A corner protector

Abstract

A corner protector 10 suitable for protecting a corner of a window or door unit which have first and second edge faces extending substantially orthogonally to one another. The corner protector has fir

Description

Field of the Invention The present invention relates to a corner protector for protecting a corner of a window or door unit. The invention also relates to window or door units with corner protectors mounted thereto and methods for mounting corner protectors to window or door units. Background to the Invention In recent years, windows and doors frames have progressed from the use of wood to plastic materials such as PVC-U. Plastic window / doors typically have an outer frame for mounting within a wall and an inner frame for mounting within the outer frame, the inner frame having a glazing unit mounted therein. The inner frame and glazing unit combination is typically referred to as a sash or leaf. The sash is moveable relative to the outer frame to open / close the sash. The outer and inner frames are formed from profile sections made of extruded plastic, with a pair of profiles joined together at each corner of a frame, typically by welding end portions of a horizontal and a vertical profile section. The corners of a frame are particularly vulnerable to damage during subsequent manufacturing steps and also during storage and / or transportation to a customer. It is known to fit a corner protector to the frame as part of the manufacturing process, the corner protector being designed to cover the corner and to protect the corner of the frame from damage during manufacture, storage and transit. Existing corner protectors are known which comprise a substantially rigid structure having a first wall and a second wall substantially perpendicular to the first wall. Such corner protectors are secured to the frame using screws to prevent the corner protectors from being ripped off, for example by the frictional forces in action if the frame is dragged across rough ground. Summary of the Invention According to a first aspect of the invention there is provided a corner protector for protecting a corner of a window or door unit, the corner of the window or door unit having first and second edge faces extending substantially orthogonally to one another, the corner protector comprising a first body portion for mounting to a first edge face and a second body portion for mounting to a second edge face, the first and second body portions being connected by a living hinge, the first body portion being configured for a snap-fit with the first edge face and the second body portion being configured for a snap-fit with the second edge face. The corner protector preferably has two body portions, namely the first and second body portions, connected by a living hinge, the first body portion covering an end of a first edge face and the second body portion covering an end of a second edge face of the window or door unit when installed. The corner protector is held in place on the window / door unit once installed by means of the snap-fit engagement. The living hinge allows the corner protector to easily be attached to the window / door unit and also aids in storing and transporting corner protectors in bulk, as they can be stored flat. Each body portion preferably comprises at least one snap-fit element thereon that cooperates with a complementary snap-fit element on the corresponding edge face. As the corner protector attaches to the window / door unit via a snap-fit engagement, no screws are needed unlike for existing corner protectors, which makes the corner protector easier to install and also easier to remove. Preferably the first and second body portions each comprise at least one projection thereon that is configured for cooperating with a complementary projection on the corresponding edge face via a snap-fit. Preferably each projection is a barbed projection for cooperating with a barbed edge face projection on the corresponding edge face via a snap-fit. Preferably the first and second body portions each comprise first and second projections thereon, each projection being configured for cooperating with a corresponding barbed edge face projection on the corresponding edge face via a snap-fit. Said first and second projections are preferably arranged, one on each side of said body portion. Preferably each projection comprises an elongate shaped projection, having a longitudinal axis parallel with the elongate axis of the corresponding edge face when mounted thereto. Preferably the first and second body portions each comprise at least one stud projecting therefrom, each stud being configured for receipt within a recess in the corresponding edge face. The at least one stud on each body portion prevents the corner protector from becoming detached from the window / door unit if strong lateral forces are applied which could otherwise overcome the snap-fit engagement. Preferably each stud has a round cross-section. Preferably each stud has a distal end, said distal end of each stud being rounded. Preferably the living hinge has a longitudinal axis, the first and second body portions each comprising first and second sides extending substantially orthogonally to a longitudinal axis of the living hinge, said stud projecting from the first body portion being located substantially midway between the first and second sides of the first body portion and said stud projecting from the second body portion being located substantially midway between the first and second sides of the second body portion. Preferably the first and second body portions each comprise an outer side for facing away from the window or door unit and an inner side for facing towards the window or door unit when mounted thereto, the inner side of each of the first and second body portions comprising a raised platform projecting therefrom, said stud projecting from the first body portion projecting from the raised platform thereon and said stud projecting from the second body portion projecting from the raised platform thereon. In preferred embodiments each body portion has a finger access recess at the distal end of said platform. A user can place their finger(s) in the finger access recess to assist with removal of the corner protector from the window or door unit. Preferably the first and second body portions each comprise an outer side for facing away from the window or door unit and an inner side for facing towards the window or door unit when mounted thereto, the first and second body portions each further comprising at least one ridge on the outer side. The at least one ridge on each of the first and second body portions provides strength to the corner protector Preferably the corner protector is made of a polymeric material. Preferably the corner protector is made by injection moulding. According to a further aspect of the invention, there is provided a window or door unit having a first corner, the window or door unit further comprising a corner protector according to any aspect described herein mounted to said corner. Said corner has a corresponding recess formed in said corner to receive each stud of the corner protector According to a further aspect of the invention, there is provided a method of mounting a corner protector to a corner of a window or door unit, the method comprising providing a corner protector according to any aspect described herein, snap fitting the first body portion to the first edge face and snap fitting the second body portion to the second edge face. According to a further aspect of the invention, there is provided a method of mounting a corner protector to a corner of a window or door unit, the method comprising providing a corner protector according to any aspect described herein, inserting each stud in a corresponding recess formed in the window or door unit, snap fitting the first body portion to the first edge face and snap fitting the second body portion to the second edge face. If corresponding recesses, each to receive a stud therein, are not already pre-formed in the window or door unit, the method may additionally include forming said recesses in the window or door unit. In the context of the present invention, the term “mounting” means connecting or joining, either directly or by means of an intermediate or auxiliary element. It is to be understood that the mere use of the term “first” does not require that there be any “second,” and the mere use of the term “second” does not require that there be any “third,” etc. The term “rectangular” or “rectangle” as used herein includes a regular rectangle (i.e. a square). Brief Description of the Drawings Embodiments of the invention will now be described by way of example only, with reference to the accompanying drawings, in which: Figure 1 shows a left side view of a corner protector according to an embodiment of the present invention, the first and second body portions being folded relative to the hinge such that they are substantially orthogonal to one another; Figure 2 shows a top view shows a right side view of the corner protector of Figure 1; Figure 3 shows a right side view of the corner protector of Figure 1; Figure 4 shows a front view of the corner protector of Figure 1; Figure 5 shows a front view of a corner protector that has been flattened e.g. for storage; Figure 6 shows a side view of the corner protector of Figure 5; Figure 7 shows a perspective view of the corner protector of Figure 1; a perspective view of the corner protector of Figure 1; Figure 9 shows a close-up view of part B identified in Figure 14, showing a close-up of a snap-fit element on the first body portion; Figure 10 shows a front view of a corner protector like that of Figure 1; Figure 11 shows a perspective view of the corner protector of Figure 1; Figure 12 shows another perspective view of the corner protector of Figure 1; Figure 13 shows a right side view of the corner protector of Figure 1; Figure 14 shows a front view of the corner protector of Figure 1; Figure 15 shows a cross-sectional view through the corner protector of Figure 1; Figure 16 shows a top view of the corner protector of Figure 1; Figure 17 shows another top view of the corner protector of Figure 1; Figure 18 shows a top view of the flattened corner protector of Figure 5; Figure 19 shows a bottom perspective view of the corner protector of Figure 18; Figure 20 shows a top perspective view of the corner protector of Figure 18; Figure 21 shows a side view of the corner protector of Figure 18; Figure 22 shows a front view of the corner protector of Figure 18; Figure 23 shows a cross-sectional view of the corner protector of Figure 18; Figure 24 shows a bottom view of the corner protector of Figure 18; Figure 25 shows a corner protector ready to be installed on a corner of a window / door unit; Figure 26 shows the assembly of Figure 25 with a first body portion of the corner protector affixed to the window / door unit; Figure 27 shows the assembly of Figure 25 with body portions of the corner protector affixed to the window / door unit; Figure 28 shows another view of a corner protector ready to be installed on a corner of a window / door unit; Figure 29 shows the assembly of Figure 28 with a first body portion of the corner protector affixed to the window / door unit; Figure 30 shows the assembly of Figure 28 with body portions of the corner protector affixed to the window / door unit; Figure 31 shows a cross-sectional view through a window / door unit with a corner protector affixed to it. Description of the Preferred Embodiments The present embodiments represent currently the best ways known to the applicant of putting the invention into practice. But they are not the only ways in which this can be achieved. They are illustrated, and they will now be described, by way of example only. Common features between the assemblies of the different figures are referenced by common reference numerals. Referring to Figure 1, a corner protector 10 according to an embodiment of the invention is shown. The corner protector 10 can be used to protect the corners of window and door units to protect them during manufacturing, storage and transit. Windows and doors typically comprise a sash (also known as a leaf), the sash optionally comprising an inner frame, with one or more glazing units mounted therein, the sash being mounted in an outer frame. Instead of a glazing unit, doors may include one or more opaque panels received in the inner frame, made of plastics or other suitable materials. The outer frame of the window or door is typically made from extruded profile sections made of a plastics material such as unplasticized polyvinyl chloride (PVC-U). An outer frame of this type is constructed from four extruded profile sections, which are fixed together to form a rectangular structure in which the sash can be mounted. For sashes including glazing, similarly, the sash is constructed from four extruded profile sections, which are fixed together to form a rectangular inner frame, forming a closed perimeter for receiving a rectangular glazing unit (or opaque plastic panel if the sash is for a door). The sash may be pivotally or slidingly mounted in the outer frame. The outer frame may receive more than one inner sash frame. The assembly of an outer frame with sash(es) therein is typically stored and transported and installed in a wall aperture as an integral assembly, any glazing typically being installed once the assembly is mounted in the wall aperture. The corner protectors of the present invention may be used to protect the corners of the outer frame (and therefore of the entire assembly if sash(es) are mounted therein) or the corners of an individual sash unit before it is mounted in an outer frame. The corner protectors of the present invention will be referred to herein as for mounting to a door or window unit, which may be an outer frame or a sash etc. The corner protector 10 has a first body portion 12 and a second body portion 14, connected by a living hinge 16. Referring to Figure 25, the corner protector 10 is configured for mounting to the corner 20 of a window or door unit 22 (which in this case is an outer frame, which may include one or more sashes therein). The rectangular window or door unit 22 has a front face 22a and a rear face 22b opposing the front face and four edge faces extending between the front face 22a and a rear face 22b. In Figure 25, first and second edge faces 24, 26 at corner 20 can be seen, the first and second edge faces 24, 26 extending substantially orthogonally to one another. The first body portion 12 of the corner protector 10 mounts to the first edge face 24 and the second body portion 14 mounts to the second edge face 26 so as to protect the edge faces 24, 26 at the corner 20. A corner protector 10 mounted to a corner 20 can be seen in Figure 27. The first body portion 12 is configured to mount to the first edge face 24 via a snap-fit engagement and the second body portion 14 is also configured to mount to the second edge face 26 via a snap-fit engagement. The snap-fit is achieved by means of the first and second body portions 12, 14 each comprising at least one snap-fit element thereon that cooperates with a complementary snap-fit element on the corresponding edge face. In the present embodiment each snap-fit element on each body portion 12, 14 is a barbed projection for cooperating with a complementary barbed edge face projection on the corresponding edge face 24, 26. Referring to Figures 25 and 31, the outer frame of a window or door is generally provided with outwardly directed peripheral projections 40, projecting from the edge faces of the outer frame, for known uses. For example, the outwardly directed projections may be used to secure a frame extender to an edge face, to increase the size of the window / door on a particular side of the window / door (which could be needed for properties with deep plaster or render or if the window / door is found to be slightly smaller than the wall aperture). A typical profile section edge face will have a pair of walls thereon, upstanding from the edge face, the walls extending longitudinally along the longitudinal axis of the profile section. Each wall typically has a barbed head portion 41 extending along the distal end of the wall, the barbed head portion comprising an overhanging ledge or lip, which forms the snap-fit element 40 on the edge face. Referring to Figure 1, the first and second body portions 12, 14 each comprise an inner side 12a, 14a for facing towards the window or door unit when mounted thereto and an outer side 12b, 14b for facing away from the window or door unit when mounted thereto. Referring to Figure 5, each body portion 12, 14 of the corner protector has two snap-fit elements 30 thereon for cooperating with the complementary snap-fit elements 40 on the corresponding edge face (more than two elements 30 can of course be provided on each body portion). The snap-fit elements 30 on the first body portion 12 will be described, but it will be understood that the features of the second body portion 14 are equivalent to those of the first body portion 12, the second body portion 14 being a mirror image of the first body portion 12. Each snap-fit element 30 comprises a projection extending from the inner side 12a of the body portion 12. Each projection 30 has a barbed head 31 at its distal end, configured to cooperate with the barbed head portion of the projections 40 on the corresponding edge face of the window / door unit. Referring to Figure 4, each projection 30 comprises a short elongate rail extending partway along the first body portion 12, along an axis parallel with the longitudinal axis of the corresponding edge face 24 when mounted thereto. The first body portion 12 has left and right sides 12c, extending away from the living hinge 16. The two snap-fit projections 30 are located, one near the left side 12c and one near the right side 12c of the first body portion 12, such that they align with the corresponding edge face projections 40 when assembled to the window / door unit 20. Like the projections 40 on the corresponding edge face, the barbed head 31 of each projection 30 on the first body portion 12 comprises an overhanging edge or lip. Each of the two projections 30 on the first body portion 12 is configured such that it snap-fits with the projections 40 on the corresponding edge face 24. In the present embodiment the barbed head portions 31 of the two corresponding projections on the first body portion 12 face away from each other and the barbed head portions 41 of the two projections 40 on the first edge face 24 face towards each other, however it will be understood that other arrangements are possible. Figure 31 shows snap-fit elements 40 of the edge face 24 retainingly engaging snap-fit elements 30 of the first body portion 12. The snap-fit elements of the edge face 26 retainingly engage snap-fit elements of the second body portion in the same way once installed. The projections 30 are moulded integrally with the corner protector 10, and are configured to be suitably resilient to achieve the snap-fit connection with the resilient projections 40 on the corresponding edge face. Referring to Figure 25, the first and second body portions 12,14 each comprise a stud 35 projecting from the inner side 12a, 14a of the body portion 12, 14. Stud 35 on the first body portion 12 is configured to be received in a corresponding recess 42 on the first edge face 24 and stud 35 on the second body portion 14 is configured to be received in a corresponding recess 42 on the second edge face 26. Each stud 35 comprises a slightly tapered cylindrical shaped post, having a rounded distal end. Stud 35 on the first body portion 12 is located substantially midway between the left and right sides 12c of the first body portion and at or near the midpoint between the living hinge 16 and the distal end side 12d of the first body portion. The stud 35 on the second body portion 14 is arranged alike that on the first body portion 12. Recesses 42 in the window / door unit 20 are substantially circular and each is sized, shaped and positioned to receive the corresponding stud 35. The first and second body portions 12, 19 are each substantially rectangular in shape. Referring to Figure 19, the inner side 12a of the first body portion 12 has a raised platform 36 thereon. Raised platform 36 has a substantially rectangular raised face 36a, the raised face 36a extending from at or near the living hinge 16 to at or near the distal end side 12d of the first body portion 12, along an axis running substantially midway between the left and right sides 12c of the first body portion 12. In the present embodiment, the raised face 36a of the platform stops slightly short of the distal end side 12d of the first body portion 12, the side walls of the platform 36 extending to the distal end side 12d so as to form a finger access recess 39 for the user to place their fingers to assist with removal of the corner protector. Referring to Figure 31, the width of the raised platform 36 is smaller than the width of the first body portion 12 between its left and right sides 12c, the raised face 36a of the raised platform 36 being configured to lie against the base of a channel 43 in the first edge face 24 between the projections 40 when the stud 35 is received in the corresponding recess 42. The second body portion 14 has an equivalent raised platform 36. Referring to Figure 7, the first body portion 12 has four ridges or ribs 37, 38 extending along its outer side 12b from the living hinge 16 to the distal end 12d. The first body portion 12 has a pair of ribs 37, one at or near each of the left and right sides 12c of the first body portion 12. The first body portion 12 also has a pair or ribs 38 which substantially align with the sides of the raised platform 36 on the inner side 12a of the first body portion 12. The second body portion 14 has an equivalent set of ribs 37, 38. The ribs 37, 38 on the corner protector strengthen the corner protector 10, thereby helping to protect the corner 20 of the window / door unit that the corner protector 10 is mounted to. The corner protector 10 is preferably made of polymeric material, such as PVC, ABS or nylon. The corner protector is preferably an integral piece formed by injection moulding (i.e. a one-piece device). The living hinge 16 (also known as an integral hinge or moulded hinge) is formed from a thinned portion of material compared to that of the first and second body portions 12, 14. The first and second body portions 12, 14 are integrally formed from the same material as the living hinge 16. Once the corner protector 10 is installed on a corner 20 of a window / door unit, the snap-fit of the first and second body portions, 12,14 with the corner 20 retains the corner protector 10 in place on the window / door unit. The inclusion of at least one stud 35 on each body portion 12,14 provides further reinforcement against the corner protector 10 falling off the corner 20 if lateral forces are applied to the corner protector 10. The living hinge 16 allows the stud 35 on the first body portion 12 to be inserted into its corresponding recess 42 first and the study 35 on the second body portion 14 to be inserted into its corresponding recess 42 subsequently (or vice versa). It would not be possible to locate studs 35 in the corresponding recesses in the first and second edge faces if the corner protector comprised a rigid structure having a first wall and a second wall substantially perpendicular to the first wall, as in prior art corner protectors. The inclusion of the living hinge 16 also allows corner protectors 10 to be stored with the first and second body portions 12, 14 aligned with each other substantially in the same plane, as shown in Figure 6. This allows the corner protectors 10 to tessellate with one another when being stored prior to installation. During storage a set of corner protectors can be stacked, one above the other, each with their inner side facing in the same way. Referring to Figures 19 and 20, the studs 35 from a first corner protector 10 can be received in the spaces between ribs 38 on a second corner protector 10, below the first corner protector, thus helping the corner protectors to tessellate. This reduces the space needed for storage and therefore also reduces costs for transporting corner protectors 10 prior to installation. In order to install a corner protector 10 on a corner 20 of a window / door unit, a recess 42 needs to be made in the first edge face 24 and a recess 42 needs to be made in the second edge face 26 of the corner 20, the recesses being sized, shaped and located to receive a corresponding stud 35 therein. The recesses 42 may be formed by drilling or similar. In operation, in order to install a corner protector 10 on a corner 20 of a window / door unit, a corner protector 10 is introduced to a corner 20 which has had a recess 42 pre-formed in each of the first and second edge faces 24, 26. The corner protector 10 is folded such that the first body portion 12 lies against the first edge face 24 and the second body portion 16 lies against the second edge face 26 and the two studs 35 are inserted in the corresponding recesses 42, one after the other. The snap-fit elements 30 on the corner protector are engaged with the complementary snap-fit elements 40 on the first and second edge faces 24, 26 to form the snap-fit engagement of the corner protector 10 with the corner 20. The design of the corner protector allows it to be removed without the need for any tools. In order to remove a corner protector 10 from a window / door unit corner 20, the corner protector 10 can simply be gripped by a user and removed by applying sufficient force to overcome the snap-fit engagement and the studs 35 are withdrawn from their corresponding recesses 42. When removing the corner protector, the user can place their fingers in the finger access recess 39 of the first or second body portion to help pull it away from the window / door unit and then do the same for the other body portion. The invention has been described in relation to the figures for use with PVC-U window / door unit profiles, however it will be understood that the corner protectors described herein can be used with window / door units of other materials, such as other plastics, or metal or wood. Figures 25 to 30 show a corner protector attached / being attached at a single corner 20, however it will be understood that a window / door unit will have a corner protector 10 installed at each of its four corners.

Claims

1015201. A corner protector for protecting a corner of a window or door unit, the corner of the window or door unit having first and second edge faces extending substantially orthogonally to one another,the corner protector comprising a first body portion for mounting to a first edge face and a second body portion for mounting to a second edge face, the first and second body portions being connected by a living hinge,the first body portion being configured for a snap-fit with the first edge face and the second body portion being configured for a snap-fit with the second edge face,the first and second body portions each comprising at least one stud projecting therefrom, each stud being configured for receipt within a recess in the corresponding edge face, each stud having a round cross-section.

2. A corner protector according to claim 1, wherein the first and second body portions each comprise at least one projection thereon that is configured for cooperating with a complementary projection on the corresponding edge face via a snap-fit.

3. A corner protector according to claim 2, wherein each projection is a barbed projection for cooperating with a barbed edge face projection on the corresponding edge face via a snap-fit.

4. A corner protector according to any preceding claim, wherein the first and second body portions each comprise first and second projections thereon, each projection being 25 configured for cooperating with a corresponding barbed edge face projection on the corresponding edge face via a snap-fit.

5. A corner protector according to any of claims 2 to 4, wherein each projection comprises an elongate shaped projection, having a longitudinal axis parallel with the 30 elongate axis of the corresponding edge face when mounted thereto.

6. A corner protector according to any preceding claim, wherein each stud has a distal end, said distal end of each stud being rounded.

7. A corner protector according to any preceding claim, wherein the living hinge has a longitudinal axis, the first and second body portions each comprising first and second sides extending substantially orthogonally to a longitudinal axis of the living hinge, said stud projecting from the first body portion being located substantially midway between the 5 first and second sides of the first body portion and said stud projecting from the second body portion being located substantially midway between the first and second sides of the second body portion.

8. A corner protector according to any preceding claim, wherein the first and second 10 body portions each comprise an outer side for facing away from the window or door unit and an inner side for facing towards the window or door unit when mounted thereto, the inner side of each of the first and second body portions comprising a raised platform projecting therefrom, said stud projecting from the first body portion projecting from the raised platform thereon and said stud projecting from the second body portion projecting 15 from the raised platform thereon.

209. A corner protector according to any preceding claim, wherein the first and second body portions each comprise an outer side for facing away from the window or door unit and an inner side for facing towards the window or door unit when mounted thereto, the first and second body portions each further comprising at least one ridge on the outer side.

10. A corner protector according to any preceding claim, wherein the corner protector is made of a polymeric material.25 11. A window or door unit having a first corner, the window or door unit furthercomprising a corner protector according to any of claims 1 to 10 mounted to said corner.

12. A method of mounting a corner protector to a corner of a window or door unit, the method comprising providing a corner protector according to any of claims 1 to 10, snap 30 fitting the first body portion to the first edge face and snap fitting the second body portion to the second edge face.

13. A method of mounting a corner protector to a corner of a window or door unit, the method comprising providing a corner protector according to any of claims 1 to 10, 35 inserting each stud in a corresponding recess formed in the window or door unit, snapCMfitting the first body portion to the first edge face and snap fitting the second body portion to the second edge face.

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