Note: Descriptions are shown in the official language in which they were submitted.
CA 02474408 2004-07-15
FENESTRATION FRAME ASSEMBLIES AND ASSOCIATED
METHODS
I~~l
TECHNICAL FIELD
fooo2l The present invention generally relates to fenestration products, e.g.,
windows. In particular, certain aspects of the invention relate to
fenestration frame
assemblies with peripheral gutters and associated methods.
BACKGROUND
foooal Increasingly, prefabricated fenestration products, e.g., prefabricated
doors
and windows, are used both in new constn~tion and in renovation of existing
buildings. Prefabricated fenestration products typically are formed for walls
having
a fixed thickness. If the thickness of the wall falls outside of acceptable
tolerances, installation of the window or door can be prd~lematic. This
problem
occurs with some frequency in new construction due to variations in the
15 Jul 04
[Application SL041630025.DOCJ
CA 02474408 2004-07-15
thicknesses and planarity of studs, sheet rock, and other components of the
wall.
This problem becomes particularly acute when installing new fenestration
proa~cts
in older buildings, which typically have a much wider variance in wall
thicknesses
depending on a number of factors, including the age and geographical location
of
the building.
(0004 Some manufacturers have attempted to address the variation in wall
thicknesses in new construction, with varying degrees of success. Baier et
al.,
U.S. Patent No. 5,791,104, the entirety of which is incorporated herein by
reference, suggests a jamb extension assembly for doors and windows. This
assembly employs a multicomponent frame that can be assembled from multiple
components by a manufacturer. The frame includes a jamb extender receiving
slot and a jamb. The jamb includes an extender flange formed of a thin sheet
of
synthetic material that is adapted to be snapped along preformed score lines
to
adjust the length of the extender flange. Variations in wall thicknesses are
accommodated by adjusting the extender flange to the appropriate length by
breaking off a portion of the extender flange along the appropriate score lie.
Unfortunately, this requires that a visible inner portion of the window unit
be
formed of a relatively thin, breakable sheet material. If the window is not
perfectly
rectangular, the jamb extender flange may not precisely align with the
receiving
slot. Particularly with larger window sizes, it can be difficult to shove the
extender
flange into the slot. Attempts to force the extender flange into the slot can
cause
the flange to break along the preformed score lines, largely defeating the
cosmetic
purpose of the jamb extender.
(ooosl Adjustable jamb designs such as the one proposed by Baier et al. can be
even more problematic in retrofit installations in existing buildings. After
the
Second World War, old-style wooden window frames were largely phased out in
new home construction in the United States in favor of prefabricated aluminum
frames. Figure 1 schematically illustrates the basic structural design of such
an
aluminum frame 1. This aluminum frame 1 includes an inner portion 2 designed
to
mount within a "rough" window housing 3 in the wall. The frame 1 also includes
an outer portion 4, which typically has a width (e.g., about 19 millimeters)
about
[Application SL041630025.DOC) -2- 15 Jul 04
CA 02474408 2004-07-15
the same as the width of the inner portion 2. The inner and outer portions 2
and 4,
respectively, of the frame 1 are demarcated at a cross~sectional midpoint of
the
frame 1 by a nailing flange 5 that extends outwardly from the outside
periphery of
the frame 1 to secure the frame 1 to the window housing 3.
looosl The prior art aluminum frames 1 were designed for insttllation into
window
housings 3 made up of 2X4 inch (50 mm X 100 mm) studs 6, or like materials,
covered externally by a sheathing, insulating, or subsiding layer 7 and,
occasionally, a subsill, jamb and header 12a. To install the frame 1, the
frame 1
was partially inserted into the window housing 3 so that the inner portion 2
overlapped the subsill, jamb and header 12a and partially overlapped the stud
6.
To secure the frame 1 within the window housing 3, a nail 10 was then driven
through the nailing flange 5 into the stud 6.
looo~ After installation of the aluminum frame 1 was thus completed, the
outside
of the window housing 3 was "finished" by securing a layer of siding material
11,
such as shingles, to the outer surface of the subsiding layer 7, abutted
agaist an
undersurface of the outer portion 4 of the frame 1 to cover the nailing flange
5.
The inside of the window housing 3 was finished by securing an inner lining
12b,
such as sheet rock or paneling, over the stud 6 and optional subsill, jamb,
and
header 12a of the window housing 3. This inner lining 12b was abutted against
the inside face of the window housing 3 to form a finished interior sill.
Sheet rock
12c or the like was used to knish the interior.
~0008~ Aluminum window frames continued to be widely used in new home
construction in the United States throughout the 1970s, after which they began
to
be phased out in favor of more energy~efficient, durable, and aesthetically
appealing double-paned windows having extruded plastic frames. A large
replacement market for modern plastic frames has developed in recent years,
too.
Accordingly, millions of households across the United States and elsewhere
have
elected to replace existing aluminum frames with more durable, attractive, and
energy-efficient plastic frames.
~ooos~ There are three common methods for retrofit installation of modern
plastic
window frames into finished window housings 3 originally designed for the
prior art
[/lpplicaGon SL041630025.DOCj -3- 15 Jul 04
CA 02474408 2004-07-15
aluminum frames 1. The most common method is to simply remove the old frame
1 in its entirety and install the replacement frame in its place (e.g., with
an inner
portion of the replacement frame seated atop the subsiding layer 7 and a
portion
of the stud 6 abutting, but not overlapping the inner lining 12b) without
modifying
the finished housing. However, modern, double~paned plastic window frames are
considerably wider (one standard width is about 80 mm) than the aluminum
frames (variable, but approximately 38 mm). This increased width is necessary
to
accommodate the double glazing panels and insulating airspace between the
panels. Therefore, when modern plastic frames are installed according to the
above method, the frame protrudes outwardly far beyond the window housing,
creating an awkward external appearance and causing a structurallyundesirable
weight distribution. Such installation methods, although widely practiced, are
discouraged or prohibited by building codes and special utility grants.
loo~o~ A second method for retrofit installation of modern, doublepaned window
frames into finished window housings 3 includes removing the old aluminum
frame
1 and mounting the new frame on top of the existing subsill, jamb, and header
12a
of the window housing 3. Under this alternative method, the installer must
trim
back the lining 12b to accommodate a deeper inset and a more flush external
appearance of the frame. If the frame 1 is mounted on top of the subsill,
jamb,
and header 12a, the installer must trim out the outer portion (i.e., the
subsill, jamb,
and header 12a and subsiding layer 7) of th: window housing 3 with wood or
other
filler material to eliminate gaps between the periphery of the new frame and
the
inner lining 12b and subsiding layer 7. This trimming, which typically
requires a
skilled carpenter at the building site, is expensive and can account for a
large
portion of the total retrofit installation costs.
loop ~~ As a third method, some installers apparently are retrofitting modern
vinyl
frames on top of the existing aluminum main frame by first removing the
existing
sash and fixed lite, rien positioning the new frame in the resulting opening.
Extensive on-site trimming with wood is still required to cover the subsill,
jamb,
and header 12b because of the variable width of the existing aluminum main
frames 1. Typically, the new vinyl frame is butt jointed to a piece of wood
custom
[Application SLl>41630025.DOC] -4- 15 Jul 04
CA 02474408 2004-07-15
ripped on-site to the current width to hide the existing frame 1. Additional
trim
pieces must be custom cut to cover gaps between the new buttjointed liner and
the existing liner, as well as for the outside of he new window. These
activities
are extremely labor intensive and require skilled carpenters, adding
significantly to
the cost of window renovation.
Ioo~2~ Retrofitting window frames into stucco-finished window openings can be
complicated by difficulties in removing the stucco siding layer covering the
nailing
flange of the original frame to allow the original frame to be removed. Unlike
shingles and other siding materials, stucco must be chipped away from the
nailing
flange and cannot be replaced easily after emoval of the old frame. Due to the
high cost of repairing stucco, it is common practice to leave the original
aluminum
frame in place and to mount the replacement frame over the original frame.
This
requires removing any nailing flanges from the replace~nent frame and mounting
the frame within the opening bounded by the original frame after its glazing
panel
and any cross-pieces have been torn out.
100~3~ Furthermore, the increased width of the replacement frame requires a
deep
inset so that the replacement franre can extend inward well beyond the inner
face
of the existing aluminum frame. This mounting arrangement forms a gap between
the inner portion of the replacement frame and the lining portion of the
original
window housing. In current practice, this gap s trimmed with wood or other
material cut on-site to fill or mask the gap, resulting in a significant
increase in total
retrofit installation costs. An additional drawback to this method is that the
replacement frame, seated within the aperture defined by the original frame,
reduces site size and daylight by narrowing the glazing panel aperture height
and
width. To avoid an unsightly external appearance of the window, the frame also
must be modified by a special flange extending peripherally from the outgle of
the
frame to cover the outer face of the original aluminum frame.
100~4~ Another problem commonly associated with conventional retrofit
installations is an inadequate seal between the retrofit window assembly and
the
structure in which it is installed. THs can permit rain or other moisture to
seep
between the new window frame and the preexisting structure. Sometimes, such
[Applicatron S1041630025.DOC] -r'J-
15 Jul 04
CA 02474408 2004-07-15
moisture can seep into direct contact with the walls. With stuccofinished
window
openings, for example, the moisture can lead to d~radation of the stucco or
other
components of the wall.
BRIEF DESCRIPTION OF THE DRAWINGS
loos) Figure 1 is a partial cross-sectional view schematically illustrating a
prior art
aluminum window frame installed in a window housing.
loos) Figure 2 is a perspective view schematically illustrating a portion of a
fenestration frame assembly in accordance with one embodiment, mounted in a
cutaway portion of an existing window housing.
~oo~~ Figure 3 is a schematic partial cross-section of the fenestration frame
assembly shown in Figure 2.
loos) Figure 4 is a schematic partial cross-sectional view of a window frame
assembly in accordance with another embodiment of the invention.
loos) Figure 5 is a schematic isolation view of a portion of the window frame
assembly of Figure 4.
10020) Figures 6A-D are schematic cross-sectional views of the leading edges
of
covers in accordance with different embodiments of the invention.
10020 Figure 7 is a schematic partial cross-sectional view, similar to Figure
4, of a
window frame assembly installed in a window housing ~ accordance with another
embodiment of the invention.
X0022) Figure 8 is a schematic view of a fenestration frame assembly in
accordance with an embodiment of the invention retrofit in a fenestration.
loots) Figure 9 is a schematic cross-sectional view of the fenestraion frame
assembly of Figure 8 taken along line GC.
loo2a) Figure 10 is a schematic cross-sectional view of the fenestration frame
assembly of Figure 8 taken along line D~D.
loots) Figure 11 is a schematic cros~sectional view of a retrofit fenestration
frame
assembly in accordance with another embodiment of the invention.
[Applicafron SL041630025.DOCj -6- 15 Jul D4
CA 02474408 2004-07-15
DETAILED DESCRIPTION
A. OVERVIEW
~oo2s~ Various embodiments of the present invention are directed toward
fenestration assemblies adapted to direct liquid that seeps into the
fenestration
assembly to flow in a channel or gutter instead of leaking into a wall in
which the
fenestration assembly is installed. Other embodiments are directed towards
associated methods for making and/or installing such assemblies. For example,
in
one embodiment a fenestration frane assembly includes a main frame adapted to
support a closure member with respect to a main frame opening. The main frame
can include an external periphery and a peripheral gutter that extends along
at
least a portion of the external periphery of the may frame. The peripheral
gutter
can be positioned to deter liquid from flowing in at least one direction
relative to
the external periphery of the main frame.
1002 In another embodiment, a retrofitted window includes a wall having an
external wall surface and a building aperture in the wall. The building
aperture can
have an inner surface. The retrofitted window can further includes an existing
window frame component installed in the building aperture proximate to the
inner
surface. The existing window frame component can have an inner edge
circumscribing an existing frame aperture smaller than the building aperture.
The
retrofitted window can still further include a main frame at least partially
received in
the existing frame aperture. The main frame cancircumscribe a window opening.
The main frame can also include an outer frame surface, at least a portion of
which is supportively engaged by the inner edge of the existing window frame
component; an external periphery; and a peripheral gutter extending adially
outward from at least a portion of the external periphery. The peripheral
gutter can
be positioned to direct liquid peripherally to limit contact of the liquid
with the
external wall surface proximate to the building aperture.
loo2a~ In yet another embodiment, a method of controlling liquid flow
proximate to
a fenestration frame assembly includes positioning a main frame with respect
to
an aperture in a wall that has an external wall surface. The main frame can
include a main frame opening, an external periphery, and a peripheral gutter
[Application SL041630025.DOC] -7-
15 Jul 04
CA 02474408 2004-07-15
flange extending radially outward from at least a portion of the external
periphery.
The method can further include receiving liquid in the peripheral gutter
flange and
directing the liquid peripherally to limit contact of the liquid with the
external wall
surface proximate to the aperture.
(oo2sl For ease of understanding, the following discussion is subdivided into
two
areas of emphasis. The first section discusses fenestration frame assemblies
in
accordance with certain embodiments of the invention; the second section
discusses fenestration frame assemblies with peripheral gutters in accordance
with other embodiments of the invention.
B. FENESTRATION FRAME ASSEMBLIES
(ooso~ As noted above, aspects of the invention provide fenestation frame
assemblies, which generally include both door frame assemblies and window
frame assemblies. The embodiments illustrated in the drawings and detailed
below focus on window frame assemblies. It should be recognized, however, that
the invention need not be so limited, and some embodiments of the invention
can
encompass door frame assemblies, as well.
1. General
(oos~~ Figures 2 and 3 schematically illustrate a window frame assembly in
accordance with one embodiment of the invention. This particular wialow frame
assembly 100 is shown installed in a retrofit application, in which the window
frame assembly 100 is installed in a finished window housing 3 similar to that
shown in Figure 1. Most of the structure illustrated in Figure 1 remains in
the
installation shown in Figures 2 and 3 and like reference numbers are used in
all
three figures to indicate like structures. In Figures 2 and 3, the glazing (15
in
Figure 1) has been removed from the aluminum frame. This defines an opening
within which a portion of the window frame assembly 100 can be received.
(0032 The window frame assembly 100 generally includes a main frame 110 and
a cover 150. In the following discussion, the right side of Figure 2 will be
generally
referred to as the "front" or "forward" portion of the structure and the left
side of
Figure 2 may be referred to as the "back" or "rearward" portion of the
structure. It
[Application SL041630025.DOC] -8- 15 Jul 04
CA 02474408 2004-07-15
should be recognized that these designations are solely for purposes of
convenience and are not intended to specify any particularorientation with
respect
to the interior or exterior of the building, for example. In accordance with
this
adopted convention, the main frame 110 is disposed rearwardly in the window
housing, and the cover 150 extends forwardly from the main frame 110.
loossl The main frame 110 generally includes an inner periphery 112, an outer
periphery 114, a front surface 116, and a back surface 118. Though only one
leg
of the window frame assembly 100 is shown in Figures 2 and 3, it is
anticipated
that the window frame assembly 100 will extend entirely about the interior
surface
of the window housing 3 defining a closed polygon, e.g., a rectangle, as is
known
in the art.
loosa~ The main frame 110 also includes a confronting periphery 120 that is
disposed immediately adjacent the cc~er 150. This confronting periphery 120
includes a recess 125 that is defined between a confronting edge 122 and a
guide
130. The guide 130 may take a variety of forms. In the embodiment shown in
Figures 2 and 3, the guide 130 comprises an elongated wal that is cantilevered
from the back 126 of the recess 125. A forward lip of the guide 130 defines a
guide surface 132. As explained below, the guide surface 132 may be adapted to
guide the leading edge 162 of a mating projection 160 of the cover 150 irm the
recess 125 during the installation process. If so desired, the guide 130 may
include one or more internal ribs 134. These internal ribs 134 may be adapted
to
engage an outer surface of the mating projection 160 to bias it upwardly
toward
the confronting edge 122 of the main frame 110, presenting a more cosmetically
appealing appearance.
loo3sl The main frame 110 may be formed of a variety of materials. In one
embodiment, the main frame 110 is integrally formed from a polymeric material,
such as an extrudable thermoplastic. In one particular embodiment, the main
frame 110 includes a series of joined legs, each of which is integrally formed
from
an extruded vinyl.
looss~ In one embodiment, the guide 130 and/or its junction to the back of the
recess 125 may be somewhat flexible. As explained below, this can permit the
[Application SL041630025.DOC] -9- 15 Jul 04
CA 02474408 2004-07-15
cantilevered wall that defines the guide 130 to deflect outwardly somewhat
when
joining the cover 150 to the main frame 110. The flexibility of the guide 130
may
be defined, in part, by the materials selected for the main frame 110
(including the
modulus of elasticity of the material), the length of the guide 130 that
extends
forwardly from the back 126 of the recess 125, and the thickness of the guide
130.
In one useful embodiment, the guide 130 isformed of a resilient material, such
as
extruded vinyl, adapted to deflect during installation of the cover 150, yet
allow the
internal surface of the guide 130 (e.g., any internal rib 134 that may be
employed)
to resiliently urge upwardly against the mathg projection 160 of the cover
150.
loose If so desired, a cowling 140 may extend peripherally outwardly from the
back surface 118 of the main frame 110. In the illustrated embodiment, the
cowling 140 is formed separately and is attached to the rest of the mainframe
110
via a conventional accessory groove 142. If so desired, though, the cowling
140
may be integrally formed with the rest of the main frame 110.
loo3s~ The cover 150 generally includes a transverse body 152 that extends
forwardly from the confronting periphery 120 of the main frame 110. The
transverse body 152 may optionally include a casing 158 that extends
peripherally
outwardly from a forward edge of the transverse body 152. The width of the
casing 158 may be varied as desired. In one embodiment, tle casing 158 extends
peripherally outwardly from the forward edge of the transverse body 152
farther
than the greatest width of a retrofit gap 172 expected to be encountered in
retrofit
installations of the window frame assembly 100. The transverse body b2 has an
inner surface 154 that faces toward the interior of the opening, and an outer
surface 156 that is juxtaposed with an interior surface of the inner lining
12b of the
window housing 3. If so desired, the outer surface 156 of the transverse body
1 g
may directly abut the inner surface of the inner lining 12b. In the
illustrated
embodiment, though, the outer surface 156 is spaced from the inner lining 12b,
defining the retrofit gap 172 therebetween.
looss~ The cover 150 may be made from a variety of millwork products including
solid wood (e.g., ponderosa pine), engineered wood fibe+thermoplastic
composites, extruded thermoplastics without fillers, or any other material
[Application SL041630025.DOC]
15 Jul 04
CA 02474408 2004-07-15
conventional in the field of window making. In the illustrated embodiment, the
transverse body 152 and casing 158 are schematically shown as being integrally
formed. In another embodiment, the casing 158 and transverse body 152 are
formed separately and later joined to form the cover 150.
looao~ A mating projection 160 extends rearwardly from the rear edge of the
transverse body 152. The mating projection 160 is sized to be slidably
received in
the recess 125 of the main frame 110. At least the leading edge 162 of the
mating
projection 160 may have a reduced thickness as compared to the thicknessof the
transverse body 152. In the illustrated embodiment, the entire mating
projection
160 is thinner than the transverse body 152, defining a shoulder 164 at the
junction between the mating projection 160 and the transverse body 152. This
shoulder 164 may serve as a stop, abutting the leading edge of the guide 130
to
limit movement of the cover 150 toward the main frame 110. In other
embodiments, the mating projection 160 and transverse body 152 may have the
same thickness.
looa~~ When the cover 150 is installed with respect to the main frame 110, the
leading edge 162 of the mating projection 160 is positioned within the recess
125.
Because the mating projection 160 is slidably received in the recess 125, the
cover 150 and main frame 110 are telescopically adjustable in a transverse
direction to accommodate varying wall widths (W in Figure 3). If the wall is
thicker,
the leading edge 162 may be positioned closer to the front entrance of the
recess
125; if the wall width W is thinner, the mating projection 1 ~ may extend
further
into the recess 125, with the leading edge 162 of the mating projection
positioned
closer to the back 126 of the recess 125.
10042 The length of the mating projection 160 and the depth of the recess 125
can
be varied. In one embodiment, the mating projection 160 has a length greater
than the depth of the recess 125. In another embodiment, the recess 125 is
deeper than the length of the mating projection 160. In still another
embodiment,
the length of the mating projection 160 is about equ~ to the depth of the
recess
125. In one particular example, the depth of the recess 125 and the length of
the
mating projection 160 are both at least about 0.5 inches, e.g., about 0.5- 2
inches.
[Application SL041630025.DOC] -~ ~ - 15 Jul 04
CA 02474408 2004-07-15
In another embodiment, this depth and length are both abort 0.75 - 2 inches.
Having a recess depth and a mating projection length between about 1 inch and
about 2 inches should suffice for most applications. It may be advantageous to
employ a deeper recess 125 and longer mating projection 160 in applications
intended for use in retrofit installations than in new building construction
because
the variability in the wall width W tends to be greater in retrofit
installations than in
new construction.
(0043 As noted above, in the embodiments shown in Figures 2 and 3, thewindow
frame assembly 100 is installed in an existing window housing 3 without
removing
the existing aluminum frame 1. In such an embodiment, the outer periphery 114
of
the main frame 110 may rest on an inner periphery of the aluminum frame 1, at
least along the bottom leg of the window housing 3. Due in part to variations
in the
thickness (or even omission) of the inner lining 12b in different
installations, the
distance between the outer surface 156 of the transverse body 152 and the
inner
surface of the inner lining 12b may vary from one installation to the next.
When
the cover 150 is joined to the main frame 110, there may be a retrofit gap 172
between the cover 150 and the inner lining 12b, as noted above.
(oo4al In one embodiment, the retrofit gap 172 remains open and the cover 150
is
simply spaced from the inner lining 12b around its periphery. In the
illustrated
embodiment, however, a shim or support 170 is disposed in the retrofit gap
172.
The support 170 supportingly engages the outer surface 156 of the cover
transverse body 152 and the inner surface of the inner lining 12b. The support
170 may structurally support the cover 150 between the main frame 110 and the
casing 158, which may be nailed or otherwise attached to the sheet rock 12c of
the wall. The support 170 need not extend around the entire periphery of the
window frame assembly 100. In one particular embodiment, the support 170 is
received in the retrofit gap 172 between the sill and the lower leg of the
cover 150,
but no shim is employed between the cover 150 and the vertically extending
jambs
or the upper header of the window housing 3. The support 170 may support the
lower leg of the cover 150 with respect to the sill if the user places a heavy
object
on the cover 150 or leans or sits on the cover 150, for example.
(Applit~dion s~041630025.DOCj ~~ 2- 15 Jul 04
CA 02474408 2004-07-15
loo4s~ The support 170 may be formed of any desirable material. In one
embodiment, the support 170 comprises a relatively rigid material such as wood
or
a stiff thermoplastic material. In another embodiment, the support 170
compris's
a more resilient material, such as a neoprene foam or the like. In addition to
providing structural support to the cover 150, such a resilient support 170
may
exert an inward bias on the cover 150, pushing the inner surface 154 of the
cover
150 toward the confronting edge 122 of the main frame 110. This can provide a
closer fit between the cover 150 and the main frame 110, enhancing the
cosmetic
appearance of the window frame assembly 100. The support 170 may comprise a
single elongate block or length In another embodiment, a series of separate
supports 170 are spaced along the inner surface of the window housing 3 to
engage spaced-apart locations on the outer surface 156 of the transverse body
152.
~oo4s~ Figures 4-6 schematically illustrate aspects a wincbw frame assembly
200
in accordance with an alternative embodiment. The window frame assembly 200
includes a main frame 210 and a cover 250. The main frame 210 has a
confronting periphery 220 including a recess 225 defined between a confronting
edge 222 and a guide 230. The guide 230 comprises a cantilevered wall
extending forwardly from the back 226 of the recess 225. A forward lip of the
guide 230 is flared outwardly to define an outwardly curved guide surface 232.
As
in the prior embodiment, the gucie 230 may be formed of a somewhat flexible
material that permits the cantilevered guide 230 to deflect and move the guide
surface 232 outwardly away from the confronting edge 222. Although the guide
230 shown in Figure 4 does not include an internal rib(134 in Figure 3), such
an
internal rib could be included on the guide 230.
~004~ The main frame 210 also includes a cowling 240. Unlike the previous
embodiment in which the cowling 140 was formed separately and attached to the
rest of the main frame 110 via an accessory groove 142, the cowling 240 in
Figure
4 is integrally formed with the other elements of the main frame 210, e.g., by
being
part of the same extruded body. In certain embodiments, the cowling 240 may be
sealingly adjoined to the aluminum frame 1 by a bead of a sealant 298, e.g., a
[Applicat'ron SL041630025.DOC] -13- 15 Jul 04
CA 02474408 2004-07-15
silicone caulk or the like. In other embodiments, the sealant 298 may comprise
a
compressible, relatively non-porous neoprene or the like. In still other
embodiments, there is no sealant 298 between the aluminum frame 1 and the
cowling 240.
(oo~~ The cover 250 of the window frame assembly 200 of Figure 4 includes a
mating projection 260 extending rearwardly from a junction with the casing
258. In
this embodiment, the transverse body and the mating projection 260 of the
cm~er
250 are all the same thickness and may be thought of as one continuous
element,
in contrast to the embodiment shown in Figures 2 and 3, in which the shoulder
164
is defined by a change in thickness where the mating projection 160 joins the
transverse body 152.
(oo4s~ The embodiment of Figure 4 also includes a support 270 disposed between
the mating projection 260 and the inner lining 12b of the wall. The support
270
may extend around the entire outer periphery of the mating projection 260,
along
just a lower leg of the mating projection 260 to support the bottom of the
cover 250
with respect to the subsill 12a, or along any other suitable segment of the
outer
periphery of the mating projection 260.
(ooso~ Figure 5 is a schematic isolation view of the confronting perphery 220
of
the main frame 210 and the mating projection 260 of the cover 250 shown in
Figure 4. In Figure 5, the cover 250 and the main frame 210 are still separate
from one another, i.e., they have not been assembled within the window housing
3
to define the completed window frame assembly 200 shown in Figure 4. To
assemble the window frame assembly 200, a leading edge 262 of the cover 250
may be inserted into the recess 225 in the main frame 210, as suggested by the
arrow A. The leading edge 262 may be advanced within the recess 225 toward
the back 226, telescopically adjusting the width of the window frame assembly
200
to accommodate different wall widths.
(oos~~ The cover 250 and recess 225 shown in Figures 4 and 5 include features
that can facilitate assembly of the window frame assembly 200 in place at a
construction site. Ideally, the window housing 3, the main frame 210, and the
cover 250 would all be precisely formed with minimal tolerances to ensure an
easy
[Application SL041630025.DOC] -~ 4- 15 Jul 04
CA 02474408 2004-07-15
sliding entry of the leading edge 262 of the cover 250 into the recess 225. In
reality, the precise alignment of the leading edge 262 with the recess 225 may
be
adversely impacted by a window housing 3 that is not perfectly true or
rectangular,
changes in dimensions of the main frame 210 and/or the cover 250 due to
changes in temperature or humidity, or other factors.
(oos2~ The leading edge 262 shown in Figure 5 is beveled to give it a reduced
thickness compared to the rest of the mating projection 260. If a portion of
the
leading edge 262 deviates inwadly (i.e., upwardly in Figure 5) from the
illustrated
position, the bevel on the leading edge 262 can abut the confronting edge 222
of
the main frame 210. Further urging of the cover 250 toward the main frame 210
will cause the main frame confronting edc,~ 222 to ride up the bevel,
directing the
leading edge 262 into the entrance of the recess 225.
(ooss~ If the mating projection 260 of the cover 250 is displaced outwardly
(i.e.,
downwardly in Figure 5) from the illustrated position, the leading edge 262 of
the
cover 250 will engage the curved, outwardly flared guide surface 232. As the
cover 250 is urged toward the main frame 210, the leading edge will slide
along
the guide surface 232, which will help guide the leading edge 262 of the cover
250
into the recess 225.
(00541 As noted above, the guide 230 may be formed of a somewhat flexible
material adapted to deflect in order to help introduce the leading edge 262
into the
recess 225. As illustrated in Figure 5, the guide 230 may comprise a wall that
is
cantilevered a length t forwardly from the back 226 of the recess 225. By
appropriate selection of materials and this length l, the forward edge of the
guide
230 may deflect outwardly away from the confronting edge 222 as suggested by
the arrow B, and into the retrofit gyp (272 in Figure 4). This will, in turn,
widen the
entrance of the recess 225, further easing introduction of the leading edge
262 into
the recess 225.
(0055 In the embodiment shown in Figure 5, the mating projection 260 of the
cover 250 is sized to have a rebtively close fit in the recess 225. This can
enhance the structural support of the back portion of the cover 250 by the
main
frame 210. This can also help ensure that an inner surface 254 of the cover
250 is
(Application SL041630025.DOC] -15- 15 Jul 04
CA 02474408 2004-07-15
positioned immediately proximate the confrontng edge 222 of the main frame
210,
enhancing the cosmetic appearance of the window frame assembly 200. Such a
close fit makes it more difficult to insert the mating projection 260 into the
recess
225, particularly with larger window sizes. Employing oneor more of a beveled,
reduced thickness leading edge 262, an outwardly flared guide surface 232, and
a
deflectable cantilevered guide 230 can significantly assist in assembling the
window frame assembly in the field by relatively unskilled labor.
looss~ The leading edge 262 of the cover 250 in Figure 5 has a single bevel
adjacent the inner surface 254 of the cover 250. Figures 6AD illustrate the
mating
projections 260a-d, respectively, of covers 250a-d, respectively, in
accordance
with four different embodiment. In the embodiment of Figure 6A, the leading
edge 262a is beveled adjacent the inner and outer surfaces of the mating
projection 260a, but includes a blunt nose between the bevels. The lower bevel
can cooperate with the guide surface (232 in Figure 5)to further assist in
guiding
the cover 250a with respect to the main frame 210. The cover 250b of Figure 6B
includes a leading edge 262b that is generally arrowshaped, with bevels
extending inwardly from the inner and outer surfaces of the mating projeci~n
260b
to meet at a relatively sharp edge. In the embodiment of Figure 6C, the
leading
edge 262c is curved, providing a smooth surface having a minimum thickness at
the rearward extent of the leading edge 262c. The embodiment of Figure 6D
includes an arrow-shaped leading edge 262d similar to the leading edge 262b of
the cover 250b shown in Figure 6B. The mating projection 260d of Figure 6D,
however, also includes a forwardly facing shoulder or barb 263. This shoulder
263
may be useful in conjunction vuth a guide 230 that includes an internal rib,
which
may be similar to the internal rib 134 shown in Figure 3. By engaging the
internal
rib, the shoulder 263 of the leading edge 262d can help retain the cover 250d
in
the recess 225 of Figure 5.
1005 Figure 7 illustrates a window frame assembly 300 in accordance with
another embodiment of the invention installed in a window housing 23 without
an
existing aluminum frame. The window housing 23 may comprise a fenestration in
a newly constructed wall or may be acheved by removing the inner lining and
[Application SL041630025.DOC] -16- 15 Jul 04
CA 02474408 2004-07-15
existing frame (12b and 1, respectively, in Figure 1) in a retrofit
application. The
window housing 23 may include an inner subsill, jamb, and header lining
component 22 defining a polygonal (e.g., rectangular) inner mounting aperture.
The framework of the window housing 23 may include a series of studs 26,
subsiding 27, siding material 31, and an interior surface 24, e.g., sheet
rock.
loossl The window frame assembly 300 includes a main frame 310 and a cover
350. The main frame 310 includes a confronting periphery 320 having a recess
325 defined between a confronting edge 322 and a guide 330. The guide 330
may comprise a cantilevered wall including an angled or curved, outwardly
flared
guide surface 332. The cover 350 includes a mating projection 360 that extends
rearwardly from a peripherally extending casing 358.
looss~ In the illustrated embodiment, a support 370 is disposed between the
mating projection 360 and an interior surface of the window housing, e.g., an
inner
surface of the subsill, jamb, and header lining component 22. Much like the
support 170 in Figures 2 and 3 and the support 270 of Figure 4, this support
270
may help structurally support the mating projection 360 about some or all of
the
periphery of the window opening 23. Unlike a retrofit installation where the
distance between the inner surface of the lining component 22 and the mating
projection 360 of the cover 350 is not known, if the window frame assembly 300
is
employed in new construction, this distar~e is likely more consistent. In such
an
application, it may be advantageous for some or all of the mating projection
360 to
have a thickness equal to that of the mating projection 360 and the support
370
shown in Figure 7, i.e., so an outer peripheral suface of the mating
projection will
extend into direct contact with the inner peripheral surface of the lining
component
22.
looso~ Many of the functional aspects of the window frame assembly 300 of
Figure
7 are functionally similar to features of the window fame assembly 200 of
Figures
4 and 5. One difference between these window frame assemblies 200 and 300 is
that the main frame 310 of Figure 7 includes a nailing flange 312 that extends
peripherally outwardly from the rest of the body 310. This nailing flange 312
may
[Application SL041630025.DOC] -~ 7- 15 Jul 04
CA 02474408 2004-07-15
be attached to a stud 26 or other portion of the window housing 23 via a
plurality of
nails 314 or the like.
2. Methods
loose As noted above, other embodiments of the invention provide methods of
installing fenestration frame assemblies. In the fdlowing discussion,
reference is
made to the particular fenestration frame assemblies shown in the drawings
discussed above. It should be understood, though, that the reference to these
particular fenestration frame assemblies is solely for purposes of iustration
and
that the method outlined below is not limited to any of the fenestration frame
assembly designs shown in the drawings or discussed in detail above.
a. New Window Installations
loos2l One embodiment of the invention provides a method of installinga window
frame assembly. In one particular application of this method, a window frame
assembly is installed in a window housing that is either a new window housing
or
is an existing window housing from which the existing frame (1 in Figure 1)
has
been removed. Certain aspects of this embodiment are discussed in the context
of Figure 7, though any of a variety of other structures may be employed.
loos3~ In accordance with this method, the main frame 310 of the window frame
assembly 300 is positioned with respect to the window housing 23. In
particular,
the main frame 310 is positioned so that at least a portion of the main frame
310
extends into the aperture defined by the window housing 23. In the embodiment
shown in Figure 7, this may include allowing an oute~ surface of the main
frame
310 to rest on an inner surface of the lining component 22 and attaching the
nailing flange 312 of the main frame 310 to a portion of the window housing
23,
e.g., via a plurality of nails 314.
loos4~ The cover 350 is positioned with respect to the window housing 23 and
the
main frame 310. In the context of Figure 7, this may comprise generally
aligning
the mating projection 360 of the cover 350 with the recess 325 in the main
frame
310.
[Application SL041630025.DOCj -~ 8- 15 Jul 04
CA 02474408 2004-07-15
loossl With the cover 350 so aligned, the cover 350 maybe advanced rearwardly,
i.e., to the left in Figure 7. This will insert the reduced thickness leading
edge 362
of the mating projection 360 into the peripheral recess 325 of the main frame
310.
In most typical installations, the guide surface 332 of theguide 330 will
engage the
leading edge 362 of the cover 350 along at least a portion of the length of
the
leading edge 362. For example, if the cover 350 is slightly skewed with
respect to
the peripheral recess 325, portions of the mating projection 360 rtay be
spaced
inwardly from the guide 330, while other portions of the mating projection 360
may
strike the guide 330. The engagement between the leading edge 362 of the cover
350 and the guide surface 332 of the guide 330 will help guide the mating
projection 360 into the recess 325. As discussed above in connection with
Figure
5, for example, the guide 330 may comprise a cantilevered wall that is adapted
to
deflect outwardly away from the confronting edge 322 in response to the force
of
the leading edge 362 against the guide surface 332. This will make the
entrance
of the peripheral recess 325 wider, facilitating entry of the mating
projection 360
into the recess 325.
looss~ The main frame 310 may telescopically receive the mating projection
360,
reducing the distance between the cowling 340 of the main frame 310 and the
casing 358 of the cover 350 until the cowling 340 and casing 358 engage
opposite
sides of the wall. The cover 350 may then be affixed within the window housing
23 with respect to the main frame310, e.g., by attaching the cover 350 to the
main
frame 310 or attaching the casing 358 of the cover 350 to the wall.
b. Retrofit Window Installations
loose In other applications, embodiments of the invention provide methods for
retrofit installation of a window frame assembly in an existing window housing
without requiring removal of an existing window frame. As a preliminary step,
the
method may include preparing an existing window to receive the new window
frame assembly. With an existing window, such as that shown in Figure 1, this
may entail removing the glazing 15 from the existing aluminum frame 1,
defining
an existing frame aperture that is circumscribed by the inner edge of the
aluminum
frame 1.
(Application SL041630025.DOC] -19-
15 Jul 04
CA 02474408 2004-07-15
loos8~ An appropriately sized main frame and cover may then be selected for
installation in the existing frame aperture. In some applications, the main
frame
and cover may be custom manufactured to fit a specific frame aperture in a
specific building. In the context of Figure 4, for example, this may entail
selecfig
a window frame assembly 200 that includes a main frame 210 having an outer
periphery (excluding the cowling 240) sized to be received in the existing
frame
aperture. In one embodiment, the outer periphery of the main frame 210 is
about
the same size as the existing frame aperture so that the main frame 210 will
substantially fill the existing frame aperture.
looss~ The main frame 210 may be positioned with respect to the existing frame
aperture by introducing a front portion of the main frame 210 into the exi~ng
frame aperture. The existing aluminum frame 1 may help support the main frame
210 within the existing frame aperture. Although the existing frame 1 may
engage
the entire outer periphery of the main frame 210, this is not believed to be
necessary. If the outer periphery of the main frame 210 is slightly smaller
than the
existing frame aperture, a lower leg of the main frame 210 may rest on the
inner
edge of the lower leg of the existing frame 1. In the particular embodiment
shown
in Figure 4, this will allow the cantilevered guide 230 to extend above the
inner
surface of the inner lining 12b, leaving room for the front edge of the guide
230 to
deflect outwardly from the confronting edge 222 of the main frame 210, as
discussed above in connection with Figure 5.
loo~o~ The cover 250 may then be positioned with respect to the main frame 210
and the window housing 3 as discussed above. The mating projection 260 of the
cover 250 may then be advanced into the peripheral recess 225 until the casing
258 of the cover 250 engages the inner surface of the wall, i.e., the inner
surface
of the sheet rock 12c in Figure 4. If the main frame 210 is not already in its
intended position, it may also be advanced forwardly within the existing frame
aperture until it is in its desired position, e.g., until the cowling 240
engages the
back surface of the existing frame 1. The main frame 210 and the cover 250 may
then be affixed in position with respect to one another and/or the wall, as
described above.
[Application SL041630025.DOC] -20- 15 Jul 04
CA 02474408 2004-07-15
loo~~~ In the embodiment shown ~ Figure 4, the outer surface of the mating
projection 260 is juxtaposed with, but spaced from, the inner surface of the
inner
lining 12b, defining a retrofit gap 272. In one embodiment, this retrofit gap
272
may be left open about the entire periphery of the cover 250. In another
embodiment, a support 270 may be disposed in the retrofit gap 272 to
supportingly
engage the inner lining 12b and the cover 250, as noted previously. If such a
support 270 is to be employed, the support 270 is advantageously paitioned on
the inner lining 12b before the cover 250 is inserted into the recess 225 of
the
main frame 210. It may be necessary to try several different supports 270
until the
correct thickness is achieved. In one embodiment, this may comprise adding a
series of layers or otherwise adjusting the thickness of the support 270, much
like
one may adjust the thickness of a shim in some other contexts.
Ioo~2~ If the support 270 is formed of a somewhat resilient material, such as
a
neoprene foam or the like, the suppo-t 270 may be positioned along some or all
of
the inner periphery of the inner lining 12b. Thereafter, the cover 250 may be
introduced, with the mating projection 260 compressing the support 270
sufficiently to allow the leading edge 262 of the cover 250 to align with the
entrance of the recess 225. Such a resilient support 270 may urge the mating
projection 260 inwardly along some or all of the periphery of the cover 250.
In
such an application, the reduced thickness leading edge 262 of the cover 250
(which may include a bevel, as noted above), the guide surface 232, and/or
deflection of the cantilevered guide 230 may facilitate entry of the slightly
misaligned mating projection 260 into the recess 225.
C. FENESTRATION FRAME ASSEMBLIES WITH PERIPHERAL GUTTERS
loo~s~ Embodiments of the present invention are directed toward fenestration
assemblies adapted to direct liquid that seeps into the fenestration assembly
to
flow in a channel instead of leaking into the wall. The fenestration assembly
can
be used in any suitable fenestration, but in one embodiment the fenestration
frame
assembly comprises a window frame assembly adapted to be retrofit in an
existing
window opening. The embodiments illustrated in the drawings and detailed below
focus on window frame assemdies retrofitted in an existing window opening. It
[Application SL041630025.DOC] -2 ~ - 15 Jul 04
CA 02474408 2004-07-15
should be recognized, however, that the invention need not be so limited, and
some embodiments of the invention can encompass other types of fenestration
assemblies (e.g., door frame assemblies) and/or offer types of installations
(e.g.,
fenestration assemblies installed in wall apertures that do not have existing
window openings). Peripheral gutters can also be combined with any single
embodiment or combination of embodiments discussed above.
1. General
loo~a~ The fenestration frame assembly 500 of Figure 8 generally includes a
main
frame 510, which may include a confronting periphery 520 and a guide 530. This
confronting periphery 520 and guide 530 may be directly analogous to the
confronting periphery 220 and guide 230 of the window frame assembly 200 in
Figures 4 and 5. In other embodiments, discussed below in further detail, the
guide 530 may be omitted and a more conventional system may be used to finish
the other side of the window housing 3 or other feiestration.
loo~s~ The main frame 510 may also include a cowling 540 that extends
outwardly
to cosmetically cover the pre-existing aluminum frame 1. If so desired, the
cowling
540 may be sealingly adjoined to the aluminum frame 1 by a bead of a sealant
598, e.g., a silicone caulk or the like. In other embodiments, the sealant 598
may
comprise a compressible, relatively non-porous neoprene or the like.
loo~s~ One difference between the window frame assemblies 100 and 200 shown
in Figure 4 and the fenestration frame assanbly 500 shown in Figures 8-10 of
the
present application is the presence of a gutter flange 544. This gutter flange
544
extends radially outwardly from an external periphery of the body of the main
frame 510. In the illustrated embodiment, the gutter f~nge 544 is spaced
forwardly from a forward face of the cowling 540 and may be generally parallel
to
the cowling 540. This defines a peripheral gutter 545 (identified in Figures 9
and
as gutter lengths 545x-d). In other embodiments, the peripheral guter can
have different shapes and/or be formed with different components. For example,
in certain embodiments, the gutter flange 544 and the external periphery of
the
main frame 510 can form the peripheral gutter, without a cowling 540.
[Application SL04163D025.DOC] -22- 15 Jul 04
CA 02474408 2004-07-15
loo~~ Looking at Figure 9, if the seal 598 is defective along the upper
portion of
the structure, water or other fluid can seep past the seal 598. Rather than
being
free to flow into contact with the other components of the wall, though, this
fluid will
be generally retained within the upper gutter segment 545a. Under force of
gravity, the fluid can then be directed down the two vertically extending
gutter
segments 545c and 545d (Figure 10) and flow down into the lower flange,
portion,
or segment 1 a of the existing aluminum fame 1. Such aluminum frames may
already include so-called "weep holes" 560a (Figure 9) to allow any moisture
captured by the frame to flow out of the frame and down the wall. If the pre
existing aluminum frame 1 does not already include weep holes 560a,weep holes
560a may be formed in the lower portion 1a (e.g., by drilling). The
cooperation of
the gutter 545 and the weep holes 560a will direct any fluid that passes
through
the sealant 598 downwardly to the lower segment 1 a and out of the
fenestration
assembly. As a consequence, the likelihood of damaging the rest of the
structure
by moisture inadvertently introduced by a defective seal can be significantly
reduced or eliminated.
loo~s~ In other embodiments, weep holes 560b can be formed in a portion of the
peripheral gutter instead of, or in addition to, the weep holes in the
existing frame
510. In still other embodiments, the assembly does not have weep holes and
fluid
exits the gutters 545 via other routes (e.g., the lower segment 1 a is
configured so
that it does not seal against the cowling 540 and configured so that it does
not
retain liquid). In yet other embodiments, the main frame can have more or
fewer
gutter segments and/or gutter segments that do not extend along the entire
length
of a portion (e.g., a side) of the external periphery of the main frame 510.
For
example, certain embodiments can include the upper gutter segment 545a and
portions of the two vertical gutter segments 545c and 545d, without having a
lower
gutter segment 545b and/or a lower segment 1 a. The various portions of the
fenestration assembly can be formed from any suitable material or combination
of
materials (e.g., wood, plastic, and/or aluminum).
loo7s~ As discussed above, embodiments of fenestration assemblies having
peripheral gutiers have been illustrated using window frame assembly similar
to
[Application SL041630025.DOC] -23- 15 Jul 04
CA 02474408 2004-07-15
the window frame assembly 200 in Figures 4 and 5. However, other embodiments
can use a more conventional system to finish the window housing 3 or other
fenestration. The fenestration frame assembly 600 of Figure 11, for example,
does
not include the guide 530 shown in Figures 4 and 5. (Like reference numbers
are
used in Figures 4 and 11 to indicate like structure.) Instead, the assembly
600
includes a more conventional confronting periphery620.
looso~ Figure 11 also differs from the embodiment of Figures &10 in another
way.
The gutter 545 in Figures 9 and 10 is defined between the cowling 540 and
gutter
flange 544. The embodiment of Figure 11, however, does not include a gutter
flange. Instead, the gutter 645 is defined as a recess or indentation the
external
periphery of the main frame 510. Although the illustrated gutter 645 is an
angular
recess in cross section, the wall defining the gutter may be curved or have
any
other suitable shape.
2. Methods
loose As noted above, other embodiments of the invention provide methods of
installing and/or making the fenestration frame assemblies. In the following
discussion, reference is made to the particular fenestration frame assemblies
shown in the draw~gs discussed above. It should be understood, though, that
the
reference to these particular fenestration frame assemblies is solely for
purposes
of illustration and that the method outlined below is not limited to any of
the
fenestration frame assembly designs shown in the drawings or discussed in
detail
above.
Ioo82~ Certain embodiments of the invention can include methods for installing
fenestration assemblies with peripheral gutters in existing fenestration
assemblies
(e.g., existing window assemblies) or n walls or structures that have an
aperture
without an existing fenestration structure (e.g., a newly constructed
building). For
example, in a retrofit window application, a main frame configured to
circumscribe
(or circumscribing) a window opening can be installed in an existing window
frame
component that is already installed in a building aperture. The main frame can
have a at least one peripheral gutter flange extending radially outwardly from
at
least a portion of the external periphery of the main fame to from at least a
portion
[Application SL041630026.DOC] -24- 15 Jul 04
CA 02474408 2004-07-15
of a peripheral gutter, in accordance with embodiments of the invention
described
above. In other embodiment, a similar main frame assembly can be installed in
a
wall aperture that does not have an existing fenestration assembly.
looss~ Other embodiments can include methods for controlling liquid flow
proximate to a fenestration frame assembly. For example, in one embodiment the
method can include positioning a main frame with respect to an aperture in a
wall
that has an external wall surface. The main frame can include a main frame
opening, an external periphery, and a peripheral gutter flange extending
radially
outward from at least a portion of the external periphery. The method can
further
include receiving liquid in the peripheral gutter flange and directing the
liquid
peripherally to limit contact of the liquid with the external wall surface
proximate to
the aperture.
loosa~ The above-detailed embodiments of the invention are not intended to be
exhaustive or to limit the invenion to the precise form disclosed above.
Specific
embodiments of, and examples for, the invention are described above for
illustrative purposes, but those skilled in the relevant art will recognize
that various
equivalent modifications are possible within the scope of the invention. For
example, whereas steps are presented in a given order, alternative embodiments
may perform steps in a different order. The various embodiments described
herein can be combined to provide further embodiments.
loossl Unless the context clearly requires otherwise, throughout the
description
and the claims, the words "comprise," "comprising," and the like are to be
construed in an inclusive sense as opposed to an exclusive or exhaustive
sense,
i.e., in a sense of "including, but notlimited to." Use of the word "or" in
reference
to a list of items is intended to cover a) any of the items in the list, b)
all of the
items in the list, and c) any combination of the items in the list.
looss~ In general, the terms used in the following claims shuld not be
construed
to limit the invention to the specific embodiments disclosed in the
specification
unless the above-detailed description explicitly defines such terms. In
addition,
the inventors contemplate various aspects of the invention in any nur~ber of
claim
forms. Accordingly, the inventors reserve the right to add claims after filing
the
[Application SL041630025.DOC] -25- 15 Jul 04
CA 02474408 2004-07-15
application to pursue such additional claim forms for other aspects of the
invention.
[Application SL041630025.DOC] -26- 15 Jul 04
