Apparatus and method for installing a closure in a building

Abstract

A mounting frame for mounting a closure within an aperture in a building. The mounting frame comprises a main frame structure and insulation. The main frame structure is arranged, in use, to extend around a perimeter of the building aperture. The insulation is on the outside of the main frame structure and extends about the whole or at least part of its periphery. The main frame structure is formed in two parts each terminating with an outwardly extending support flange. The insulation couples together the support flanges and thereby coupling together the two parts of the main frame structure. The support flanges and the insulation are configured such that, in use, the insulation and the support flanges are positioned between interior and exterior wall skins of a wall surrounding the building aperture. There is also disclosed a construction method using the mounting frame.

Description

P50015W031APPARATUS AND METHOD FOR INSTALLING A CLOSURE IN A BUILDINGTECHNICAL FIELD

[0001] The present invention relates to an apparatus and method for installing a closure within an aperture in a building. In particular, the present invention further relates to mounting frames for closures and constructions methods using such mounting frames.

[0002] The term “closure” is used generically in this document to refer to a window or a door or anything that closes off an opening or aperture in a building. Particular embodiments are presented in the detailed description referring to windows, window frames and window apertures in a building (in a wall or roof of the building) however in each instance this should not be considered to be limiting and the present invention in all cases encompasses doors and windows (and mounting frames for frames of doors and windows) unless the context specifically requires otherwise. The term “building aperture” is used in this document to mean an opening within a structure of a building, for instance an opening through a wall or roof. An opening through a structure of the building remains a building aperture even if it is closed by a closure such as a window or door. For instance, in a completed building a window is located within a building aperture, the building aperture extending through a wall of the building.BACKGROUND

[0003] In the construction industry, it is well-known that the energy efficiency of buildings can be improved using construction materials and components having good thermal insulating properties. In particular, significant improvements in the energy efficiency of buildings have been achieved through the use of double and triple-glazed window and door units, mounted in polymeric or composite window or door frames having low thermal transmission rates. These have been shown to greatly reduce thermal losses through apertures of buildings, in comparison to prior single-glazed units, mounted in plain wooden or metal frames.

[0004] However, the ultimate thermal efficiency of a window or door depends upon other factors, including the way in which the frame is installed in its aperture. It is important that the frame be mounted in the aperture in such a way that the passage of air between the frame and a wall or roof structure in which the frame is mounted is restricted, as this could otherwise permit egress of warm air from the building, and ingress of cold external air. This has been achieved by sealing the frame to a structure of the building surrounding the aperture. In recent years, dedicated adhesive-backed sealing tapes have been developed for this purpose.P50015W032

[0005] The window or door frame is first installed in the aperture resting on blockwork of the wall structure, such as bricks or cement blocks. Any cavity between internal and external wall skins is typically filled using a suitable insulating material, of which many types exist. The frame is sealed to the blockwork using the adhesive tape, which extends over surfaces of blocks adjacent the frame and on to an internal surface of the frame itself. The tape overlaps an interface between the blocks and the frame, restricting the passage of air (and moisture) around the frame. The tape itself is normally supplied in a long roll. Taping of the frame is relatively complicated, particularly at its corner regions.

[0006] Other options include positioning a membrane around the perimeter of the frame overlapping the block-frame interface, securing the membrane in place using staples or other mechanical fixations, and then taping the membrane to the frame in corner regions and at other potential leak points. This approach may be more common where a simple wooden frame is positioned in the aperture, to which the membrane can be secured.

[0007] As is well-known however, modern window and door systems of this type have a limited lifetime. For example, glazed units can deteriorate and require replacing, and polymeric materials used to form the frames can deteriorate over time, particularly through exposure to UV light. Consequently, a time comes when the window or door requires replacing. Whilst this is a relatively straightforward process, problems can occur in correctly sealing a new window frame within the window aperture.

[0008] In particular, it can be difficult to effectively seal the new frames to the building blockwork. This is because, in the process of removing an old polymeric or composite frame, it is necessary to cut the sealing tape (or tape and membrane) positioned at the interface between the blocks and the frame. A portion of the tape remains in place, trapped beneath window framing boards (typically plaster based or wooden) which provide a decorative finish in the window or door reveal area. It is not possible to tape the replacement frame in the same way, because the tape would necessarily have to be positioned over the top of the decorative structure in the reveal area.

[0009] Consequently, the only cost-effective way in which a seal can be achieved is by using a flowable sealant such as a viscous time-setting silicone material, which is applied to the block-frame interface. Decorative finishing strips are then positioned over the sealant on the framing boards. A similar sealant is also applied to the external surface of the frame, to provide a primary barrier against air and water ingress at the external perimeter of the frame. This can be challenging as the sealant is applied directly to the outer surface of the blocks, which are often rough and uneven. The block surfaces and the sealant also tend to degrade over time. Degrading of the sealant or its bond to theP50015W033 blocks, and / or incorrect application of the sealant, can therefore lead to air flow past the frame, and potentially water ingress.

[0010] Separately, it is known to employ so-called ‘cavity closers’ when constructing a building comprising internal and external wall skins. The cavity closer is locatable within the cavity so that it extends around the perimeter of a window aperture. The primary function of a cavity closer is to bridge the cavity between the internal and external wall skins (which can be comparatively large in modern buildings), and to provide a mounting surface for the window or door frame. However, it remains necessary to seal the frame to the cavity closer, which is again achieved using tape (or membrane and tape) as described above, and thus the same problems arise. In addition, whilst the cavity closer can provide a surface to which the frame may be secured, precise positioning of the frame relative to the closer - which is necessary to achieve an effective seal - can be challenging.

[0011] Similar issues can arise in connection with replacement windows and doors for other building types, such as those comprising a timber-frame structural core.

[0012] Furthermore, constructing a wall including a building aperture to receive a closure frame is a skilled job. Typically, this process includes building a wall to a first level corresponding to the bottom of the required aperture and building a temporary frame corresponding to the required aperture size. The wall may then be built up either side of the temporary frame to the top of the required aperture. Frequently, a lintel must then be secured in place over the top of the aperture (depending on the width of the aperture and the height of the wall above the aperture) and then the wall built up and over the lintel. It will be appreciated that if this process is not done accurately then the closure frames will either not fit into the aperture, or an excessive gap will be formed around closure frame which must be filled. Alternatively, often it is the case that the doors and windows may only be finally measured and ordered after a wall including suitable apertures has been completed, which can cause delays to the construction of a building.

[0013] It is an aim of certain examples of the present invention to solve, mitigate or obviate, at least partly, at least one of the problems and / or disadvantages associated with the prior art. Certain examples aim to provide at least one of the advantages described below.BRIEF SUMMARY OF THE INVENTION

[0014] The scope of the present invention is defined by the appended claims.

[0015] According to a first aspect of the present invention there is provided a mounting frame for mounting a closure within an aperture in a building, the mounting frame comprising: a main frame structure arranged, in use, to extend around a perimeter of the building aperture; and insulation on the outside of the main frame structure and extendingP50015W034 about the whole or at least part of its periphery; wherein the main frame structure is formed in two parts each terminating with an outwardly extending support flange, the insulation coupling together the support flanges and thereby coupling together the two parts of the main frame structure; and wherein the support flanges and the insulation are configured such that, in use, the insulation and the support flanges are positioned between interior and exterior wall skins of a wall surrounding the building aperture.

[0016] According to a second aspect of the present invention there is provided a construction method comprising: building a wall up to a first height except for a gap along the length of the wall and positioning a mounting frame according to any one of the preceding claims into the gap; or building a wall up to a first height, positioning a mounting frame according to any one of the preceding claims on top of the wall, and continuing to build the wall to either side of the mounting frame up to top of the mounting frame; wherein the method further comprises: continuing to build the wall over the top of the mounting frame such that the mounting frame is located in a building aperture and the mounting frame supports at least a portion of the building above the building aperture.

[0017] There is further disclosed a mounting frame for mounting a closure within an aperture in a building, the mounting frame comprising: a main frame structure arranged, in use, to extend around a perimeter of the building aperture; and insulation on the outside of the main frame structure and extending about or at least part of its periphery, the insulation being configured such that, in use, the insulation is positioned between interior and exterior wall skins of a wall surrounding the building aperture.

[0018] There is further disclosed a construction method comprising: building a wall up to a first height except for a gap along the length of the wall and positioning a mounting frame as described above into the gap; or building a wall up to a first height, positioning a mounting frame as described above on top of the wall, and continuing to build the wall to either side of the mounting frame up to top of the mounting frame; wherein the method further comprises: continuing to build the wall over the top of the mounting frame such that the mounting frame is located in a building aperture and the mounting frame supports at least a portion of the building above the building aperture.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Examples of the invention are further described hereinafter with reference to the accompanying drawings, in which:Figure 1 is a perspective view of a mounting frame for mounting a window within a window aperture in a building;P50015W035Figure 2 is a cross-sectional side view of the mounting frame shown in figure 1, drawn to a larger scale, sectioned in a direction along a depth dimension of the mounting frame, with certain features of the frame removed for ease of illustration;Figure 3 is a perspective view of a building in the form of a house, comprising windows which have been fitted in window apertures employing the mounting frame of figure 1, with a roof and some walls of the building removed, for illustration purposes;Figure 4 is a cross-sectional side view of a wall of the building shown in figure 3, drawn to a larger scale and sectioned in a vertical plane through one of the windows, showing the mounting frame and the window located in a window aperture of the wall;Figure 5 is a perspective view of a closure mounting frame according to an embodiment of the present invention;Figure 6 is a cross section of a closure mounting frame of figure 5; andFigure 7 is a flow chart for the building construction method using the closure mounting frame of figure 5..DETAILED DESCRIPTION

[0020] According to certain embodiments there is disclosed herein a mounting frame for mounting a window or a door (generically, a closure) within an aperture in a building. According to certain other embodiments, there is disclosed herein a closure mounting structure incorporating a mounting frame and a lintel. In other embodiments there is disclosed a closure mounting structure incorporating a closure frame and a lintel. In other embodiments construction methods making use of mounting frames or closure mounting structures are disclosed.

[0021] In the following description of certain embodiments, the terms “window”, “window frame” and “window aperture” are used, though the skilled person will understand that the word “door” or the word “closure” may be substituted for “window”. The term closure means that the window or door closes off an opening or aperture in the building. It will be appreciated that doors are openable and closable through a hinge or sliding mechanism, whereas windows can be openable and closable or fixed (permanently closed). Either way, the term “closure” refers to something that can close an aperture or opening either permanently or can be opened and closed.

[0022] A mounting frame may comprise: a main frame structure extending around a majority of the whole of the perimeter of a building aperture (which may be referred to as a closure aperture or a door or window aperture. In certain embodiments a mount for a closure frame of the closure, the mount extending, in use, away from the main frame structure and into the building aperture, and comprising an abutment surface adapted toP50015W036 abut a surface of the closure frame, to thereby define a mounting location for the closure frame within the building aperture.

[0023] Alternatively, the mounting frame may be termed a sealing frame for sealing a closure frame within a building aperture in a building. Similarly, the mount may be termed a sealing component comprising a sealing surface for abutting the closure frame and comprising a sealing surface for sealing the closure frame relative to the main frame structure and so the closure is sealed relative to the building. In the following description, the terms “mounting” and “sealing” and similarly the terms “mount” and “sealing component” should be considered to be interchangeable except where the context requires otherwise.

[0024] The building aperture is typically an aperture in a wall of the building. However, the mounting frame may be applied to a building aperture in other structural features of the building, such as in a roof structure of the building. The abutment surface may be adapted to abut a rear-facing surface of the closure frame.

[0025] The mounting frame may be of a polymeric material, such as plasticised polyvinylchloride (LIPVC), which is frequently used in window frame manufacture. However, other materials could be employed, including but not limited to metals, metal alloys, wood and wood composites, and other composite materials such as glass-fibre based composites.

[0026] The mounting frame may comprise an insulation material, which may cover at least part of an outer peripheral surface or inner peripheral surface of the main frame structure. The insulation material may comprise at least one insulation component, which may be of a substantially rigid material such as a polymeric foam, and the insulation component may be mounted to one or more frame part of the main frame structure.

[0027] Turning now to figure 1, there is shown a perspective view of a mounting frame 10. The mounting frame of this embodiment and further embodiments described below is suitable for use with a closure such as a door or window in an aperture formed in any surface of a building (such as a wall or roofline) though the example of a window in a window aperture is given. The term building should be broadly interpreted to cover any structure that generally defines an interior and an exterior. The interior need not be fully enclosed: it may be open on one or more sides to the exterior. The building could be of any suitable type, and could for example be for domestic, commercial, or industrial use. Suitable buildings could include houses, flats or apartments, hotels, office buildings and factories. In principle the mounting frame may be used for mounting a closure in any wall or structure, for instance a freestanding wall. However, it will be appreciated that where a wall is freestanding - that is, exposed to the elements on both sides - then the need toP50015W037 render the closure air and watertight may be less compelling. In practical terms the mounting frame is primarily intended for fully enclosed buildings where weather tightness and thermal efficiency is a key concern.

[0028] The mounting frame 10 is also shown in the cross-sectional side view of figure 2, which is drawn to a larger scale, and shown sectioned in a vertical plane, along a depth direction 64 of the mounting frame. Certain features of the mounting frame 10 are not shown in figure 2, for ease of illustration. In the perspective view of figure 3 the mounting frame 10 has been used to install windows in a building 14, which takes the form of a detached house, as shown in the perspective view of figure 3. A roof and certain walls of the building 14 have been removed, for illustration purposes. Figure 4 is also referred to, which is a cross-sectional side view of a wall 15 of the building shown in figure 3, drawn to a larger scale and sectioned in a vertical plane through one of the windows 22. The drawing shows the mounting frame 10 and the window 22 located in a window aperture 12 of the wall 15. In the illustrated embodiment, the window aperture 12 is provided in the wall 15, but it will be understood that the aperture may be provided in other structural parts of the building, including but not limited to its roof (not shown).

[0029] The mounting frame 10 generally comprises a main frame structure 16, and a mount 18 for a window frame 20 of the window 22 installed in the aperture 12. The main frame structure 16 is generally quadrilateral-shaped (square or rectangular) and comprises a top frame part 24, a bottom frame part 26, a left-side frame part 28, and a right-side frame part 30. The frame parts 24 to 30 are arranged so that the main frame structure 16 extends continuously around a perimeter of the window aperture 12, the perimeter indicated generally by numeral 32 in figure 4. The mount 18 extends generally in a direction away from the main frame structure 16 into the window aperture 12, and comprises an abutment surface 34 adapted to abut a surface 36 of the window frame 20, to define a mounting location (indicated at 38 in figure 4) for the window frame 20 within the window aperture 12. In the illustrated embodiment, the surface 36 is a rear-facing surface of the window frame 20, which facilitates an external mounting procedure of the window frame and so minimises disruption. However, the surface could be another surface of the window frame 20, suitably one which is generally in a plane of the window such as a front-facing surface.

[0030] In use, and as will be described in more detail below, the mount 18 facilitates insertion of the window frame 20 within the window aperture 12 at the correct final position for the window 22, that position being determined by factors including a depth dimension of the window frame, and a thickness of the wall 15 in which the window 22 is to be located. The wall thickness is dependent on the respective thicknesses of inner and outer wallP50015W038 skins 40 and 42 of the wall, as well as of a cavity 44 between the wall skins. Once located in the window aperture 12, the mounting frame 10 serves to restrict movement of the window frame 20 in an inward (or insertion) direction along the aperture towards an interior 46 of the building 14, and so effectively provides a fixed location for the window frame 20 (and so the window 22).

[0031] In figures 1 and 2 the mounting frame 10, particularly the main frame structure 16 is shown in a first configuration in which the main frame structure 16 terminates at a tip 200 that does not extend significantly beyond the mount 18. However, in figure 4, while the mounting frame 10 is generally similar, a portion 201 of the main frame structure 16 extends further beyond the mount 18 before terminating at tip 200. Thus, in figure 4, the portion 201 of the main frame structure 16 extends fully or substantially around the window frame 20 and to an external edge of the window frame 20 (or may be set back from the outer edge of the window frame, for instance by 10 mm and the gap sealed after installation). As illustrated in figure 4 the extended portion 201 allows the main frame structure 16 to fully span inner and outer wall skins 40, 42 and the cavity 44. Accordingly, the main frame structure 16, and indeed the mounting frame 10 as a whole, serves as a cavity closer as well as securing and sealing to the building about the window aperture and sealing to the window frame. It will be appreciated that where the main frame structure 16 is foreshortened as illustrated in figure 2 then tip 200 may abut or only slightly span onto the outer wall skin 42. The lengthened or shortened form of the main frame structure 16 may be used in combination with the remaining features of the mounting frame 10 in any of the preceding or following described embodiments. Additionally, as discussed in further detail below, the main frame structure 16 may be cut to length during installation.

[0032] An installation procedure for the window 22 involves firstly positioning the mounting frame 10 in the window aperture 12, and then securing the mounting frame to blockwork 48 of the wall 15 using mounting anchors (three shown and given the numerals 49a to 49c). The wall 15 will typically comprise cement blocks and / or bricks (not shown) forming the inner and outer wall skins 40 and 42. However, the building 14 may be of any suitable alternative construction, such as one comprising a timber frame structure defining the inner skin 40, and a blockwork (e.g. brick) structure forming the outer skin 42.

[0033] Once the mounting frame 10 has been positioned as shown in figure 4, the window frame 20 is inserted into an outer (or external) opening 50 of the aperture 12, and translated along the aperture until the rear-facing surface 36 of the window frame 20 contacts the abutment surface 34 of the mount 18. The window frame 20 is then in the mounting location 38, and can be secured to the wall 15 using mechanical fixings such as threaded anchors (not shown) which pass through the window frame, optionally throughP50015W039 the extended portion 201 of the main frame structure 16 if present at the anchor location, and into blockwork of the outer wall skin 42. The window frame 20 is then in the correct, installation position, and a glazed unit or units (not shown) of the window 22 can be positioned within the window frame to complete the window. Of course, if desired the window frame 20 may be inserted with the glazed unit(s) already positioned, although that would increase its weight and make handling more challenging.

[0034] The mount 18, and in particular its abutment surface 34, acts to restrict further translation of the window frame 20 along the aperture 12 in a direction away from the outer opening 50. An operator installing the window frame 20 is therefore provided with a positive indication that the window frame is in the correct position when its rear-facing surface comes 36 into contact with the abutment surface 34 of the mount 18.

[0035] The window frame 20 can also be sealed relative to the mount 18 using a seal 52 (shown in figure 2 but not figure 4), which takes the form of a sealing strip of an elastomeric or rubber material applied to a core structure 54 of the mount, which takes the form of an elongate wall. The seal 52 defines at least part of the abutment surface 34 of the mount, and in the illustrated embodiment defines the entire abutment surface. In a variation, a sealing material such as a flowable time-setting silicone may be applied to the core structure 54 of the mount 18 and / or to the window frame 22, prior to bringing the frame and the mount into abutment. A further variation may employ a combination of a sealing strip and a flowable sealing material.

[0036] Arranging the abutment surface 34 of the mount 18 so that it abuts the rear-facing surface 36 of the window frame 20 may enable a compressive loading to be applied to the seal 52. This may be achieved by imparting a load on the window frame 20 during installation, causing the seal 52 to be compressed, and then anchoring the window frame to the outer wall skin 42 so that the compressive load is maintained. This may provide a much-improved seal bond in comparison to prior window systems, including those employing a cavity closer.

[0037] The mounting frame 10 can also be used in a building renovation procedure involving the removal of an existing window located in a window aperture, and the mounting of a replacement window in the aperture. For illustration purposes only, reference is made to a window 22a located in an aperture 12a in the building 14, which is to be replaced. A window frame 20a of the existing window 22a is firstly removed from the window aperture 12a. This may require that any external and / or internal sealant be removed or cut away, and that any mounting tape used to seal the window frame to the building (or tape and membrane if used) be severed. The mounting frame 10 can then be positioned in the window aperture 12, and the replacement window frame 20 inserted intoP50015W0310 the aperture and positioned in contact with the abutment surface 34 of the mount 18, following the procedure described above. In a similar fashion therefore, an installer is provided with a positive indication that the replacement frame 20 has been located in the correct position, when the rear-facing surface 36 of the replacement frame abuts the surface 34 of the mount 18.

[0038] As can be seen from the above, the mounting frame provides both an improved method of installing a window in a building, and an improved method of renovating a building by replacing a window, if for example a structure or visual appearance of the window degrades over time (such as due to UV light exposure).

[0039] Further structural details of the mounting frame 10 and associated methods will now be described.

[0040] The main frame structure 16 of the mounting frame 10 extends around the entire perimeter 32 of the window aperture. The main frame structure 16 therefore provides a secure mounting for the window frame 20 around its entire perimeter 32, and optionally also provides for sealing of the window frame around its entire perimeter by means of the seal 52.

[0041] The frame parts 24 to 30 forming the main frame structure 16 are provided as separate components which are coupled together to form the frame. This is typically achieved by cutting lengths of frame material to the sizes required to form the frame parts 24 to 30, and coupling the frame parts together. In a variation however, frame parts of appropriate lengths may be selected from a kit of parts having different lengths. As will be understood by the skilled person, suitable materials for the frame parts include extruded polymers such as un-plasticised polyvinylchloride (LIPVC), which can easily be bonded or thermally welded together to form the frame structure 16. However, other materials including wood, metals / metal alloys and composite materials could be used. A mounting frame 10 of a desired shape and / or dimensions to suit the window aperture 12 can be easily formed by selecting frame parts of appropriate dimensions, and / or by cutting the frame parts to the required lengths.

[0042] In one embodiment the frame parts may be cut to size and bonded in a factory environment. In another embodiment a method of installing a window may comprise cutting frame parts from a continuous length of material, inserting the cut frame parts into a window aperture and bonding or thermally welding the cut frame parts together. The cut parts may comprise the main frame structure being integrally formed with one or more of the mount and the mounting flange. However, alternatively these may be separately cut parts that are also bonded or thermally welded together. The frame parts may be cut fromP50015W0311 a continuous length of extruded polymer mounting frame material. Thus, a more flexible site-build method for constructing a mounting frame for a window frame is enabled.

[0043] In the illustrated embodiment of figures 1, 2 and 4, the mount 18 is formed integrally with the main frame structure 16, for example in a manufacturing process for the frame material which is used to assemble the frame parts 24 to 30. The mount 18 and the main frame structure 16 are therefore of a unitary or one-piece construction. This can easily be achieved in the case of an extruded polymeric frame material.

[0044] The main frame structure 16 comprises an inner peripheral surface 56 which, in use, faces inwardly towards the window aperture 12. The inner peripheral surface 56 is defined by respective inner surfaces 24i to 30i of the frame parts 24 to 30 forming the main frame structure 16. The inner peripheral surface 56 opens on to the aperture 12, and the inner frame part surfaces 24i to 30i are substantially planar. The inner peripheral surface 56, or at least part of the inner peripheral surface, receives decorative finishing panels, two being shown in figure 4 in the form of a side panel 58 and a windowsill 60. These are secured to the mounting frame 10 following positioning of the window frame 20 at its mounting location 38. As is well-known, the finishing panels can be decorative, and / or can provide a surface to which a decorative coating (such as a cementitious plaster material) can be applied. The mounting frame 10 is effectively permanently secured to the building 14, in that it is at least partly hidden behind the decorative finishing panels 58 and 60 and / or any cementitious coating. The fixings 49a to 49c are similarly hidden. As will be understood, the mounting frame 10 can remain secured to the building 14 during a subsequent window replacement procedure, involving the location of a replacement window frame in the window aperture. As such a window replacement procedure comprises removing the original window frame and inserting the replacement window frame from the exterior of the building (that is, from the side opposite to the finishing panels) the finishing panels may remain undisturbed during the window replacement procedure.

[0045] As can clearly be seen in the drawings, the mount 18 extends out of or away from the inner peripheral surface 56 of the main frame structure 16, laterally into the window aperture 12. Each part of the mount 18 defined by the frame parts 24 to 30 extends generally out of the planes defined by the frame part surfaces 24i to 30i, and so are upstanding from the surfaces. The main frame structure 16 also comprises an outer peripheral surface 62 which, in use, faces away from the window aperture 12 towards the building structure surrounding and defining the window aperture (in this case the wall 15 structure). The outer peripheral surface 62 is defined by respective outer surfaces 24o to 30o of the frame parts 24 to 30 forming the main frame structure 16.P50015W0312

[0046] As best shown in figure 2, the abutment surface 34 of the mount 18 extends in a direction which is substantially perpendicular to the main frame structure 16. This provides an effective abutment for the window frame 20, and so secure positioning of the window frame in the aperture 12. It can also facilitate sealing of the window frame 20 to the mounting frame 10, by providing a location for the seal 52, which is compressed between the window frame and the core structure 54 of the mount as described above. The abutment surface 34 extends, in use, in a direction which is substantially perpendicular to a main axis 64 of the aperture 12, the axis extending along the aperture from the outer opening 50 to an internal opening 66. This axis 64 may be referred to as a window aperture depth axis. It will be understood here that the rear-facing surface 36 of the window frame 20 faces Inwardly, towards the interior 46 of the building 14. The abutment surface 34 (also referred to as a sealing surface 34) thus faces outwardly, towards the exterior of the building 14.

[0047] The seal 52 acts as a frame seal, for sealing the window frame 20 relative to the main frame structure 16. The frame seal 52 is typically bonded to the core structure 54 of the mount 18 using a suitable adhesive. However, the frame seal 52 may be provided integrally with the mount 18, or may be formed by the mount, for example in an overmoulding procedure, particularly where the mount is of a polymeric material.

[0048] The mounting frame 10 also comprises a building seal which abuts a surface of the building 14 such as its wall 15, for sealing the mounting frame relative to the building surface, and so the window frame 20 relative to the building surface once the window frame is positioned in the aperture 12. A number of such building seals are typically provided in order to ensure a good sealing effect, three such seals shown in figure 4 and indicated by numerals 68, 70 and 72. These seals are mounted on the main frame structure 16, and are typically elastomeric or rubber sealing strips that are bonded to the main frame structure using a suitable adhesive. Again however, the building seals 68 to 72 may be provided integrally with the main frame structure 16 or may be formed by the frame structure. For example, the seals 68 to 72 may be over-moulded on the main frame structure 16, particularly where it is of a polymeric material. Other options for one or more of the building seals exist, including beads of time-setting sealant material applied to the main frame structure, and / or to the building, prior to positioning of the mounting frame 10 in the window aperture 12. Suitable options for the sealant material include viscous silicone-based sealants.

[0049] The mounting frame 10 also comprises a mounting component 74 for locating the mounting frame on the building 14, such as on its wall 15. The mounting component 74 takes the form of a mounting flange which is provided integrally with the main frameP50015W0313 structure 16, and which extends around its perimeter. In use, the mounting component 74 abuts an inner wall surface 76 of the wall 15, as shown in figure 4. The mounting frame 10, comprising the mounting component 74, overlaps an internal edge 78 of the wall 15 defined by the inner wall skin 40, at an intersection between the vertical inner wall surface 76 and a generally perpendicular surface 79 in a window reveal area 80. The mounting frame 10 passes over the edge 78 so that the mounting component 74 is disposed on the inner surface 76 of the wall.

[0050] As discussed above, the mount 18 defines a first sealing surface for sealing to the window frame. The mounting flange 74 defines a second sealing surface for sealing to the wall about the window aperture. The sealing may use seals already attached to one or both of the sealing surfaces or a sealant may be applied during installation. It will be apparent from inspection of the figures that the sealing surfaces face in the same direction. In particular, where the mounting frame is inserted from the inside of a building and the window aperture is inserted from the outside of the building, both sealing surfaces face to the exterior of the building. However, they are offset along the window depth axis.

[0051] The mounting frame 10, in particular its main frame structure 16, is generally L- shaped in cross-section, taken along the window aperture depth axis 64 (that is, in the depth direction of the frame), from front to back. The main frame structure 16 comprises a window reveal component 82 which resides within the window aperture 12 (in the reveal area 80), and the mounting component 74. Part of the L-shape is defined by the window reveal component 82 (forming part of the main frame structure 16) and part by the mounting component 74.

[0052] The mounting frame 10 may also comprises an insulation material, indicated generally by numeral 84, which covers part of the outer peripheral surface 62 of the main frame structure 16 (and optionally the entire surface or a substantial part of it). The insulation material 84 comprises a number of separate insulation components 86a to 86c, which are arranged around the outer perimeter of the main frame structure 16. Alternatively, the insulation material 84 may be integrally formed, for instance by an overmoulding process. The insulation components 86a to 86c are of a substantially rigid material such as a polymeric foam, and are mounted to frame parts 24 to 30 of the main frame structure 16. In the illustrated embodiment, the top frame part 24 is free from insulation material. It may not be necessary to provide insulation over the top frame part 24 as a lintel 88 forming part of the wall 15 (which in part defines the aperture 12) typically incorporates insulation material. Insulation material is also typically provided in the cavity 44, as indicated at 90, 92 and 94 in figure 4. Although not illustrated, in some embodiments, insulation may be provided on internal or external portions of the mainP50015W0314 frame structure about all or part of its periphery. Where insulation is provided on part or all of the internal periphery of the main frame structure, finishing panels such as panels 58 and 60 described above may be provided over the insulation.

[0053] In a further alternative the insulation 84 may comprise an air gap formed by a pocket within the main frame structure 16 (that is, an integrally formed part of the main frame structure 16) such as through a continuous extrusion process. This is illustrated in figures 2 and 4, whereas certain other figures show the insulation being separately formed or applied to the main frame structure 16. The air gap insulation 84 may be applied about part or the whole of the periphery of the main frame structure 16 and may extend over part or the whole of the depth of the main frame. The air gap or other form of insulation 84 forms a thermal break about the mounting frame to prevent thermal bridging through the mounting frame from the exterior to the interior of the building. Portions of the mounting frame may be formed from a polymeric material, which is itself insulative. The addition of air gaps or insulation such as an expanded foam applied to interior or exterior portions of the mounting frame increase the insulation of the mounting frame.

[0054] The mount 18 is typically formed integrally with the main frame structure 16, as described above. The illustrated mount 18 comprises a plurality of generally elongate protrusions in the form of lips or ribs 96 which together form the mount. Each frame part 24 to 30 comprises a respective such protrusion, and so the mount 18 comprises a top protrusion 96a, a bottom protrusion 96b, a left-side protrusion 96c and a right-side protrusion 96d. The elongate protrusions 92 each extend in a direction along a main length of the respective frame part 24, 26, 28 or 30 and the mount extends continuously (or substantially continuously) in a direction around the perimeter of the main frame structure 16.

[0055] The frame seal 52 and the building seals 68 to 72 together provide a primary barrier against cold air and moisture ingress along the window aperture 12 past the window frame 20, and warm air egress from the building interior 46. However, following positioning of the window frame 22 in the aperture 12 and securing of the frame, external seal beads 95 and 97 may be applied. These may provide a secondary barrier and / or a decorative finish. As is described below, the mounting frame provides multiple sealing surfaces (principally on the abutment or sealing surface of the mount and on the mounting flange) but also on other portions of the main frame structure that serve to seal about the mounting frame to prevent the ingress of rainwater or to prevent water ingress through capillary action.

[0056] Figure 4 shows an example installation in which the mounting frame 10 is installed in a window aperture 12 formed in a wall 15 having interior and exterior wall skinsP50015W031540 42 formed from brick or blockwork and a cavity 44 therebetween. However, embodiments of the mounting frame are not limited to this. For instance, in an alternative, not illustrated, the wall 15 may be constructed using Structural Insulated Panels (SIPs). A SIP comprises an insulating foam core sandwiched between two structural facings. The facings may be wooden, for instance Oriented Strand Board (OSB). Commonly a SIP panel wall is covered with a waterproof and / or airtight membrane which may be preapplied or applied on-site. Accordingly, a window aperture may be formed in a SIP wall and a mounting frame as described above inserted into the aperture and secured on the inside of the building with the mounting frame flange attaching to the surrounding wall surface. It may be secured in place and sealed as described above. Then the SIP membrane may be secured to the outer periphery of the mounting frame for instance by being glued to the outer side of the main frame structure. This process may be aided by cutting the membrane such that it extends into the window aperture allowing it to be splayed outwards onto the mounting frame and glued. Cladding material may then be applied over the SIP wall about the window aperture. The main frame structure may be dimensioned so that it extends partially or fully through the cladding (and may help support or locate the cladding). The window may then be offered up to and secured to the mounting frame.

[0057] The mount of the mounting frame may be provided separately from its main frame structure and may be coupled to the main frame structure for instance by bonding with an adhesive or coupling with a mechanical fixing. For instance, the main frame structure may comprise a corresponding coupling feature in the form of a channel or slot to receive the mount in a push or sliding-fit or an interference fit. A plurality of coupling features may be provided spaced apart along the length of the main frame structure so that the mount can be coupled at varying locations. Multiple different mounts may be provided having different sizes or shapes to accommodate different closure frames.

[0058] The mounting frames described above have been presented in the context of a mounting frame serving for mounting a window within a window aperture in a wall of a building. As will be understood from the foregoing description however, the mounting frame as described also provides for sealing of a window frame within such a window aperture. The description therefore applies equally to a sealing frame for sealing a window frame within such an aperture. In addition, whilst aspects of mounting and sealing frames are described, more generally this may be considered to be a frame for mounting a window within a window aperture in a building and for sealing the window. A two-piece window assembly may comprise a window frame of the type shown in the drawings, and aP50015W0316 mounting frame, sealing frame, or mounting and sealing frame of the type described above.

[0059] In a further variation, a mounting frame may be provided which comprises a plurality of different mounts. A kit comprising two or more different mounts may be provided. At least one parameter of a first mount of the kit may differ from the corresponding parameter of a further one or more mount of the kit. A selected parameter may be a height of the mounts, which may determine the extent to which the mounts extend from the main frame structure into the window aperture. A selected parameter may be an angle of the abutment surface defined by the mount, considered relative to the main frame structure and / or to a main axis of the window aperture. A selected parameter may be a profile of the mount e.g. in cross-section.

[0060] The main frame structures of the embodiments shown in the drawings are generally quadrilateral in shape, but could be other shapes including generally circular, oval, oblong, and triangular, the shape defined by the window aperture. It will be understood that main frame structures having such different shapes may not necessarily have the top, bottom, left-side and right-side frame parts shown in the drawings. However, the principles of the mounting frame described above apply equally to such structures in terms of the way in which the mount / sealing component extends from the main frame structure to abut / seal against a window frame surface.

[0061] In some embodiments, reference is made to an abutment surface or a sealing surface which is adapted to abut a rear-facing surface of a window frame. It will be understood however that the abutment may be with a surface other than the rear-facing surface of the window frame, and may for example be with a front or outward-facing surface. Abutment with a rear-facing surface may however be preferred as this enables external fitting of the window frame, which may reduce disruption to internal building structures, particularly during window replacement.

[0062] Reference is made in this document to features as being in ‘top’, ‘bottom’, ‘left’ or ‘left-side’ and ‘right’ or ‘right-side’ orientations, with particular reference to frame parts of the main frame structure. It will be understood that these apply generally to a typical location of a window in a wall of a building, in a generally vertical plane, or optionally in a plane which is angled relative to the vertical (e.g. inclined, or potentially horizontal in the case of a window installed in a flat-roof type structure). References to such features should not therefore be taken to imply a particular orientation of the window during use, and so are not to be taken as limiting on disclosed embodiments of the invention.

[0063] The embodiments presented above are directed to mounting frames that are primarily used with an existing building aperture. For instance, when a building is initiallyP50015W0317 constructed, a building aperture may be formed through a conventional construction technique and the mounting frame inserted into the building aperture and secured to the fabric of the building. Alternatively, when a building is renovated, a conventional closure frame may be removed to leave an open building aperture into which the mounting frame may be inserted. A closure frame, such as a window frame, may be inserted into the mounting frame, and as discussed above this provides significant improvements over the state of the art in terms of the ability to seal the closure frame to the building. However, the construction of the building aperture is not affected by the choice to use a mounting frame according to the preceding embodiments: up to the point of inserting the mounting frame in place of directly inserting a closure frame into the building aperture, the construction process may be wholly conventional.

[0064] As noted in the background section of the present specification, conventionally a building aperture is formed in a structure (typically a wall) of a building by building a wall up to a first level, forming a temporary frame defining the size of the aperture, building the wall up to either side of the temporary frame, installing a structural lintel over the top of the temporary frame, and building the wall over the top of the lintel. The lintel serves to support the weight of the wall over the top of the building aperture. In some limited cases a lintel may not be required for a sufficiently narrow building aperture and / or where there is limited weight of building over the top of the building aperture.

[0065] The temporary frame must then be removed from the building aperture before a closure frame such as a window frame can be inserted to close the aperture (or indeed before a mounting frame as described above can be inserted into the aperture). The construction of the temporary frame requires considerable skill and judgement from the builder to ensure that the resulting building aperture has the exact size to receive the closure frame. Alternatively, the final measurement and ordering of the closure frame from a supplier may not take place until after the building aperture is complete to ensure a close fit, which may delay the construction of the building and leave it partially open to the weather until the building aperture is finally closed off with a window or door. Furthermore, the construction of the temporary frame may itself be time consuming and wasteful of materials. Additionally, the separate installation step of fitting the lintel over the building aperture is a skilled process that can be time consuming.

[0066] The present inventors have identified that a mounting frame may provide distinct advantages during the construction of a building. As will be described below, the mounting frame may be used during the construction of the building aperture in place of any need for a temporary frame. That is, the mounting frame itself directly defines the dimensions of the building aperture and the installation of the mounting frame is combined with theP50015W0318 construction of the wall around the building aperture (the wall being formed around the mounting frame). Advantageously, this means that the exact dimensions of the closure such as a window and window frame are known in advance (at least at the time that the mounting frame is sourced) and the required closure may be ordered at that time (or be provided as a kit of parts combined with the mounting frame). This can significantly speed up the construction process, particularly by removing the time taken to construct a temporary frame for the building aperture, as well as reducing material waste. Additionally, the building may be made watertight much sooner as the closure, for instance a window, may be installed in the mounting frame as soon as the mounting frame is built into the building structure (or even before the building aperture is complete if required).

[0067] This construction method is substantially the same regardless of whether the wall is constructed from brick or block work, modular panels such as SIP panels, 3D printing such as a wall built up in layers from concrete deposited by a moveable nozzle or any other known construction technique. Furthermore, the construction method is substantially the same regardless of whether the wall is constructed with a cavity, as a solid wall, or any other known wall type.

[0068] Turning now to figures 5 and 6, these illustrate in a perspective view and a vertical cross section view respectively a further embodiment of a mounting frame 2800 for mounting a closure within an aperture in a building. The mounting frame 2800 is intended for use in a construction method as described below in connection with figure 7.

[0069] Mounting frame 2800 comprises a main frame structure 2801 arranged, in use, to extend around a perimeter of the building aperture. Main frame structure 2801 is formed in two parts, 2801a and 2801b, which may suitably be formed from a metal or a rigid plastics material suitable for resisting lateral forces from the wall to either side of the mounting frame 2800 and to resist the weight of the building overlying the mounting frame 2800. Each main frame structure part 2801a, 2801b includes an outwards facing planar surface 2802a, 2802b intended to bear against an interior wall skin and an exterior wall skin respectively on each side of the mounting frame 2800.

[0070] Each main frame structure part 2801a, 2801b further includes an outwards extending flange 2803a, 2803b which face one another and are separated by (and attached to) an insulation layer 2804. Insulation 2804 serves to thermally separate the main frame structure parts 2801a, 2801b and as such the mounting frame 2800 may be referred to as a thermally broken mounting frame. However, in other examples the mounting frame 2800 may not be thermally broken, and the main frame structure 2800 may be continuous across the whole depth of the mounting frame 2800. The combination of the outwards extending flanges 2803a, 2803b and insulation 2804 is intended to beP50015W0319 inserted into a wall cavity formed between interior and exterior wall skins on all four sides of the mounting frame during construction of the building aperture about the mounting frame. In some embodiments the combination of the outwards extending flanges 2803a, 2803b and insulation 2804 may not extend fully around all four sides of the main frame structure 2801. For instance, it may be missing from an upper side allowing the use of a conventional lintel or coupling means may be provided for attaching a lintel with corresponding coupling means to the upper side of mounting frame 2800. Insulation 2804 may be any suitable insulation material known in the construction industry. In some cases the insulation may be a porous or vapour permeable material. In order to ensure that the mounting frame is air tight (preventing movement of air from the wall cavity into the building aperture) in some embodiments an airtight seal, for instance a membrane or tape, may be applied to the outside or inside of insulation 2804.

[0071] As for previously described embodiments, mounting frame 2800 further comprises a mount 2805 extending, in use, away from the main frame structure 2801 (particularly main frame structure 2801b in the illustrated embodiment of figures 5 and 6) and into the building aperture to define a mounting location for a closure frame of the closure later to be inserted into mounting frame 2800. The mount 2805 may be configured to be sealed to a closure frame mounted within the mounting frame 2800. The mount 2805 may be integrally formed with the main frame structure 2801 , or the mount 2805 may be provided as one or more separate components and configured to be secured to the main frame structure 2801 through a corresponding coupling feature, using a fixing device or with an adhesive.

[0072] The mounting frame 2800 further comprises a mounting flange 2806 adapted to abut an interior building surface for locating the mounting frame in the building aperture. However, given that the mounting frame 2800 is positively engaged with the wall by virtue of the insulation 2804 extending into the wall cavity, mounting flange 2806 may be omitted.

[0073] The mounting flange 2806 if provided may define a sealing surface for sealing the mounting frame 2800 to the building about part or the whole of the periphery of the building aperture.

[0074] A two-piece closure assembly comprises a mounting frame 2800 as illustrated in figures 5 and 6 and a closure frame configured to be mounted within the mounting frame 2800.

[0075] Turning now to figure 7, a construction method according to an embodiment of the present invention will now be described using the mounting frame 2800 of figures 5 and 6.P50015W0320

[0076] At step 2701 of the flowchart of figure 7, a wall is built up to a first height corresponding to the bottom edge of a desired building aperture. The wall may be a brick and blockwork cavity wall comprising a blockwork interior wall skin and a brickwork exterior wall skin separated by a cavity filled with insulation. However, this is only one example, and the present construction technique is applicable to any type of wall construction.

[0077] At step 2702 a mounting frame 2800 is positioned on top of the wall 2200. The mounting frame 2800 defines the dimensions of the eventual building aperture, particularly through the shape and configuration of the main frame structure 2801. Mounting flange 2806 is positioned overlapping the interior wall skin at the bottom edge of the mounting frame 2800.

[0078] At step 2703 the wall is built up either side of the mounting frame 2800 up to its upper edge. The side portions of the main frame structure 2801 provide a guide for the construction crew building the wall, for instance ensuring correct alignment of the bricks or blocks along the sides of the building aperture. Similarly, the mounting flange 2806 defines the interior plane of the interior wall skin. Where the wall is constructed using 3D printing, the main frame structure 2801 provides a surface for the deposited material to butt up against. It will be appreciated that so long as the mounting frame is formed from a suitable material and thickness of material to withstand lateral loading from the wall as it is constructed to either side then the mounting frame or closure frame will preserve the precise desired dimensions of the building aperture without risk of deformation.

[0079] At step 2704 the wall is built over the top of the mounting frame 2800 such that the mounting frame is located within and defines a building aperture.

[0080] The method may further comprise securing the mounting frame or the closure frame to the surrounding wall (beneath and to either side of the frame) with fixings extending through the frame and into the wall structure (for instance blockwork and / or brickwork), as previously described in connection with embodiments of a mounting frame.

[0081] The method may further comprise inserting a closure frame into an opening of the building aperture and securing the closure frame to the building at the mounting location.

[0082] The method may further comprise suitable conventional construction techniques well-known to the skilled person, for instance the provision of a damp proof course over the top of the lintel and keyed into the interior wall skin.

[0083] In a variant to the construction method, the method may instead comprise building the wall up to a first height except for a gap along the length of the wall corresponding to the dimensions of the mounting frame and then inserting the mounting frame or closure frame.P50015W0321

[0084] Throughout this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other components, integers, or steps. Throughout this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise. Throughout this specification, the term “about” is used to provide flexibility to a range endpoint by providing that a given value may be “a little above” or “a little below” the endpoint. The degree of flexibility of this term can be dictated by the particular variable and can be determined based on experience and the associated description herein.

[0085] Features, integers, or characteristics described in conjunction with a particular aspect or example of the invention are to be understood to be applicable to any other aspect or example described herein unless incompatible therewith. All of the features disclosed in this specification, and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive. The invention is not restricted to the details of any foregoing examples. The invention extends to any novel feature or combination of features disclosed in this specification. It will also be appreciated that, throughout this specification, language in the general form of “X for Y” (where Y is some action, activity or step and X is some means for carrying out that action, activity, or step) encompasses means X adapted or arranged specifically, but not exclusively, to do Y.

[0086] Each feature disclosed in this specification may be replaced by alternative features serving the same, equivalent, or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

[0087] The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

Claims

P50015W0322CLAIMS:

1. A mounting frame for mounting a closure within an aperture in a building, the mounting frame comprising: a main frame structure arranged, in use, to extend around a perimeter of the building aperture; and insulation on the outside of the main frame structure and extending about the whole or at least part of its periphery; wherein the main frame structure is formed in two parts each terminating with an outwardly extending support flange, the insulation coupling together the support flanges and thereby coupling together the two parts of the main frame structure; and wherein the support flanges and the insulation are configured such that, in use, the insulation and the support flanges are positioned between interior and exterior wall skins of a wall surrounding the building aperture.

2. A mounting frame according to claim 1, wherein the mounting frame further comprises a mount extending, in use, away from the main frame structure and into the building aperture to define a mounting location for the closure frame of the closure.

3. A mounting frame according to claim 2, wherein the mount is configured to be sealed to a closure frame mounted within the mounting frame.

4. A mounting frame according to claim 2 or claim 3, wherein the mount is integrally formed with the main frame structure, or the mount is provided as one or more separate components and configured to be secured to the main frame structure through a corresponding coupling feature, using a fixing device or with an adhesive.

5. A mounting frame according to any one of the preceding claims, wherein the mounting frame further comprises a mounting flange adapted to abut a building surface for locating the mounting frame in the building aperture.

6. A mounting frame according to claim 5, wherein the mounting flange defines a sealing surface for sealing the mounting frame to the building about part or the whole of the periphery of the building aperture.

7. A two-piece closure assembly comprising: a mounting frame according to any one of the preceding claims; andP50015W0323 a closure frame configured to be mounted within the mounting frame.

8. A construction method comprising: building a wall up to a first height except for a gap along the length of the wall and positioning a mounting frame according to any one of the preceding claims into the gap; or building a wall up to a first height, positioning a mounting frame according to any one of the preceding claims on top of the wall, and continuing to build the wall to either side of the mounting frame up to top of the mounting frame; wherein the method further comprises: continuing to build the wall over the top of the mounting frame such that the mounting frame is located in a building aperture and the mounting frame supports at least a portion of the building above the building aperture.

9. A construction method according to claim 8, wherein the mounting frame further comprises a mount extending, in use, away from the main frame structure and into the building aperture to define a mounting location for the closure frame of the closure.

10. A construction method according to claim 9, wherein the mount is integrally formed with the main frame structure, or the mount is provided as a separate component and the method further comprises securing the mount to the main frame structure through a corresponding coupling feature, using a fixing device or with an adhesive.

11. A construction method according to any one of claims 8 to 10, wherein the method further comprises: inserting a closure frame into an opening of the building aperture; translating the closure frame along the depth axis of the building aperture in a direction away from the opening to a mounting location defined by the mount; and securing the closure frame to the building at the mounting location.

12. A construction method according to any one of claims 8 to 11 , wherein building a wall comprises: building a wall using bricks, blocks, wood, or preformed panels; or 3D printing a wall by depositing layers of a construction material.

13. A construction method according to any one of claims 8 to 12, wherein building a wall comprises:P50015W0324 building a solid wall, at least part of the depth of the solid wall being supported by the lintel above the building aperture; or building a wall incorporating an inner wall skin and an outer wall skin separated by a cavity, at least part of the inner wall skin or the outer wall skin being supported by the lintel above the building aperture.

14. A construction method according to any one of claims 8 to 13, further comprising sealing at least a portion of the mounting frame or the closure frame about its periphery to the wall surrounding the building aperture.

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