The present invention relates to a process for making a fixture, and a fixture achievable by means of said process. More specifically, the invention can be conveniently used for the manufacturing of other types of doors, windows and/or fixtures that can be installed on buildings and the like, as well as on similar fixtures, for example of the type installed on containment structures typically associated with machine tools, machining centres, and the like.

The fixtures, for example for doors and windows, essentially comprise one or more doors suitably constrained to a fixed chassis which can be anchored at an opening obtained in a wall of a building.

Normally the doors each comprise a framework formed like a perimeter frame, which circumscribes a glass or other stratiform panel, so as to adequately retain it along the perimeter edges.

The fixed chassis is in turn formed like a perimeter frame circumscribing the door and complementarily shaped, and is equipped with anchoring brackets that allow the fixing of the fixture to masonry works. Door and fixed chassis are also usually provided with other connection accessories, for example hinges mutually engageable to determine a rotatable connection between the door and the fixed chassis, and/or closing mechanisms for their mutual fixing in the closing condition.

Currently the perimeter frames that outline the door and the fixed chassis are made by means of segments usually obtained by cutting to size a continuous section bar, and subsequently assembled with each other. The materials commonly used are wood, aluminium or other metal material, as well as plastic materials such as PVC.

These construction techniques allow a certain operational flexibility for the manufacturing of fixtures of different sizes but, for example, significantly affect the possibility of making fixtures with different shapes from the classic rectangular or polygonal profile, without significantly penalizing the construction costs.

US5061531 A proposes the moulding of a polyurethane frame around a multi-layer glass panel, in partial replacement to various mechanical and vacuum sealing systems otherwise required for fixing the glass panel itself to the frame.

The frame can be formed so as to present a protruding flange portion, which offers a surface to allow the fixing of additional covings, for example by means of nails or clips.

However, the proposed solution is appropriate exclusively to the installation of fixed glass walls. It is not foreseen to provide the polyurethane frame with structural support functions in a fixture with openable door as a whole.

The aim of the present invention is to overcome the limits of the state of the art, proposing a process that allows the use of moulding techniques of polyurethane material for the manufacturing of fixtures with doors.

More specifically, it is an object of the invention to propose a production process that allows to remove the current design constraints in the manufacturing of fixtures with doors of various shapes and sizes, also with profiles other than the polygonal shape.

Object of the invention is also to propose a production process which allows to obtain fixtures with frames of polyurethane material, which have a simple structure and high reliability in terms of structural strength.

A further object of the invention is to offer a process that allows the manufacturing of fixtures in a simple and inexpensive way, which also lends itself to simplifying the operations required for installation purposes. These objects and others, which will become clearer in the course of the present disclosure, are substantially achieved by a process for the manufacturing of fixtures as defined in claim 1.

In accordance with a further aspect, the invention proposes a fixture according to claim 1. The manufacturing of the frames by forming inside a mould offers, both in relation to the fixtures and in relation to the buildings to which they are applied, a freedom of architectural design not available with current production systems through the assembly of pieces of section bars. In fact, windows having any desired perimeter development, for example circular, elliptical and/or at least partially defined by one or more curvilinear portions connected to each other can be made, without significantly affecting production costs.

The absence of mutual connection elements between different pieces of the frame, and the lack of need to provide spaces for their housing, also allows an advantageous containment of the frame dimensions, to the advantage of the width of the glass surface available in the window.

In at least one preferential embodiment, the invention can also comprise one or more of the following preferential characteristics.

Preferably, the manufacturing of said door further comprises the action of positioning in the mould, before introducing the polyurethane material, a stratiform panel having perimeter edges protruding inside the moulding cavity, so that the perimeter edges are embedded in the perimeter frame formed from expanded and crosslinked polyurethane material.

Preferably, before the introduction of the polyurethane material, said connection accessory has at least a first portion extending inside the moulding cavity to be incorporated in the polyurethane material, and a second portion counter-shaped to the engagement seat to face or protrude externally from the perimeter frame formed by expanded and crosslinked polyurethane material.

Preferably, said connection accessory comprises at least one fixing insert which can be removably engageable with the engagement seat.

Preferably, said connection accessory comprises at least one half-hinge. Preferably, said half-hinge comprises a hinge portion engageable in the engagement seat, and a bracket protruding into the moulding cavity.

Preferably, said connection accessory comprises at least a closing mechanism having at least a latch movable upon the action of a control linkage.

Preferably, the closing mechanism is engaged in the moulding cavity with the latch engaged in the respective engagement seat.

Preferably, the latch is defined by a rod end movable longitudinally upon the action of the control linkage.

Preferably, a release agent is applied at least on the rod before the introduction of the polyurethane material into the moulding cavity.

Preferably, in the manufacturing of the door, said at least one connection accessory comprises at least one door half-hinge operatively couplable with a chassis half-hinge carried by the fixed chassis.

Preferably, in the manufacturing of the fixed chassis, said at least one connection accessory comprises at least one chassis half-hinge operatively couplable with a door half-hinge carried by the door.

Preferably, in the manufacturing of the fixed chassis, said at least one connection accessory comprises an anchoring bracket having a first portion extending inside the moulding cavity to be incorporated in the polyurethane material, and a second portion counter-shaped to the engagement seat to protrude externally the perimeter frame formed by the expanded and crosslinked polyurethane material.

Preferably, in the manufacturing of the fixed chassis, said at least one connection accessory comprises a grafting bushing protruding into the moulding cavity and having a recess engageable with the engagement seat of the mould.

Preferably, the perimeter frame of at least one of said door and fixed chassis is made in a single piece.

Preferably, the connection accessory carried by at least one of said door and fixed chassis, has at least a first portion incorporated in the polyurethane material, and a second portion operatively engageable with the connection accessory of the other of said door and fixed chassis.

Preferably, the first portion of the connection accessory comprises at least one fixing insert which can be removably engageable with the second portion.

Preferably, said fixing insert comprises at least one grafting bushing.

Preferably, the first portion of the connection accessory comprises a bracket integral with the second portion.

Preferably, the connection accessory carried by one of said door and fixed chassis is a half-hinge operatively engageable with a half-hinge carried by the other of said door and fixed chassis.

Preferably, said connection accessory comprises at least a closing mechanism having at least a latch movable outside the frame upon the action of a control linkage at least partially incorporated in the polyurethane material.

Preferably, the latch is defined by a rod 1 end incorporated in the polyurethane material and movable longitudinally upon the action of the control linkage along a sliding seat defined in the polyurethane material. Preferably, the closing mechanism further comprises a box-shaped casing which encloses the control linkage.

Preferably, said at least one connection accessory carried by the fixed chassis comprises an anchoring bracket having a first portion incorporated in the polyurethane material, and a second portion protruding outside the perimeter frame of polyurethane material.

Preferably, said at least one connection accessory carried by the fixed chassis comprises a grafting bushing incorporated in the polyurethane material and having a recess which can be engaged by the latch.

Preferably, the fixed chassis has at least one collection compartment connected to a drainage pipe formed through the perimeter frame.

Preferably, the perimeter frame of at least one of said door and fixed chassis has, along its perimeter development, rectilinear portions mutually interconnected by connecting portions with an arched profile.

Further features and advantages will become more apparent from the detailed description of a preferred, but not exclusive, embodiment of a process for the manufacture of a fixture, and of a fixture which can be obtained by said process, in accordance with the present invention.

Such description will be set forth hereinafter with reference to the accompanying drawings given only for illustrative and, therefore, non limiting purpose, wherein:

- figure 1 represents a front view of a fixture made according to the present invention;

- figure 2 is a section carried out according to the line ll-ll of figure 1 ;

- figure 3 is a section carried out according to the line Ill-Ill of figure 1 ;

- figure 4 is a section carried out according to the line IV-IV of figure 1 ;

- figure 5 is a section carried out according to the line V-V of figure 4;

- figure 6 shows a mould for the manufacturing of a door, in an open condition with connection accessories positioned at respective engagement seats;

- figures 7a, 7b and 7c show the portions indicated with "VII" of the mould of figure 6 with the respectively semi-open mould with the half-parts in the approaching phase, in closing condition filled with polyurethane material, and in open condition when moulding is completed;

- figures 8a, 8b and 8c show the portions indicated with "VIII" of the mould of figure 6 with the respectively semi-open mould with the half-parts in the approaching phase, in closing condition filled with polyurethane material, and in open condition when moulding is completed;

- figure 9 shows a mould for the manufacturing of a fixed chassis, in an open condition with connection accessories positioned at respective engagement seats;

- figures 10a, 10b and 10c show the mould portions indicated with "X" in figure 9, with the respectively semi-open mould with the half-parts in the approaching phase, in closing condition filled with polyurethane material, and in open condition when moulding is completed;

- figures 1 1 a, 1 1 b and 1 1 c show the mould portions indicated with "X" in figure 9, with the respectively semi-open mould with the half-parts in the approaching phase, in closing condition filled with polyurethane material, and in open condition when moulding is completed.

With reference to the accompanying figures, 1 generally indicates a fixture that can be manufactured according to the present invention. In the illustrated example, the fixture 1 is intended for manufacturing a window. However, the invention can be conveniently used to manufacture different types of fixture, for example for internal or external doors.

The fixture 1 essentially comprising a fixed chassis 2 configured to be rigidly engaged at an opening (not shown) arranged in a wall of a building. At least one door 3 is oscillatably constrained to the fixed chassis 2.

The fixed chassis 2 includes a perimeter frame of polyurethane material, hereafter also called chassis frame 2a, carrying one or more connection accessories "A" designed to determine a mechanical connection between the fixed chassis itself and the door 3 and/or the masonry parts of the building. In the present disclosure, the connection accessories carried by the fixed chassis 2 will also be called frame connection accessories "A". In the illustrated example, the frame connection accessories "A" comprise one or more chassis half-hinges 4, configured for the operational engagement with the door 3. The frame connection accessories "A" can further comprise one or more grafting bushings 5 rigidly carried by the chassis frame 2a, and each having a recess 5a open towards the inside of the perimeter development of the frame itself.

The frame connection accessories "A" may include other parts, such as for example one or more anchoring brackets (not shown) configured for the engagement with the masonry parts of the building.

In the fixed chassis 2, near a lower side thereof, at least a collection compartment 6 can also be present connected to a drainage pipe 7 obtained through the chassis frame 2a, to discharge outside any rainwater, condensation or other elements collected within the perimeter development of the fixed chassis 2.

The door 3 in turn has a perimeter frame of polyurethane material, also identified hereinafter as door frame 3a, circumscribed by and counter shaped to the fixed chassis 2. The door frame 3a in turn circumscribes a stratiform panel 8 consisting, for example, of one or more glasses arranged parallel at a short distance from each other.

The door frame 3a, as well as the chassis frame 2a, can advantageously present along a perimeter development thereof, rectilinear portions mutually interconnected by connecting portions with an arched profile. In the accompanying figures, the connecting portions arranged respectively on the frame 2 and on the door 3 are marked respectively with 2b and 3b. The presence of the connecting portions considerably reduces the risk of accidents following impacts in correspondence of the corners, and facilitates cleaning operations.

In this way, sharp corners are eliminated which can represent a danger of accidents due to any impact, and/or unwanted points of accumulation of dirt that cannot be easily removed during cleaning operations.

The door frame 3a carries respective connection accessories "B" designed to connect the door 3 with the fixed chassis 2, preferably cooperating with the frame connection accessories "A". In the present disclosure, the connection accessories carried by the door 3 will also be called door connection accessories "B".

In the illustrated example, the door connection accessories "B" comprise one or more door half-hinges 9 which can be operatively engaged each with one of the chassis half-hinges 4, so as to rotatably constrain the door 3 with respect to the fixed chassis 2.

The door connection accessories "B" also comprise at least a closing mechanism 10 having a latch 11 movable outside the door frame 3a, upon the action of a control linkage 12 at least partially incorporated in the polyurethane material constituting the door frame 3a. In the illustrated example two latches 11 are provided, protruding from opposite parts with respect to the door frame 3a. Preferably, the control linkage 12 is enclosed in at least one protective box-shaped casing 13, facing against an internal wall of the moulding cavity "C". The latch 1 1 is defined by a rod 1 1 a end movable longitudinally upon the action of the control linkage 12. The box shaped casing preserves the internal mechanisms from contact with the polyurethane material, ensuring the control linkage functionality. In the illustrated example, the box-shaped casing 13 also encloses the rod 1 1 a. Alternatively, the rod 1 1 a can be engaged along a sliding seat defined in the polyurethane material constituting the door frame 3a.

When the door 3 is approached in closing condition against the fixed chassis 2, the movement of the rod 1 1 a determines the insertion and disconnection of each latch 1 1 from the recess 5a arranged in the respective grafting bushing 5 carried by the fixed chassis 2, so as to determine the locking and unlocking, respectively, of the door 3 with respect to the fixed chassis 2.

The door frame 3a and the fixed chassis frame 2a, or at least one of them, are advantageously manufactured of polyurethane material, preferably in a single piece, and at least partially incorporate each of the respective door connection accessories "B" and/or frame connection accessories "A".

More particularly, as exemplified in figure 2, each of the door half-hinges 9 and/or chassis half-hinges 4 can for example comprise a fixing insert "K" incorporated in the polyurethane material constituting the door frame 3a and/or the chassis frame 2a. As schematically shown in the accompanying drawings, the fixing insert "K" can be made in the form of a plate-shaped bracket, at least partially incorporated in the polyurethane material and possibly shaped to ensure an effective retention within the polyurethane material itself. In a possible embodiment not shown, at least one of the fixing inserts "K" can comprise one or more threaded bushing operatively engageable by respective threaded members for fixing the door half-hinge 9 or the chassis half-hinge 4 to the respective door frame 3a or chassis frame 2a.

More particularly, as exemplified in figure 1 , each of the door half-hinges 9 and/or chassis half-hinges 4 can comprise for example a respective hinge portion "H" protruding from the respective door frame 3a or chassis frame 2a, and rigidly carried to one or more of the fixing inserts "K" incorporated in the polyurethane material constituting the frame itself.

The closing mechanism 10 can be entirely incorporated in the polyurethane material constituting the door frame 3a, with the exception of the rod 1 1 a end carrying the latch 1 1 , which comes out of the frame itself to engage in the grafting bushing 5, in turn at least partially incorporated in the polyurethane material composing the chassis frame 2a. Preferably, on the obtained door 3, the closing mechanism 10 can be at least partially accessible, at least in correspondence with the control lever 12, from at least one side of the door frame 3a, for the possible engagement of a control knob.

In accordance with the present invention, the manufacturing of the fixture 1 preferably provides that for each of said fixed chassis 2 and door 3 a respective mould "S" is arranged, defining a moulding cavity "C" counter shaped to the respective chassis frame 2a or door frame 3.

In the mould "S" one or more engagement seats "G1...G5" are defined, communicating with the moulding cavity "C", and each arranged to accommodate one of the frame connection accessories "A" or one of the door connection accessories "B", respectively.

In the example of figures 6 to 8c, which represent a mould "S" for manufacturing door 3, one or more first engagement seats "G1 " are provided to accommodate the fixing inserts K of the door half-hinges 9, and at least a second engagement seat "G2" to accommodate the closing mechanism 10, and possibly one or more third engagement seats (not visible in the figure to accommodate each of the latches 1 1 ). In figures 9 and 1 1 c, which represent a mould "S" for manufacturing the fixed chassis 2, one or more fourth engagement seats "G4" are provided to accommodate the fixing inserts K of the chassis half-hinges 4, and at least a fifth engagement seat "G5", made for example in the form of a pin, to accommodate the grafting bushing 5. One or more further engagement seats may be provided as well, each configured to accommodate at least partially one of the anchoring brackets or other accessories.

In the mould "S" dedicated to the manufacture of door 3, the stratiform panel 8 formed by the glass is also positioned. This stratiform panel 8 will have its perimeter edges protruding inside the moulding cavity "C".

Each of the chassis connection accessories "A" and the door connection accessories "B" is positioned on the respective engagement seat "G1...G5". More particularly, the closing mechanism 10 can be engaged inside the moulding cavity "C" with the latches 1 1 in insertion relation in the respective engagement seats.

In other words, after positioning, each connection accessory "A", "B" will have at least a first portion (in particular the fixing inserts "K", the radially external portion of the grafting bushing 5, the box-shaped casing 13 and/or the rod 1 1 a of the closing mechanism 10) protruding inside the moulding cavity "C" to be incorporated in the polyurethane material, and a second portion counter-shaped to the respective engagement seat "G1...G5" (in particular the hinge portions "H", the recess 5a of the grafting bushing 5, the latches 1 1 ), which is appropriate to face or protrude externally from the respective chassis frame 2a or door frame formed by the expanded and crosslinked polyurethane material.

If the rods 11 a are to be incorporated in the polyurethane material in absence of the respective parts of box-shaped casing 13, the closing mechanism 10 can be treated with a release agent applied at least on the external surfaces of the rod 1 1 a, before or after positioning on the respective engagement seat "G2". This release agent, in a per se known manner, can also be applied on the internal surfaces of the mould "S", defining the moulding cavity "C" to facilitate its opening and the product removal when moulding is completed. After positioning the connection accessories "A" or "B" on the respective engagement seats "G1...G5", the mould "S" is closed so that the moulding cavity "C" is substantially isolated from the external environment. Then, for example through suitable pipes arranged in the mould "S", the introduction of an appropriate quantity of polyurethane material in the moulding cavity "C" is carried out.

In a per se known manner, the polyurethane material expands and reacts creating crosslinking molecular bonds inside the moulding cavity "C", so as to fill the internal volume of the moulding cavity itself to give rise to the perimeter frame 2a which incorporates at least partially each of the connection accessories "A" or "B".

After crosslinking, the mould "S" can be opened to extract the door 3 or the fixed chassis 2 obtained. The door 3 and the fixed chassis 2 are appropriate to be mutually connected by means of the respective half hinges, to create a finished fixture 1.