirement to punch additional slots in the side wall or bottom wall of the extrusion to drain water from the inside of the extrusion.

One of the channels on the extrusion may be provided with a weather seal which may again comprise a co-extruded seal.

The door sash may comprise another pair of larger vertical members which can at least partially cover the vertical extrusions which are attached to the vertical edges of the glass pane. It is envisaged that one of these larger vertical members will contain a lock to enable the sliding door to be locked in the closed position, and this vertical member can be called a lock stile for the sake of convenience. The other larger vertical member can be called an interlock member for the sake of convenience.

Each of these larger vertical members may comprise an extrusion and it is envisaged that each of these members will be made of extruded aluminium.

These members may comprise elongate tubular members having a somewhat rectangular cross-section although this can vary to suit.

It is envisaged that each of these members will have an opening in the top and the bottom to allow a comer connector to be fitted into each opening thereby enabling the door sash to be assembled in a simple yet robust manner. In practice, it is envisaged that the opening will extended entirely through each member.

A corner connector is provided on each corner of the sash. This allows the various sash extrusions to be square cut without any fancy profiles.

It is preferred that each comer connector has a somewhat L-shaped configuration or a configuration that allows a part of the corner connector to be attached to a vertical member the lock stile) and another part that allows the comer connector to be attached to a horizontal member the upper or lower extrusion that attaches to the glass pane).

The comer connector is from plastic as this provides a number of advantages hitherto not realised. One advantage of being manufactured from plastic is that the comer connectors can be made with enhanced accuracy due to the moulding process and therefore provide accurate fixing points which is unlike machined fixing points. The plastic connectors can also provide thermal enhancements by minimising linear heat transfer around the sash and conductive transfer to the head and the sill. The plastic connector will also provide a quieter operation when sliding the door.

It is preferred that at least one, and preferably each of the corner connectors can be snap fitted or push locked into the respective extrusions. However, there may be circumstances where additional fastener attachments (such as screws etc) can be used to further ensure the fixing and rigidity of the sash.

In one form, the comer connector may be provided with a projection (for instance a snap detail) and the respective extrusion can be provided with a detail to lock to the projection. Thus, in a simple form, the extrusion may contain an opening into which the projection can pass to snap fit the comer connector to the extrusion. Of course, it is envisaged that there will be many other mechanisms or arrangements to allow the comer connector to snap fit or push lock into a frame member/extrusion. For instance, the frame member may contain the projection and the comer connector may contain the opening. In another alternative, each member may contain both the projection and the opening. Various shapes of projections (that is the snap detail) are envisaged including buttons, teeth, ridges, shoulders, hooks, and the like. Spring locking mechanisms are also envisaged.

In one form of the invention, the comer connector is connected to the vertical and horizontal extrusion/frame member in a particular matter which makes the sash suitable as a relatively heavy door sash. In this form of the invention, the comer connector fits substantially within the vertical and the horizontal extrusion/frame member such that when the corner connector is in place, the vertical extrusion/frame member and the horizontal extrusion/frame member abut each other or are very close to each other as opposed to being spaced apart with the corner connector forming part of the periphery.

Alternatively, the comer connector may be connected to the horizontal frame member using screws and the like.

Brief Description of the Drawings.

Embodiments of the invention will be described with reference to the following drawings in which:.

Figure 1. Illustrates an exploded view of a door sash and also illustrating the head and sill of the surround frame.

Figure 2. Illustrates the assembled sash without the head and sill Figure 3. Illustrates the assembled sash from one side and positioned between the head and the sill of the surround frame.

Figure 4. Illustrates a corner connector according to a second embodiment of the invention.

Figure 5. Illustrates a comer connector according to a first embodiment of the invention positioned adjacent a bottom horizontal extrusion.

Figure 6. Illustrates a roller.

Figure 7. Illustrates the corner connector of figure 5 attached to the bottom horizontal extrusion.

Figure 8. Illustrates a head corner connector for a screw fixed rail (second embodiment of the invention).

Figure 9. Illustrates a corner connector according to a first embodiment of the invention and particularly illustrating the snap detail.

Figure 10. Is a side partially section view of the comer connector of figure 9 attached to the lower horizontal extrusion.

Figure 11. Illustrates a section view of the comer connector showing the inserted roller and also illustrating drainage of the lower extrusion (rail).

Figure 12. Illustrates a square cut sash assembly.

Figure 13. Illustrates the assembled sash from the side opposite to that illustrated in figure 3 Figure 14. Illustrates a cross section of the extrusion 14,15.

Best Mode.

Referring to the drawings and initially to figures 1-3, figure 1 shows an exploded view of a door sash Figure 2 shows the door sash assembled and figure 3 shows the door sash fitted within a surround frame.

Referring initially to figure 1, there is illustrated the door sash and the upper and lower part of the surround frame which, in the particular embodiment, includes a head section 10 and a sill section 11. The head section 10 and the sill section 11 do not form part of the sash but form part of the surround frame.

The door sash itself in the embodiment comprises the following components each of which will be described in greater detail below: an infill panel which in the particular embodiment is a rectangular sheet of glass 12, vertical extrusions 13 which surround each vertical edge of glass 12, an upper horizontal extrusion 14 which surrounds the top horizontal edge of glass 12, a lower horizontal extrusion 15 which surrounds the bottom horizontal edge of glass 12, a larger lock stile extrusion 16 (the lock stile extrusion being the extrusion which contains the sliding door lock) which fits about one of the vertical extrusions 13, a larger interlock extrusion 17 which fits about the other vertical extrusion 13, and four plastic corner connectors 18.

It should be appreciated that the figures do not illustrate the sash in full-size. It is expected that the door sash will have a width of between 1-2 m and a height of between 1.8-2.1 m although this can vary to suit.

The sheet of glass 12 will be cut to size and will typically comprise toughened glass.

The vertical side edges of glass 12 are held by the two vertical side extrusions 13.

These extrusions can be made of plastic or metal. Each extrusion contains a longitudinal channel into which a side edge of glass 12 can pass. A co-extruded weather seal (not illustrated but similar to the seal in extrusions 14 and 15 which will be described in greater detail below) sits on both side walls of the channel such that when the extrusion is pushed on to the edge of the glass, there will be a reasonable seal provided. These extrusions can be square cut at their opposed edges.

The top and bottom horizontal edges of glass 12 are held by the upper horizontal extrusion 14 and the lower horizontal extrusion 15. These extrusions can be formed of plastic or metal and it is preferred that extrusion 14 is identical to extrusion The extrusion is illustrated in somewhat greater detail in figure 5 and figure 9 and it can be seen that the extrusion comprises a generally hollow tubular member which is somewhat rectangular in cross-section and contains an upper and lower channel 19 (best illustrated in figure the design being such that the extrusion is symmetrical.

Channel 19 has a shape and a size to accommodate the edge of the glass. A coextruded weather seal 20 (illustrated in figure 5 and figure 9) is provided on both side walls of channel 19 see figure 14). Thus, the extrusion can be used as both the upper extrusion 14 or the lower extrusion 15 simply by turning the extrusion around.

Slots 21 (illustrated in figure 9) can be formed in channel 19 to drain the water from the channel into the interior of the extrusion.

Figure 11 shows the drainage arrangement. The figure shows channel 15 in a partially cutaway view with the slots 21 causing water to pass into the channel the water then moving in the direction of arrow 22 to drain from the channel via an opening in the plastic connector 18. Thus, it is not necessary to punch holes in the side wall of the channel in order to drain water.

Referring back to figure 1, the sash further contains a lock stile extrusion 16 which is formed from extruded aluminium and which can be powder coated if desired. Lock stile 16 comprises a tubular member which is substantially rectangular in cross-section and comprises a front wall 16A, a rear wall 16B, an outer edge wall 16C and a channel 23 located on an inner edge which passes over the corresponding extrusion 13 to conceal extrusion 13. Thus, once fitted in place (see for instance figure 2 and figure extrusion 13 is hardly visible.

Similarly, the other vertical extrusion on the other side of glass 12 is mostly hidden by an interlock extrusion 17 which is also formed from extruded aluminium which may be powder coated. The interlock extrusion is also substantially tubular and contains a channel 24 which passes over vertical extrusion 13.

The remaining major component of the sash comprises the corner connectors 18. In the embodiment, four comer connectors are provided which, when required, can be identified as bottom left-hand corner connector 18 a, bottom ight-hand comer connector 18b, top left-hand corner connector 18 c, and top right-hand comer connector 18 d. However, the comer connectors can be collectively identified simply by reference 18.

The corner connectors are made from plastic which provides a number of advantages.

One advantage is that the plastic comer connectors can be made extremely accurately thereby providing accurate fixing points which is not always possible with machine fixing points. Another advantage is that the plastic material can provide a better heat insulate and a further advantage is that the door sash can slide with less noise as there is less metal to metal contact.

The corner connectors are somewhat L-shaped but contain a much larger main body portion 25 (see for instance figure 5) and a smaller leg portion 26. The main body portion 25 can be seen as one "leg" of the generally L-shaped corner connector.

Main body portion 25 is substantially hollow (see for instance figure 11) and contains a cavity in which a door roller 27 (see for instance figure 6) can fit. Thus, the sash can be supported by the rollers which are fitted into the corner connectors as opposed to many types of conventional sashes where the rollers need to be fitted into the bottom of the profiled vertical extrusions, or in cutouts in the bottom horizontal rail (for instance extrusion 15). Making cutouts in the horizontal rail can weaken the rail and also makes the rail "peculiar" for the bottom rail, which means that a separate top rail and a separate bottom rail is required which is undesirable unless cutouts are placed in many positions in the rail in which case the rail is further weakened.

Door roller 27 (see for instance figure 6) comprises a roller body 28 the bottom of which supports a wheel 29 in a manner which is quite well known. Adjustment of the wheel relative to the bottom of the corner connector (that is how far the wheel "sticks out" of the comer connector) is done in a particular manner which is best illustrated in figure 6 and figure 11. Basically, the top of roller body 28 contains a ramp 30. Above the ramp is a "travelling nut" 31 which basically comprises a metal nut which is supported within a nut housing (see figure Movement of the travelling nut 31 to and fro in a horizontal manner will cause it to ride along ramp 30 and therefore push the door roller either up or down. As an example, and referring to figure 6, if the travelling nut is in the "uppermost" portion of the ramp (the left-hand side when view in figure the door roller has been pushed down to its maximum amount and conversely when the travelling nut has moved to the "lowermost" portion of the ramp the door roller can move up.

Referring to figure 11, the travelling nut 31 is operated by a bolt 32 which has a screw type head arrangement to allow a screwdriver (or philips head screwdriver) to rotate the bolt and therefore cause the nut to move to and fro.

The bolt 32 is also illustrated in figure 4 and figure 5 and is accessible through an opening in the wall of the main body portion 25 of the comer connector. When the corner connector is fitted, (and best illustrated in figure the lock stile 16 and the interlock 17 also contain a small opening 33 to allow a screwdriver to rotate bolt 32 in either a clockwise or anticlockwise direction.

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Referring again to the corner connectors, and this time particularly to figure 5 and figure 9, and initially to figure 5, the corner connector 18 contains a small protruding button which can be seen as the "connector snap detail" 35. Detail 35 contains a pair of tapered faces. Referring now to figure 2, the lock stile 16 contains a second opening 36 which functions as the "connector snap hole". Thus, when the corner connector is pushed into the bottom of lock stile 18, detail 35 will lock into opening 36 to snap lock the comer connector to the bottom of lock stile 16.

The other comer connectors can be snapped into upper and lower ends of the interlock stile or the lock stile in a similar manner.

If there is a need or advantage in providing additional fixing, the comer connector 18 (see for instance figure 7) is provided with a further optional screw fixing 37 opening to allow the comer connector to also be screwed to the interlock and lock stile extrusions. Figure 7 also illustrates friction ribs 60 to facilitate fastening of the corner connector in place, guide blocks 61 and drainage holes 62.

Thus, the interlock extrusion 17 and the lock stile extrusion 16 can be square cut at their opposed ends and the corner connectors can be snapped fitted into each square cut open end.

Referring now to figure 5, figure 7 and figure 9 but not to figure 4, figures 5 and 7 illustrate that the comer connector 18 has the leg member 26 that can push fit into the lower horizontal extrusion 15. Again, a snap detail is provided, and the snap detail on leg member 26 is illustrated in figure 9 as snap detail 38. Thus, the leg member contains the snap detail 38, and the extrusion 15 contains a corresponding opening in a manner similar to that described with respect to the snap detail 35 on the corner extrusion.

Thus, each of the extrusions (13, 14, 15, 16 and 17) can be square cut and the comer connectors 18 can be snapped fitted to provide a door sash.

Each comer connector contains the internal opening to accommodate the door roller 27 but the door roller is only fitted to the bottom corner connectors (18 a, 18 while the top corner connectors do not contain the door roller. Nevertheless, the corner connectors can all be made identical which can cut down on inventory costs and improve assembly costs.

Figure 4 illustrates a slightly different version of the corner connector. In this version, the comer connector does not contain the second leg (26. In figure However, the comer connector still contains the main body portion 25 which can accommodate a roller of the type illustrated in figure 6. This type of connector may be required if the lower (or upper) rail/extrusion (that is 14, 15 in the other figures) is not tubular but instead comprises a more conventional rail design 40 illustrated in figure 4. In this variation, rail 40 needs to be screwed to corner connector 41 using screws 42 instead of a snap lock.

Similarly, figure 8 shows a comer connector 50 which can be seen as a head connector and for a screw fixed rail (not illustrated) but similar to the screw rail 40 of figure 4.

Another advantage with this assembly system is that the comer connectors 18 do not themselves form a significant (if any) part of the extrusions that fit around the sheet of glass 12, and are designed such that the lock stile extrusion or the interlock extrusion (16 and 17) have a part that abuts or is very close to the upper and lower extrusions 14, 15. This provides a strong sash arrangement using square cut components. This is contrary to many other systems where the vertical and horizontal members are spaced apart by a significant distance and the spacing is filled by the comer connector which therefore forms a significant part of the periphery. As the corner connectors of the present invention are preferably made from plastic to provide advantages that have been previously or which will be hereinafter described, it might be difficult to provide a robust heavy door sash with plastic comer connectors if the comer connector forms a significant part of the periphery.

The arrangement provides many advantages including the following: Eliminates expensive machining for sash members.

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Eliminates expensive press tools necessary to produce machining.

Reduces handling costs of sash members through the factory by elimination of machining.

Reduces the exposure of damage to sash member by reduced handling.

Reduces material wastage.

Enables rapid sash assembly.

The square cut sash slides more quietly due to the plastic comer connectors providing less friction/resonance in the head and the sill.

The plastic comer connectors provide a thermal enhancement by minimising linear heat transfer around the sash and conductive transfer to the head and sill.

Provides enhanced accuracy due to moulded plastic comer connectors having accurate fixing points on like machined fixing points.

The square cut sash members minimise workplace health and safety exposure due to the elimination of press tool machining and its inherent sharp edges.

The plastic corner connectors can provide for integral sash rollers or head guides.

The plastic corner connectors can provide for a snap in all screw fix option for the sash member assembly.

The assembly provides a single piece plastic rail and seal co-extrusion that replaces the current two-piece rail and go extrusion thereby allowing the rail to have a symmetrical design that does not require orientation went being installed.

The lower extrusion (15) provides for drainage that directs any water into the corner connectors and into the sill.

The interlock connectors provide for continuous seals through the full length of the interlock extrusion and the sill/head connectors.

The connectors provide for all moving sash/door requirements XO and OXXO.

The corner connectors allow an adjustable sash/door roller to be snapped fitted on the assembly.

The elimination of having to machine sash extrusions minimizes the sharp edges that cut out weather seals.

The comer connectors provide a guide detail which minimises movement of the sash/door in the head and the sill.

Throughout the specification and the claims (if present), unless the context requires otherwise, the term "comprise", or variations such as "comprises" or "comprising", will be understood to apply the inclusion of the stated integer or group of integers but not the exclusion of any other integer or group of integers.

Throughout the specification and claims (if present), unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms.

Any embodiment of the invention is meant to be illustrative only and is not meant to be limiting to the invention Therefore, it should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the spirit and scope of the invention.

Claims (4)

1. A door sash comprising an infill glass panel, opposed vertical frame members and upper and lower horizontal frame members, all of which are square cut, each opposed vertical frame member comprising a front wall, a rear wall, an outer edge wall and an inner edge, the lower horizontal frame member having a bottom wall and a pair of opposed sidewalls, the said pair of opposed sidewalls extending upwardly from the bottom wall, the upper horizontal frame member having a top wall and a pair of opposed sidewalls, the said pair of opposed sidewalls extending downwardly from the top wall, the inner edge of each vertical frame member comprising means to accommodate an edge portion of said infill glass panel, and corner connectors interconnecting the horizontal frame members with the vertical frame members, the corner connectors containing a cavity between planes defined by opposing sidewalls of the horizontal frame member, said cavity adapted to accommodate a door roller.

2. The door sash as claimed in claim 1, wherein each corner connector is made of plastic.

3. The door sash of claim 1 or claim 2, wherein each comer connector contains a snap detail to allow the corner connector to be snapped locked to a lower or upper horizontal extrusion, and each corner connector contains another snap detail to allow the comer connector to be snapped locked to a vertical extrusion.

4. The door sash as claimed in any one of the preceding claims, comprising a pair of lower comer connectors, each said lower comer connector containing a door roller positioned within the cavity in the comer connector. The door sash as claimed in any one of the preceding claims, wherein the horizontal frame member is connected to the corner connector by at least one screw.