Background and Unresolved Needs

Some of the inventions described within find application in addressing an age-old problem with doors and gates, that of fitting a pre-made door or gate to an opening eo as to occupy the opening with acceptable working clearances so as to be neither too large and unable to fit within the opening nor too small and having unacceptable "gaps" around the periphery. Some of the inventions within find application in addressing such a problem that currently exists in relation to security and storm doors screens, windows, window screens, shutters and gates.

Although prompted by the needs outlined above, the Inventions within are applicable to structures in general and in particular structures configured as wings that more particularly may take the form of doors, screens, shutters or barriers. This specification describee the integers relating to the various aspects of the inventions described within including the integers relating to the Invention claimed within, and it includes integers relating to the invention to be claimed within future divisional applications.

Summary of the invention as Claimed

According to the invention there is a structure comprising infilling material bounded by a peripheral frame that is adaptable to change the shape of the structure

said structure including a substantially continuous peripheral recess occupied by an outer frame that includes outer frame members and comer covers which together extend from the channel to have a substantially uninterrupted form.

According to a second aspect of the invention, the continuous peripheral recess comprises a channel having a substantially uniform cross-section within Hs whole length defined by side walls and the exposed outer frame surfaces on each side extend relative to respective walls of the channel.

According to a third aspect of the Invention, the channel has a substantially rectangular external form defined by a depth substantially 19 MM.

According to a fourth aspect of the invention, each outer frame member comprises a single elongated member that extends

between offset ends which extend longitudinally to underlie a respective corner cover. According to a fifth aspect of the invention, there is a comer joint to connect one outer frame member to another,

each said corner joint comprising a comer connector having angularly spaced legs where one leg Is connected to the end of one outer frame members and the other leg is connected to the end of the other outer frame member.

According to a sixth aspect of the invention, the end of at least one outer frame a member is displaeeable relative to the comer connector whereby to

change the effective length of the respective outer frame member.

According to a seventh aspect of the invention, at least one outer frame member in relation to another may be angularly displaced within pre-deterrnined limits.

According to an eighth aspect of the Invention, at least one leg has spaced parallel longitudinally elongated surfaces and the associated outer frame end has opposed inwardly disposed end shoulders that project into the hollow of the respective outer frame member, one end shoulder abutting one parallel longitudinally elongated surfaces the other end shoulder abutting the other parallel longitudinally elongated surface whereby to restrict the outer frame end to relative rectilinear movement.

According to a ninth aspect of the Invention, there is a fixing block within the hollow of the respective outer frame member and being fixable to the leg to

restrict the end of the outer frame to relative rectilinear displacement.

According to a tenth aspect of the Invention, each leg extends within a respective outer frame member to abut a fixing block within the hollow of the respective outer frame member to be etectively be fixed relative to the leg to restrain the outer frame member against relative angularly displace.

According to an eleventh aspect of the invention, each leg is electively fixed to its associated fixing block by an operable corner fastener.

According to a twelth aspect of the invention, the fixing block is fixable to the respective outer frame member to restrain to restrain the outer frame member against relative rectilinear displacement

According to a thirteenth aspect of the invention, each fixing block is electively fixed within its supporting outer frame member by an operable comer fastener.

According to a fourteenth aspect of the invention, there is an orthogonal joint comprising a threaded boss portion supported by the outer frame and a threaded fastener that extends to act on the adjacent inner frame,

the said fastener operable to displace the boss portion and adjacent outer frame member away form the inner frame. Subs

fram

members of the other pair by a corner connector and each including orthogonal joints disposed towards their respective ends,

wherein the effective length of each outer frame member and the included angle of each corner may be changed.

According to a sixteenth aspect of the invention, the effective length of each outer frame member may be changed by operation of an orthogonal joint fastener and the included angles of each corner may change in response to changes in length of outer frame members.

According to a seventeenth aspect of the invention, the infill comprises infilling material connected to and bounded at least in-part by an inner frame having the peripheral recess.

said infilling material including a peripheral return that projects sideways to occupy the peripheral recess .

According to an eighteenth aspect of the Invention, the peripheral frame id occupied by a fixing bar,

said return portion being sandwiched between the said fixing bar and a wall of the recess.

According to a nineteenth aspect of the invention, fasteners extend through the said recess wall to extend through the infilling material return to be in threaded engagement with the fixing bar to better retain the infilling material.

According to a twentieth aspect of the Invention, the fasteners may be tightened to draw the return towards the recess wall and/or to sqeeze the return between the recess wall and fixing bar to better retain the infilling material.

According to a twenty-first aspect of the invention, return portion is substantial enveloped by an insulating material.

According to a twenty-second aspect of the invention, return portion is substantial enveloped by a compressible material.

According to a twenty-third aspect of the invention, the infilling material comprises woven steel mesh or perforated aluminium sheet According to a twenty-fourth aspect of the invention, configured as a substantially conventional Australian screen door having a substantially conventional Australian security door lock.

The elements relating to the various aspects of the invention claimed within are identified within the specification as follows; where unless the context requires otherwise,

• "Locks" or variations such as "lock" will be understood to include

complete locks, locks in-part and improvements for locks without being limited to the complete locks described herein.

• "Comprise" or variations such as "comprises" or "comprising" will be

understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

• Positional prepositions such as "rear" and "forward* are used to assist in description of the preferred embodiments and with reference to the accompanying drawings and have in general, no absolute significance,

· Overlap" and derivations such as 'overlaps" implies at least in-part.

occupying a same plane as.

• "Meshes with implies "engaging with"

• "Extent" will be understood to embrace area, form and shape.

• Headings are included for convenience only and not to affect on interpretation. · "Preferably" or variations such as "prefer" does not impfy that the form of an integer is restricted to that referred to as preferred, but implies adequate and if need be, able to adequately perform a function required by the invention.

• "Alternative" or variations such as alternatively does not imply that the form of an integer is less or more preferred but simply implies adequate and if need be, able to adequately perform a function required by the invention.

• "improvements" does not imply that the form of an integer is restricted to that referred to as "improved", but implies an alternative form of the integer/s "well suited' to particular applications and if need be, able to adequately perform a function required by the invention.

· 'Wing" or variations such as "wings' includes complete wings; improvements to wings and alternative forms of wing constructions transportable into other wings and other structures without being limited to the wings described herein, and more particularly, wings embraces wings configured as "doors", "windows", "shutters", "screens" and gates,

· "Structure" or variations such as "structures ^* implies a man-made fabrication consisting of one or more members and embraces complete structures and

improvements in and alternative forms of constructions without being limited to the wings described herein; structures more particularly embraces wings and more particularly wings configured as (or included in) doors, windows, window screens, gates and shutters,

• "Member" is an identifiable entity having material form that may include one or more identifiable components.

• "Material ^* includes elements, alloys, plastics and other substances.

• 'Aperture ^* and "recess" embrace a hole that extends from a surface white

"aperture" In some contexts Implies a hole that extends between surfaces.

• "Furniture" includes door furniture that includes a "handle assembly" that includes a handle supported by a base that together in one form comprise a disengaging handle supported by a back-plate or base;

• "Latching ^* implies displacement of an "engaging member into

engagement with an 'Engageable Member" under the action of biasing means.

• "Latch-Bolt" or "latch bolt" Is an outwardly biased bolt capable of executing

(or participating in) latching and Includes bolts having a leading end that is chamfered or otherwise profiled on one or both sides.

• "French Door" means a door including a frame and an ln-fill that may comprise glass or other suitable material,

• "Screen door" means a door including a frame and an insect restraining in-fil) such as fiberglass mesh, woven mesh or perforated metal mesh; a "conventional security door" is regarded being a screen door having an axial hollow frame having a depth not exceeding 45 MM and a width not exceeding 16 MM and an industry-standard door preparation suits conventional security doors.

• "Lock Body" includes an engaging member and a lock casing and an

"conventional security door lock body" is able to fit within the industry-standard door preparation having a lock casing not exceeding 45 MM in depth, a width not exceeding 1Θ MM and preferably a length substantially 147 MM. Some conventional single point locks (not including multipoint locks) however, only require a depth of 40 MM.

• "Mortise Lock" means a lock including a lock body, a strike plate, a pair of handle assemblies and a cylinder where the lock body Is configured to be fitted within the frame of the wing.

• "Cylinder" includes "Double-Cylinder" that includes opposed coaxially supported single Cylinders with opposed barrels each operabty connected to the same angularly displaceable "first cam" having a "first cam arm" characterized by a "free end" that extends radially to a "peripheral surface" defined in part by a radial distance from the first cam pivotal axis and where in one form of conventional double cylinder, this radial distance is substantially 15.0 MM. In some forms, each barrel Is connected with free movement to the same first cam such that the cam Is free (between limits) to be angularly displaced white the barrels remain undisplaced. This type of cylinder is commonly used in conventional Australian security door locks

• "Cross-Sectional View" In relation to figures should be interpreted as an orthogonal cross-sectional view definsd by a plain orthogonal to the axis of the member in consideration.

• Patent Specification shall be taken to include: a Body [comprising a Title, a Description of Preferred Embodiment/s, an Abstract and a Summary of the Invention] and Claims,

• A "mortise joint ^* in relation to a frame In a structure includes two elongated members (relatively disposed at an 'included angle") having ends that abut along an angled edge when the Included angle is equal to a 'nominal angle"; this can be regarded as a perfect mortise joint

• An orthogonal mortise joint has members having ends angled at 45

Degrees and the included angle is 90 degrees.

· A "pseudo orthogonal mortise joint" has members having ends angled at 45 degrees but the Included angle is 90 degrees + Deviation so they abut only at a corner to give rise to a visible wedge-like gap.

• A "butt joinf in relation to a frame In a structure is characterized by two elongated hollow members relatively disposed at an included angle where the end of a first member abuts an edge of a second member along the entire end when the included angle is equal to a "nominal angle"; this can be regarded as a perfect butt joint,

• An 'orthogonal butt joint" Is a joint characterized by the two elongated

hollow members being relatively disposed at an angle 90 degrees and having orthogonal ends.

· "Deviation" is an incremental angle = nominal angle - Included angle.

Unless the context requires otherwise, any prior publications and usage referred to herein, is not an assertion that any of this material forms part of the common general knowledge in the art in any other country at the priority date of any claim herein (or the priority date of any future claim derived at least in part from this specification).

The integers described within include those related to the various aspects of the invention claimed within and they include those related to the various aspects of other Inventions to be claimed in future divisional applications and continuations in part.

Where an integer Is attributed with attributes different from those attributed in an earlier application on which this application relies for priority, the integer will be regarded as the same integer in a different form; where there is actual Inconsistency, the. latest description will prevail. The inventions described within although not limited to such, include alternative forms of, and Improvements to the structures described in the following specifications:

PCT/AU2007/000865 Wings and ensuring 2007 264 393 and Convention Application 2007 202 074,

PCT/AU2009/000081 Structures and ensuring 20092080 15.

PCT/AU2010/000409 and Complete Application AU 2010201468.

Provisional Applications 2010 903715 and

PCT/AU2010/001383

these prior patent specifications being hereby Included bv reference and being referred to as "the patent specifications included by reference".

Description of the Figures

Notwithstanding any other forms that may fall within its scope one preferred form of the invention will now be described by way of example only with reference to the accompanying drawings In which:

Figure 1 is an isometric view of a structure taking the form of a substantially rectangular hinged security door.

Figure 2 is a side view of a structure taking the form of a sliding door.

Figure 3 is a side view of the structure taking the form of a fixed screen or shutter. Figure 4 is an exploded isometric view of the top left-hand corner of the structure of Fig t (with the comer connecting member omitted for ease of description).

Figure 5 is an isometric (unexploded) view of the inner frame of Fig 4,

Figure 6 is a aide view of the structure of Fig 1 ,

Figure 7 is sectional view AA of Fig 6.

Figure 8 is sectional view BB of Fig 6,

Figure 9 is sectional view CC of Fig 6,

Figure 10 is an enlarged sectional view AA of Fig 8,

Figure 11 is a partly exploded view of the inner frame of the structure of Fig 1 showing each outer frame member adapted at each end to cooperate in a respective corner joint that provides both angular and tranalational relative displacement arid where each outer frame member is connected to a corresponding Inner frame member by a respective orthogonal joint.

Figure 12 is an exploded isometric view of a comer joint including a comer connector the end portions of outer frame members,

Figure 13 is a schematic side view of the comer joint of Fig 12 with fitting spacers in-situ, Figure 14 is a schematic side view of the corner joint of Fig 12 but with the fitting spacers omitted or collapsed,

Figure 15 is a schematic side view of a corner joint where the Included angle has been increased by 2 degrees.

Figure 16 is an Isometric view of the top left-hand comer of the wing of Fig 1 ,

Figure 17 is cross-sectional view AA of Fig 16,

Figure 18 Is cross-sectional view BB of Fig 16,

Figure 19 is a schematic side view of the corner of the structure of Fig 16, Figure 20 is an isometric view of a comer cover,

Figure 21 is a plan view of a comer cover before being folded.

Figure 22 Is cross-sectional view EE of Fig 21

Figure 23 is cross-sectional view FF of Fig 21

Figure 24 is cross-sectional view AA of Fig 21

Figure 25 is cross-sectional view BB of Fig 21

Figure 26 is an enlarged part-view of the cross-sectional view of Fig 10 in which the Infilling material is retained between an integral extension of the frame comprising a bar the base of the Inner frame where fasteners extend through the base, through the infilling material to extend into the bar, the fasteners having clearance holes in the bar and engaging in threaded engagement with the base.

Figure 27 is the structure of Fig 26 but where the fasteners having clearance holes in the base and they engage in threaded engagement with the bar,

Figure 28 is the structure of Fな 27 but where the fasteners have been tightened to draw the bar towards the base.

Figure 29 is the structure of Fig 28 but where the fasteners have been tightened to substantially displace the bar towards the base.

Figure 30 is an enlarged part-view of the cross-sectional view of Fig 10 in which the infilling material is retained between an enclosed separate member comprising a separate bar and the base and where fasteners extend through the base to extend through the infilling material to extend into the bar. said fasteners having clearance holes in the base and engaging in threaded engagement with the bar,

Figure 31 is the structure of Fig 30 but where the fasteners have been tightened to substantially displace the bar towards the base.

Figure 32 is schematic representation of a hand tool that can be inserted into the offset side recess to locally prize loose the bar from the inner frame, Figure 33 is an un-adjusted structure configured as a conventional security door and where the outer frame extends from the inner frame by substantially 12.5 MM on all sides and ends,

Figure 34 is a schematic side view of an orthogonal joint,

Rgune 35 is a schematic side view of an alternative orthogonal joint,

Figure 36 is an isometric view of woven mesh,

Figure 37 is an exploded schematic isometric view of a portion of the structure of Figure 1 to which a lock is attached, including an inner frame having side apertures configured to receive a lock and being elongated and widened to accommodate the vertical and horizontal relative displacements DeltaH and DeltaV respectively between the inner and outer frames (relative to which the lock is located) and in a particular form, configuration to suit a conventional security door lock where the appertures provides passage for handle spigots, a shaft, a double cylinder and a snib lever irrespective of which end of the structure Is disposed upwardly (ie not inverted or inverted); and an outer frame having elongated side apertures configured to receive the lock handle spigots, the shaft, the double cylinder and the snib lever irrespective of which end of the structure is disposed upwardly,

Figure 38 is the structure of Fig 37 where the outer frame is disposed upwardly relative to the inner frame,

Figure 39 is the structure of Fig 37 where the outer frame is disposed downwardly relative to the inner frame,

Figure 40 is an exploded schematic isometric view of a portion of the structure of

Fig 37 to which a lock is attached including an outer frame as and an inner frame having side apertures configured (for a structure that will not, be inverted) to receive the lock handle spigots, the shaft, the cylinder and the snib lever with only working clearances, this side aperture In some forms being manufactured by a drill saw referencing the inner frame,

Figure 41 is an Isometric view of a portion of inner frame having a particular profile,

Figure 42 is a cross-sectional view of Fig 41 ,

Figure 43 is an Isometric view of a portion of bar having a particular profile, Figure 44 is a cross-sectional view of Fig 43.

Figure 45 is a labelled diagram to assist with understanding of Fig 17,

Figure 46 is a schematic side view of an alternative outer frame corner joint, Figure 47 is a schematic view of a nut carrier.

Figure 48 is an isometric view of an alternative fixing block. Detailed Description of Embodiments Consistent with the Concepts of the

Inventions

GENERAL

Reverting to the problems with doors and screens, some openings are fabricated according to standard dimensions, some are constructed on site of convenient dimensions, some through poor workmanship are non-rectangular and some openings become skewed as a result of house settlement. In spite of this. DIY hardware retailers sell doors of standard sizes to suit such openings often resulting in poorly fitting doors. In other cases, doors are "made-to-measure" by a time consuming process where the opening is measured and a door is manufactured to suit the particular opening - sometimes even this process results in a poorly fitting door.

The above deficiencies raise the possibility of designing a door that is configurable to suit openings of different widths and/or different heights and raises a particular objective of same of the inventions within, that of being able to provide a screen door that suits the different common door openings in a particular countries/territory and a more particularly to provide a door that suits all the different common openings.

Such adjustable doors would be manufactured without reference to particular openings (which is time consuming and expensive) and by modem manufacturing techniques and- systems resulting in reduced manufacturing costs and improved quality. Further, it would advantageous if (at least some) doors could be configured to fit within a normal sedan vehicle so that they could easily be transported home to be assembled and fitted by the home owner or a handyman - this feature overcoming a difficulty experienced by shoppers who purchase doors from retail outlets.

In Australia for example, most screen and security doors, referencing Fig 35, fall within a range in widths of 806 to 818 MM and within a range of heights of 2024 to 2042 MM so an adjustable door that embraced these ranges could meet would satisfy some of our objective. Doors of course could be configured to embrace other pre-determined ranges to suit common sizes in other jurisdiction or territories.

Notwithstanding that the inventions within are described (in some places) with reference to wings Including doors, and in particular with reference to those shown In the figures, they are not limited to such structures.

In some forms, a structure 1, referencing the figures. Includes an infill 2 (that in some forms is resistant to deformation), that in some forms includes flat glass, woven steel mesh, fiberglass mesh, perforated sheet metal, bars or a combination thereof or any other suitable material. In some forms the structure includes a peripheral frame that in some forms Includes an outer frame 3; the infill 2 and outer frame 3 configured to be relatively disposed and in some forms they are configured to mutually overlap and In some forms, the outer frame 3 supports the infill 2.

In some forms, referencing Fig 10, the Infill 2 is bounded by a return 4 that extends along the periphery of the infill (and although not limited to, may take the form of a continuous portion or multiple discrete interrupted portions that extend outwardly) to - overlap the outer frame 3; some infills are further configured to include a pair of spaced returns 4 configured as sides 6 that define between them, a substantially U shaped, elongated U channel 6 that extends along the periphery of the infill 2 by extending inwardly from an opening 7; in some forms the sides 5 are substantially parallel. In some forme, the infill 2 includes an inner frame 9 that extends along its periphery, this Inner frame 9 being configured to include a base 10 from which the return 4 or sides 5 extend outwardly to overlap the outer frame 3 and in some forms, this inner frame Θ extends along the entire periphery of the infill 2.

OUTER FRAME

The outer frame 3 referencing Fig 10 and 11, 12 extend along the periphery of the infill and In some forms extends along the entire periphery of the infill; in some forms it is configured to include one or more elongated outer frame members 11 that (although not limited to such) in some forms, include a longitudinally elongated recess 19, an outer edge wall 22 (or outer edge wall 21) connected to a side 18 and in some cases, connected to opposed sides 18; (although not limited to, in some forms) having a substantially rectangular cross-section and including a hoDow 19 also having a substantially rectangular cross-section where the sides 18 extend between the outer edge wall 22 and the opposed Inner edge wall (or inner edge) 21 , referencing Fig 10: the outer frame member 11 defined by an edge depth ^* D", a side width "W" and a side-wall thickness Ύ and by a longitudinal axis that in planar wings, is parallel to the plane defining a side of the wing. Some outer frame members additionally include extensions 14 to the sides 18 that form an outwardly disposed peripheral channel 16 that In some forms is WT deep and configured to receive the fixing tabs of a lock, in a particular format it is WT deep.

Hollow rectangular outer frame members are well suited to many structures including wings and in particular doors; they may be manufactured from any suitable material and by any suitable process; in some forms they comprise drawn steel tube, extruded aluminium, roll -formed steel (having the essential features described herein but modified to suit the roll-forming process), extruded plastic (including pvc) and in some forms they are fabricated from multiple portions to have as a whole, the essential features described herein. In more particular forms, the outer frame is configured to accommodate a mOrtise lock body and in some forms, it is configured to accommodate a substantially conventional security door lock body.

For convenience and by way of example only, the outer frames employed in the figures are configured to accommodate a substantially conventional Australian security door lock body, referencing Fig 37, but the structures described herein are not limited to the examples described.

It may be necessary to change the effective length of an outer frame member to render the structure suitable for a larger opening; the objective being to fill the opening with the structure with only working clearances. Some structures have comer joints as described in Patents included by reference and some structures referencing Fig 11, have at least one adaptable corner joint 23 to facilitating changes in the included angle and in some forms, enabling a change in the effective length of an outer frame members; in some forms, corner joint included angles automatically adjusts in response to changes in the effective length of outer frame members.

A particular form of structure includes a rigid infill bounded by an inner frame on ail sides that is bounded by an outer frame on all sides where the outer frame has a smallest configuration when each outer frame member is adjacent to a corresponding inner frame member 24 along its length, and where each comer has an included angle equal to its respective nominal included angle and where after the structure has been adjusted to a larger extent, the outer frame members are parallel to their respective configurations in the smallest configuration and where each corner joint has an included angle that is equal its respective nominal angle and the joint is referred to as being "perfect ^* and where after adjustment, the outer frame members will become not parallel to their respective configurations In the smallest configuration resulting In at least one comer joint having the configuration of a "peeudo mortise joint" and having an included angle [ ^* Alpha"] that differs (by a deviation) from its respective nominal angle, and if the joint were an orthogonal mortise joint, the joint would take the form of a pseudo orthogonal joint.

In a particular form of such a structure configured as a "rectangular structure" the inner frame Is substantially rectangular and the outer frame has:

1) a smallest configuration where each outer frame member is adjacent and parallel to a corresponding inner frame member 24 along its length, and

2) nominal angles of ninety degrees at each corner, and

3) the outer frame, referencing Fig 11 includes an upper outer frame member 31. a lower outer frame member 32, a left hand side outer frame member 33 and an opposed right hand side outer frame member 34; the upper and lower outer frame members 31 , 32 connected to a left and right hand side outer frame member 33, 34 by respective comer joints. In some forms, each outer frame member includes a pair of orthogonal joints located one towards each of its ends denoted OJ-X.

In some structures it is desirable for the inner and outer frame members 24, 11 respectively to have minimum widths for the reasons described below but a competing consideration however, requires the widths to be large enough to enable the structure to be adjusted In extent to embrace a pre-determined range of opening sizes and a more particular objective of some of the inventions within, Is for a single structure to embrace a range of common openings (in some cases, common within at least a territory); a further competing consideration for some structures is the need for the outer frame member to accommodate a lock and of course, in general, the smaller the depth the less expensive will the frame be.

In a more particular form, the structures is further configured as a hinged security door having a ["security door form"] that is to embrace common door openings in a particular territory and the door sizes considered appropriate (after allowing for operating and fitting tolerances) are: height "H" between 2024 and 2042 (where the incremental height Delta H = 18) and width "V" between 806 and 818 (where the incremental width Delta V = 12). In some forms of doors addressing the above requirement, the following convenient size ranges have been adopted:

HD: 2020 to 2045 (Delta HD=25) and WD: 800 to 820 (delta WD=20).

Where the outer frame member is configured to suit a substantially conventional security door single point lock, the depth may conveniently be set to W = 46.6 MM, the Depth D=19, t=1.5, WT=3 so the channel 15 depth WC, referencing Fig 10, can conveniently be set to WC=2.5 +W+WT- WE= 2.5+46.3+3-13 - 39.0 where WE =13, WT=3 and W=46.3 these sizes being compatible with a conventional multipoint lock.

If such structure were skewed by 10 MM (so that each comer takes the form of a

"pseudo orthogonal-mortise joint") so that an outer frame side member 11 became 10 MM lower (than it would be if the door remained rectangular), then the widest part of the gap between the comer cover flap (cut to size orthogonally) and the shoulder 170 would be very small. Although these gaps are unfortunate, they are preferable to the common solution of fitting a rectangular door into a skewed opening to leave gaps through which insects have passage and/or where security is compromised or of reconstructing the door opening to suit the door. Although joints could be configured to accommodate larger deviations, it is envisaged that in practice where the structures have a "security door form", the deviations will be within a range -3 degrees to +3 degrees.

It should be said that the smaller is the width of the outer frame, the smaller will any comer gaps be for a give angle of skewing and this is another reason for minimizing the width of the outer and inner frame members. In a particular form, the outer frame member has a 'security door form'

OUTER FRAME ADAPTABLE JOINTS

Outer frame members may be connected by comer joints described in Patents included herein by reference but some structures referencing Fig 10 and 11 and 12 have outer frame members connected by corner connector 40 that enable the included angle to be adjusted. In some forms, each comer connector comprises a two pairs of legs, a first pair off legs 41 ["legs 41"], and a second pair of legs 43, ["legs 43*1 relatively disposed at a pre-determined angle, legs 41 extending into the hollow 19 of a first outer member 42 and legs 43 (extending into the hollow 19 of a second outer member 44) each legs 41 ,43 having elongated portions SO having edge surfaces angled to the walls 21 and 22 of the respective outer frame member to enable the outer frame members to angularly displace relative to the associated leg 41,43.

In some forms, legs 41 includes opposed substantially parallel edge surfaces 45 one on each single leg within the pair and similarly, legs 43 includes opposed substantially parallel edge surfaces 45 one on each single leg within the pain In some forms, each comer connector comprises single castings

In some forms, referencing Figure 12 and 19, each end of each outer frame members include inwardly projecting edge shoulders 46 separated by a distance substantially the same as the distance between opposed parallel surfaces 45 so that for so long as the edge shoulders 46 remain over the parallel portions 45, the respective outer frame member during adjustment, rotates about these points of contact.

In some forms, the single legs within legs 41 are connected by a bridge 47 that includes aparture& 48 and in some forms aperture 48 is circular having a diameter substantially the same as the fastener the extends through it. and In some forms, aperture 48 is oval having a depth substantially the same as the fastener that extends through it and being elongated in width to enable the fastener 78 and associated outer frame member to angularly displace relative to the respective comer connector. Similarly the single legs within legs 43 are connected by a bridge 48 that includes apertures an 49 and in some forms aperture 49 is circular having a diameter substantially the same as the fastener the extends through it, and In some forms, aperture 49 is oval having a depth substantially the same as the fastener that extends through it and being elongated in width to enable the fastener 79 and associated outer frame member to angularly displace relative to the respective comer connector.

In some forms of comer joint, each pair of legs 41 ,43 support a respective plate

347, 348 that extend between the legs within each pair, each plate 347, 348 including an aperture 348, 349 respectively and in some forms theses apertures are circular having a diameter substantially the same as that of the respective comer fastener that extends through it and in some forms having a depth substantially the same as the fastener that extends through it and being elongated in width to enable the fastener and associated outer frame member to angularly displace relative to the respective comer connector.

In some forms, referencing Figure 12, the ends of the outer frame members are formed to also have outer elongated edge recesses 60 and side recesses 61 respectively configured to receive the wings 221 and edge plate 220 respectively of a respective comer coyer 20, referencing Fig 21; the recesses 61 being bounded by side shoulders 170 that extend along the interface with the unformed side of the respective outer frame member.

In some forms referencing Fig 21, the comer cover 20 comprises a flat profiled member 222 having fold lines 223 of reduced thickness enabling the member 222 to be folded to assume the configuration of Fig 20, a configuration that enable it to occupy the surface recesses of the comer it covers while residing within the channel 15 of the inner frame. For convenience, the flaps or legs 221 Include orthogonal cutting channels 224 to receive a cutting tool so the flaps may more easily be cut to length so each respective wing 221 occupies a respective recess 61 while abutting a respective shoulder 170 while each respective edge 220 encloses a respective recess 60.

Preferably, the fixing blocks are configured to be a size for size fit within the hollow

19 of the respective outer frame member.

A FIRST TYPE OF FIXING BL OCK

In some forms, at least one of aperture 48, 49 is oval or if the alternative construction is employed, at least one of aperture 348, 349 is oval to enable the respective comer fastener to angulary displace relative to the associated legs 41. 43 and each leg 41, 43 is connected to a respective fixing block 62, 63 that can be fixed relative to respective outer frame members 42, 44; in some forms the fixing block 62, 63 has a curved shoulder 64, 65 defined by a constant radius R also centred midway between the edges 21 and 22 of the respective outer frame member and this abuts a corresponding leading edge 56, 37 of the leg 41, 43 defined by a constant radius R having the same centre. The connecting member includes apertures 71 configured to receive a threaded corner fastener 79 that extends to engage in a recess 75 in the respective fixing blocks 63, 64

In some forms, referencing Fig 13 to 15, each fixing block 56 includes an outwardly dlsplaceable member 71 and Inwardly dlsplaceable member 72 that may comprise pins that extend between aperture 74, 75 and the outer edge 20 and the inner edge 21 respectfully of the associated outer frame members and being configured such that when abutting the sides of the fastener 78, 79 respectfully, they each extend to form and to extend into recesses in the edges 20 and 21 of the respective outer frame members 42, 44; this being achieved by the coned end 170 of the respective fastener being driven between the inner ends of the pair of pins 71 ,72 to cause these ends to slide up the walls of the cone while displacing outwardly.

In usage, a substantially rectangular wing, referencing Fig 1, 11 has fixing blocks 82, 63 respectively are held restrained against the bridges 47, 48 by fasteners 78, 79 whose heads 80,81 respectively are held spaced from the bridges 82, 83 by removable or destructable spacers 84, 85. Each outer frame member is then displaced from the corner connectors between which it extends (by means that may include use of the orthogonal connecting members) to have the desired effective lengths (for clarity "effective length" and where the context requires it "length", means the distance between comer connectors which the respective outer frame member extends); after which, the spacers 84, 85 are removed or crushed one by one as the fasteners 78, 79 in the entire structure are lightly tightened ! to drive respective pairs of pins 71, 72 outwardly to form recesses in the side walls as described above (to fix the respective outer frame members relative to their respective corner connector): after which the screws 79 may be lightly loosened (while still retaining the pins outwardly displaced) to enable the outer frame to be skewed as required; subsequently the fasteners 79 are tightened to rigidfy fix the outer frame.

In summary, the effective length of each outer frame member may be changed by operation of either one of the associated orthogonal joint fasteners and the included angles of each comer may automatically change in response to changes in length or changes of configuration of outer frame members (before final tightening of the comer fasteners).

ALTERNATIVE FIXING BKICKS

In some forms of comer Joint, each pair of legs 41 ,43 support a respective plate 347,348 that extend between the legs within each pair, each plate 347, 348 including an aperture 348, 349 having a diameter substantially the same as that of the respective comer fastener that extends through it to prevent the fastener from angularly displacing relative to the respective comer connector.

In some forms, each pair pairs oDegs 343,341 is connected to a respective - alternative fixing block 362, 363 that is able to be fixed relative to respective outer frame members 342, 344; in some forms each fixing block 362, 363 has a curved shoulder 366 defined by a constant radius R (in the plane of the wing) centered midway between edge wells 21 and 22 each abutting a corresponding leading edge 357 of the associated pair of legs 341 , 343 defined by the same constant radius R and having the same centre of radius. The pairs of legs 341, 343 each include apertures 371 configured to receive threaded corner fasteners 379 that extend to engage with respective the fixing blocks 362, 363.

in some forms, referencing Fig 46, each fixing block 362, 363 Includes an adjacent profiled nut aperture 395 defined in part by a curved shoulder 397 defined in part by a curved nut surface 396 defined by a constant radius centered midway between edge walls 21 and 22 and where the curved shoulder 397 is slotted (to form a slotted aperture 420) to allow passage of the respective fastener 379 while allowing the respective fixing block 362, 363 to displace relative to the respective fastener 79 that is fixed relative to the connecting member and legs 341 , 343.

Each legs 341 , 343 has an associated comer fastener 379 that extends to engage with a respective nut 398 supported within the respective nut aperture 395 and abutting the associated curved shoulder 397. in some forms, the nut comprises a lockout supported by a nut carrier 399 that has legs 401 between which the locknut is held captive and legs 402 between which a compressible washer 403 is held to be held in compression by being urged towards the curved shoulder 397 by tightening of the respective corner fastener 379.

In some forms, referencing Fig 46, each fixing block 362, 363 includes ah orthogonal profiled nut aperture 410 defined in part by a shoulder 411 defined in part by a profiled nut surface 412 and where the shoulder 411 is slotted (to form slotted aperture 421) to allow passage of an orthogonal fastener 413 that extends from and through an aperture 424 in the respective outer frame member (to engage in a respective nut 414). Each orthogonal fastener 413 engages with a respective nut 414 supported within the respective nut aperture 410 and abutting the associated nut surface 412.

In some forms, the nut comprises a lock nut supported by a nut carrier 399 that has logs 401 between which the lock nut is held in compression and legs 402 between which a compressible washer 403 Is held to be held in compression by being urged towards the nut surface 412 by tightening of the respective orthogonal fastener 413.

The configuration described above, enables the respective fixing block 362, 363 to displace (within limits) rectilinearly relative to the respective outer frame member by enabling the respective fixing block 362, 363 to slide over the associated orthogonal fastener 413; this capability enabling the respective outer frame member to have its effective length changed.

In the adjusted and fitted wing, where all orthogonal and comer fasteners are tightened, each end of outer frame member is connected to an underlying fixing block 362, 363 by a respective orthogonal fastener so as to become resistant to relative displacement and to oppose any moment tending to rotate the respective outer frame member relative to the associated comer connector.

It should be noted, referencing text above, that in some cases where "each end of each outer frame members include inwardly projecting edge shoulders 46 separated by a distance substantially the same as the distance between opposed parallel surfaces 45 ^* , - tightening of an associated orthogonal fastener may cause the associated outer wall 21 to slightly deform as the outer wall is drawn into contact with the underlying fixing block.

In use, when the orthogonal fasteners are untightened, the effective length of each outer frame member may be changed by any means (including operation of either one of the associated orthogonal joint fasteners) and when the comer fasteners are untightened the included angles of each comer may be changed. In some forms of adjusting the shap of the wing, the comer fasteners remain untightened while orthogonal fasteners are progressively tightened as each outer frame member has Its effective length changed and set; during which process all the included angles automatically change in response to these changes in length and after which the wing is skewed to suit the particular opening after which all the comer fasteners are tightened and after which the orthogonal fastener may be tightened to displace the infill to the desired position relative to the outer frame.

INNER FRAME α INFILL

The Infill may comprise any means of filling the space between the outer frame members having means of being attached to rt Some structures include an infill as described in the Patent Specifications Included herein by reference.

In some forms, the inner frame 9 extends along the entire periphery of the infill 2 to provide a continuous peripheral recess that in some forms comprises a channel 15, referencing Fig 5, that extends along the entire periphery of the Inner frame. In some forms, the channel 6, 15 is U shaped having a depth D has a width WC, referencing Fig 8. In some forms, referencing Fig 4, the inner frame is comprised of elongated inner frame members 24 connected at corners 25 configured to enable the respective channels 6 to be connected to form the continuous channel 15, referencing Fig 5, that extends along the entire periphery of the inner frame 9 by extending around each comer.

In some forms referencing Fig 4 and Θ, the inner frame corner joints are substantially butt joints where the horizontal members extend between the vertical frame members and where the horizontal members include screw apertures 18S whereby to receive fasteners 184 that extend through apertures 185 in the base 10 of the respective vertical member; it being appreciated that the base of vertical frame members adjacent to the horizontal members are removed to enable the recess 6 to extend round the comer as shown in Fig 19; it will be further appreciated that the wing 80 portions of the vertical and horizontal outer frame members participating in a joint comprise mortise portions again to enable enable the recess 81 to extend round the comer as shown in Fig 19.

In some forms, each inner frame member 24 includes an elongated wing 80 referencing Fig 10. 26, 41 that extends along substantially the entire periphery of the respective inner frame member to provide a continuous offset recess 81 to receive the infilling material return portion 102 (a sideways extending portion that may extend along the entire periphery of the infilling material). In some forms it comprises a channel 82 having a side opening 89 of width Q and a hollow bounded by the base 10, a supporting wail 93, the inner wall 92 and the return wall 91. Within the hollow is a peripherally elongated fixing bar that occupies some of the hollow but which leaves clear sapace substantially Q in width. The return portion 102 extends sideway to extend through the opening 89 to occupy the clear space to be fastened there by fasteners 86 referencing Fig 26 to 32 and 42. spaced along the channel 6 of the inner frame and extend inwardly (by having threaded shank portions that extend In a direction substantially coplanar with the face of the wing) to extend through the infilling material to extend into a fixing bar 87. In some forms, referencing Fig 26, the fasteners are in threaded engagement with the base 10 but having clearance holes in the fixing bar 87; in some forms, referencing Fig 27 to 31 , the fasteners are in threaded engagement with the fixing bar but not the base 10. In some cases the fixing bar comprises an extension to the inner frame, in other cases, the fixing bar 88 is a separate member housed within the hollow.

In some forms, the surface of the fixing bars 87.88 are textured and it may be ramped 130. the ramping including inclined surfaces 131 that extend inwardly as they extend away from opening 89. In some forms, the infilling material comprises substantially planar material formed to have an elongated peripheral return portion 102 described above that extends sideways to extend into the recess 81 and in some forms the return portion extends along the entire periphery of the infilling material. The infilling material may comprise any suitable material including woven steel mesh and perforated sheet metal and flexible materials such as fiberglass mesh where the return portion is formed on fitting- The infill may art adapted inner frame to suit bars attached to the or an adapted inner frame as described in patents included herein by reference.

In summary, in part, the peripheral channel is occupied by a fixing bar so the return portion Is between the said fixing bar and a wall of the recess and fasteners extend through the said recess wall to extend through the Infilling return to be in threaded engagement with the fixing bar to better retain the infilling material. In some forme the fasteners are tightened to draw the return towards the recess wall and/or to sqeeze the return between the recess wall and fixing bar to better retain the Infilling material and/or to urge the adjacent infilling material outwardly.

In some forms, including those where the infilling material is of a different material to the inner frame material «nd galvanic corrosion is to be prevented, for example, the infilling material is of stainless steel woven mesh and the inner frame is of aluminium, the infilling material is separated from the inner frame by a non-conductive gasket 104 (that in one form comprises PVC) that extends peripherally to enclose the return portion 102 and adjacent material; it will be appreciated in this case that the fasteners extend through apertures punctured In this gasket In one form, the gasket includes sideways wings 104 configured to engage with the walls of the recess 81.

In some forms, the gasket is a material softer than the woven mesh that if squeezed will deform to protrude into spaces on the surface of the woven mesh and into the spaces adjacent to the ramped surface of the fixing bar 87,88 so that to better retain the infilling material return portion within the fixing recess; dislocation of the return portion requiring shearing of the gasket in a direction parallel the base 10.

The inner frame members may be manufactured from any suitable material and by any suitable process and may comprise drawn steel tube, aluminium extrusion, roU- formed steer (having the essential features described herein but a but modified to suit the roll-forming process), extruded plastic (including pvc) and in other forms,- they may be fabricated from multiple portions to as a whole, have the essential features described herein.

ALTERNATIVE INFILING MATERIAL

In some forms, referencing Fig 38 of PCT/AU2009/000081. the infill may include glass attached to the inner frame 3 by a resilient and/or elastic grommet 211 that acts to support the glass or other material while holding it separate from the inner frame.

iri a unique form, the wing comprises a substantially conventional security door having infilling material supported by an outer frame but where the infilling material comprises polycarbonate sheet attached to the outer frame by any means including a resilient and/or elastic grommet 211 that extends within a peripheral channel of the outer frame, referencing Fig 38 of PCT/AU2009/000081 and where the resilient and/or elastic grommet 211 overlaps the peripheral edge of the polycarbonate sheet

In other forms where the wing is adjustable, referencing Fig 10, the polycarbonate infilling material is formed to Include a return portion 102 as described above that extends sideways to be retained in the continuous offset recess 81 described above, this recess extending substantially the entire periphery of the inner frame. In forms where the infill includes polycarbonate sheet the polycarbonate sheet in some forms includes a multiplicity of apertures and in some forms these apertures are such that the ratio of hole area to total area is between 45 and 55%; in some forms, the apertures have are substantially 3 MM; in some forms the apertures are drilled while in other forms they are or punched.

CENTRALIZlNG/POSITIONING THE INFILL

In some structures, referencing Fig 34,35 the infill 2 may be centrally located in the outer frame or otherwise relatively aligned to suit particular situations or needs. In some structures this is achieved by means of orthogonal joints 120 situated relative to ends of outer frame members, they having a boss 121 that is supported between in the outer and inner edge 21,22 of the respective outer frame member. Each boss 121 includes an axially elongated threaded aperture 123 that supports a threaded fastener 124 (such as a grub screw) that is accessible to enable a tool (such as an Alan key) to be inserted into the fastener drive recess 125 to rotate the fastener to cause it to protrude through an aperture 126 in the outer frame to act on the associated inner frame member 24 to displace the outer frame member 11 away from the inner frame member 24 (not shown). In some forms the boss 121 substantially comprises a fixing block 56 having the pins. 71 ,72 replaced by a single elongated fastener 124.

In some forms, the drive recess 125 is accessible through a coaxial aperture 126 in the outer wall 22 and in some situations, the drive recess 125 (in an inverted fastener) is accessible through a coaxial aperture 127 in the wing 80 and a corresponding recesses 128 and 129 in the base 10 and inner wall 21 respectively - in this case the fastener 124 would always at least protrude Into aperture 128 and the boss 121 would be free to displace in the associated hollow 19. This latter configuration being suitable for window screens and shutters as well as other applications.

Referencing Fig 11, we see an orthogonal joint towards each end of each outer frame member. The fasteners in these may be turned to displace the ends of the outer frame members to their desirable configurations relative to the infill (when the spacers 85 are in-situ); for example the fasteners in either OJ-U/LH and/or OJ-U/RH may be displaced inwardly to lengthen the upper outer frame member 31.

LOCKS. HINGES. α ROLLERS

Where a structure, takes the form of a hinged or sliding door it comprises a structure having a substantially rectangular infill and an outer frame comprising two pair of opposed outer frame members where each outer frame member has associated a adaptable joint and is connected to each outer frame member of the other pair by a corner joint and where the outer frame member corresponding to the closing edge is adapted to support a lock 200. In some forms (and in particular, when the lock is a conventional security door lock) the door is prepared by making an aperture 201 in the outer edge of the outer frame to enable a lock body 202 to be inserted into the outer frame to in-part occupy recess 19 and making apertures 203 in the opposed sides of the outer frame to enable a cylinder 304, a drive rod 305 and handle back plate fixing spigots 306 to extend through the sides of the outer frame; in some cases, these apertures are configured to enable the lock to be fitted either end up so accommodating the door to be fitted either end up (as this is an objective of some of the patents described within).

Being able to Invert the wing, requires the outer frame to have enlarged aperture/s 207 that enable the lock communicating lock components to have passage through the outer frame irrespective of which way up the wing is but with the lock always orientated so that downward action of an unlatching handles causes the bolt to retract. Where the lock comprises a substantially conventional security door lock (or a similar lock) the lock has upper and lower fixing tabs 208 that are. attached within channel 16 by fasteners as would be one leaf of the hinges. These apertures a p re-determined and can be machined or pressed into the outer frame member during manufacture of the door. ft will be appreciated, that because the lock is fixed to the outer frame, it will displace together with the outer frame as the inner frame is displaced relatively to the outer frame during adjustment (if the lock is fitted at that time) and this requires the aperture/s 207 to be even further enlarged to enable the lock communicating lock components to have passage through the outer frame irrespective of how (within the predetermined ranges) the door is adjusted.

In general, the structure may be configured such that the required increase in width is provided by the outer frame opposed side member being displaced to protrude further from their associated channel 15 and in some cases, to protrude an equal distance from their associated channels 6 up to e pre-determined convenient distance and similarly with the height.

Referencing Figs 37 to 40. the apertures in the inner frame 207 can be pre-made as enlarged apertures configured to enable the cylinder, spigots and drive rod to have passage through the Inner frame irrespective of its disposition relative to the outer frame and for the particular structures within the ranges determined by the need for the wing to have outer dimensions (as described previously): height = HD to HD + Delta HD and width = WD to WD + Delta WD.

A!ternativety, once the door has been assembled and adjusted, referencing Fig 40, apertures can be made in the inner frame member (with reference to the apertures in the outer frame) to enable the cylinder, spigots and drive rod to have passage through the inner frame; these apertures can conveniently be made with a conventional hole saw 209 guided by a template attached relative to the outer frame

Where the structure configured as a sliding door, referencing Fig 2, the outer frame member corresponding to the lower edge of the structure will usually be adapted to support a roller 210 and may comprise making spaced elongated apertures 211 to enable the roller assemblies to be inserted into the outer frame. Where the structure configured as a hinged door, referencing Fig 1, the outer frame member opposed to the dosing edge will usually be adapted to support spaced hinges 212 that may comprise making spaced apertures to enable hinge the fixing screws to be attached.

In some forms of wings and being particularly applicable to doors, the inner frame is held spaced from the outer frame in the vicinity of the fixing tabs 302 and the hinges by an adjustable spacer that in some forms comprising an adapted orthogonal joint where aperture 126 has been omitted, to restrict the outer frame from being inwardly displaced as may occur during attempted forced entry.

ADDITIONAL FASTENERS

After the structure has been adapted to suit a particular opening, it can be strengthened by the application of additional fasteners; some being applied to the side/s of the inner frame to extend through and mate in threaded engagement in apertures in the sides of the outer frame - in some cases these being applied towards the upper and lower ends of the structure on both sides; and/or in some cases being applied adjacent to the lock and hinges to lend rigidity to the structure and to amongst other things, to restrict the outer frame from being inwardly displaced relative to the infill as may occur during attempted forced entry; and some such being applied to the edge/s of the outer frame to extend through and mate in threaded engagement In apertures In the edges of the legs 41 , 42 of each corner connector .

A SUBSTANTIALLY RECTANGULAR WING EMPLOYING THE INTEGERS

Notwithstanding any other forms of structures employing combinations of the integers described within this patent specification (that includes the patent specifications included herein by reference) that may fall within the scope of the inventions described herein, a form of one of the inventions comprising: a wing having a substantially rectangular infill and an outer frame comprising two pair of opposed outer frame members where wherein each outer frame member has associated a pair of adaptable comer joints to be relatively displaceabte to change the effective length of the respective outer frame member, each outer frame member being connected to each outer frame member of the other pair by the adaptable corner joint wQI now be described, with reference to the manner in which it can be adapted to suit a particular opening.

Prior to adjustment (and fitting if the structure comprises a door), the wing would be assembled by assembling the outer frame members to the peripheral channel 15 of the inner frame. The wing, referencing Fig 1 , would then be adjusted to suit a particular opening by means including:

• If the wing is further configured to be a door, making the apertures in the outer frame member to receive the lock

· Assembling the outer frame to the inner frame and lightly tapping the outer frame members till they have assumed a configuration corresponding to the smallest extent of the wing.

• Loosely tightening comer fasteners and orthogonal fasteners (while the wing is substantially rectangular)

* Adjusting the length of a particular outer frame members [by mean that may

Include equally rotating fasteners in the closest orthogonal joints in the outer frame members connected to the particular outer frame member] (during which process the associated fixing blocks are. enabled to slide relative to the associated orthogonal fasteners) and progressively tightening the orthogonal fasteners as each outer frame member has its length set

• Skewing the wing as required and then tightening corner fasteners

• If the wing is farther configured as a hinged door, attaching the hinges to outer frame member.

• Cutting the wings of comer wrap covers to length and applying them to occupy the corner surface recesses

• If a lock is required, cutting the apertures in the outer frame member with the hole saw to accommodate the lock by using a template referencing the inner frame.