Note: Descriptions are shown in the official language in which they were submitted.
CA 02483721 2004-09-28
METHOD OF AND SYSTEM FOR
THE MANUFACTURE AND INSTALLATION OF
PREFABRICATED WINDOW TRIM AND CASING SYSTEMS
INCLUDING AN ADJUSTABLE CUTTING GUIDE
FIELD OF THE INVENTION
This invention relates to the field of window trims and casings. More
particularly, this invention relates to a method of and system for the
manufacture and
installation of prefabricated window trim and casing systems, whereas the
apparatus
for installing includes an adjustable cutting guide.
BACKGROUND OF THE INVENTION
Often it is desired to trim and case a window opening, on its interior side,
in
various manners through the use of jambs, headers, sills, stools, casings, or
aprons.
Window trim and casings serve to increase the beauty and the energy efficiency
of
window units. Further, the window trim and casings enhance the practical
usefulness
of the sill or stool area of the window units and are typically installed
during new
construction of a building or during replacement of existing windows.
During new construction, a window trim and casing is installed around a
rough opening formed within and defined by the frame of a building structure.
In
retrofit applications, replacement window trim and casings are often installed
around
an existing window opening, either during renovation of the structure or
during
replacement of the structure's windows.
Current window trim and casings used in new and retrofit applications require
a great degree of skill and time to measure, custom fabricate, and install.
Under
current practice, trimming and casing interior window openings require a
skilled
finish carpenter working at a job-site to individually measure, cut. fit, and
install each
individual piece of trim and casing for each individual window opening. This
current
process has numerous disadvantages including: (1 ) the high hourly cost of a
finish
carpenter; (2) the great amount of time required to carry out this procedure
for each
CA 02483721 2004-09-28
individual window opening; (3) the entire procedure must be performed at the
job-
site, often an occupied residence, disrupting the normal routine, order, and
cleanliness
of the job-site for an extended period of time; (4) due to varying skill
levels and
output productivity of finish carpenters, there are variations in quality and
efficiency
of the end result; (5) the time and cost associated with the need to smooth,
square, or
otherwise prepare the sides and face of the window opening for the proper
acceptance
of the trim and casing components; and (6) the sawdust, discarded materials,
and
refuse created as a result of carrying out this process at the job-site.
SUMMARY OF THE INVENTION
A method of and apparatus for installing prefabricated window trim and
casing systems including an adjustable cutting guide apparatus is disclosed.
The
current invention allows for the accurate, repeatable manufacture of window
trim and
casing assemblies in a controlled manufacturing environment on a high
production
1 S and high quality basis. The current invention also provides a quick,
simple, clean,
accurate, and economical method of installing the prefabricated window trim
and
casing apparatus into the interior side of any window opening. The preferred
prefabricated window trim and casing apparatus is a decorative molding for
interior
applications and comprises a casing subassembly configured to cover a window
opening and a customizable jamb subassembly coupled to the rear of the casing
subassembly. The casing subassembly is preferably configured to cover a window
opening in an interior wall. The customizable jamb subassembly comprises a
customizable jamb depth and is configured to be inserted into the window
opening
and fastened to the wall.
The customizable jamb subassembly allows custom installation of the window
trim and casing into window openings with unique jamb depth dimensions. The
unique dimensions are a result of typical construction variations such as, for
example,
variations in overall wall thickness, plastering, window frame positioning,
window
design/style variations, and window manufacturing tolerances. The jamb depth
dimension varies, in some cases, by inches from one window opening to the
next.
The current invention provides for a method, useable at the job-site, for
quick, simple,
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accurate, and economical customization of the jamb depth dimension of the
prefabricated window trim and casing apparatus to match that of the window
opening
into which the assembly is to be installed.
An adjustable cutting guide apparatus used for customizing and installing the
prefabricated window trim and casing apparatus is also disclosed. The
preferred
adjustable cutting guide apparatus comprises a guiding region, with the
guiding region
comprising a fenestrated planar deck. The adjustable cutting guide apparatus
is
configured to detachably couple to a base plate of a portable power cutting
tool,
preferably an electric saw comprising a cutting region, such that the guiding
region is
positioned outside of, and not interfering with, the cutting region.
Specifically, the
guiding region is configured to detachably couple through the base plate of
the
electric saw, preferably through mounting slots. The mounting slots allow the
adjustable cutting guide apparatus to couple with base plates of various
portable
power cutting tools. The guiding region is configured to rest against the
customizable
jamb subassembly of the prefabricated window trim and casing apparatus. Once
coupled, the planar deck and the guiding region configures the cutting region
so the
cutting region aligns the blade of the electric saw with the customizable jamb
subassembly and the blade evenly trims the customizable jamb subassembly to a
desired thickness.
Preferably, the prefabricated window trim and casing apparatus comprises
wood. In alternative embodiments, the prefabricated window trim and casing
apparatus comprises polyvinyl chloride. In further alternative embodiments,
the
prefabricated window trim and casing apparatus comprises fiberglass. In yet
other
embodiments, the prefabricated window trim and casing apparatus comprises
insulating material providing for greater heat gain protection and energy
efficiency.
The configuration of the prefabricated window trim and casing apparatus varies
to
meet the needs of the consumer, the particular end use application, or the
type of
installation to be used also in a hollow configuration. For example,
embodiments of
the prefabricated window trim and casing apparatus include, but are not
limited to,
picture frame, full-bound, double-hung, rectangular, full casing, or awning
configurations.
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In addition to the prefabricated window trim and casing apparatus discussed
above, a window trim and casing system is disclosed. The system comprises a
customizable jamb subassembly and an adjustable cutting guide apparatus. The
customizable jamb subassembly is preferably prefabricated and comprises a
length, a
width, and a depth. The depth of the customizable jamb subassembly is trimmed
to a
custom size. The customizable jamb subassembly is configured to be trimmed to
the
custom size, inserted into an opening in a wall, and fastened to the opening
in the
wall. The custom size depends on the particular end use application and field
dimensions, but is preferably the approximate distance between the outer edge
of an
opening in the wall and the frame of a window contained within the opening.
The
adjustable cutting guide apparatus is preferably configured to mount to a
portable
power cutting tool and allows the portable power cutting tool to trim the
customizable
jamb subassembly to the custom size.
Further, a method of installing a prefabricated window trim and casing
apparatus having a customizable jamb subassembly with a jamb depth is also
disclosed. The method comprises first determining a jamb depth. Preferably,
the
jamb depth comprises a deepest of depth measurements from a window to a wall.
After determining the jamb depth, a jamb depth mark is marked on the
customizable
jamb subassembly of the window trim and casing apparatus. Following marking of
the jamb depth mark on the customizable jamb subassembly, an adjustable
cutting
guide apparatus is mounted to a portable power cutting tool with a blade. The
portable power cutting tool with a blade is preferably an electric circular
saw and the
preferred blade is a finish blade. The adjustable cutting guide apparatuses
aligned
such that the blade of the portable power cutting tool is aligned with an
outside edge
of the jamb depth mark and is configured to cut the customizable jamb
subassembly
to a customized depth. The blade is preferably adjusted to a blade depth not
more
than 1 /16 of an inch greater than the thickness of the customizable jamb
subassembly.
Finally, the portable power cutting tool is used to trim all sides of the
customizable
jamb subassembly to the jamb depth. The trimming of the customizable jamb
subassembly to the jamb depth dimension as described above allows the exposed
edge
(i.e. the edge not coupled to the casing subassembly) of the customizable jamb
frame
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subassembly to rest flush against the frame of an installed window while
simultaneously allowing the rear surface (i.e. the surface not visible from
the interior
when installed into a window opening) of the casing subassembly to rest flush
against
the wall surrounding the window opening.
In other embodiments, the installation method described above further
comprises the steps of positioning the window trim and casing apparatus into a
window opening and securing the window trim and casing apparatus into the
window.
Additional steps in alternative embodiments include blocking below a window
stool
to center the window trim and casing apparatus vertically against the window
opening
and centering the window trim and casing apparatus horizontally. Also, an
additional
step includes nailing an apron against the wall and under the stool.
The adjustable cutting guide apparatus is preferably detachably coupled to the
portable power cutting tool through a base plate of the portable power cutting
tool by
at least one butterfly nut and complementary fastener and washer. In
alternative
embodiments, the adjustable cutting guide apparatus is coupled through the
base plate
by at least one quick release nut and complimentary fastener.
A method of manufacturing a prefabricated window trim and casing system is
also disclosed. The method of manufacturing comprises first fabricating a
casing
subassembly comprising a front and a rear. The casing subassembly is
preferably
configured to cover an opening in an interior wall. Next, a customizable jamb
subassembly is fabricated. Finally, the customizable jamb subassembly is
coupled to
the rear of the casing subassembly. As described above, the customizable jamb
subassembly is configured to be customized to a desired depth, inserted into
the
opening, and fastened to the wall. Further, the prefabricated window trim and
casing
apparatus preferably comprises wood, but in alternative embodiments, comprises
polyvinyl chloride, fiberglass, or insulating material.
The invention addresses the shortcomings of current methods of trimming and
finishing window openings and provides a cost effective, easier, higher
quality, and
attractive method and apparatus for installing prefabricated window trim and
casing
systems.
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BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 A illustrates a front view of a prefabricated window trim and casing
apparatus, in accordance with the instant invention.
FIG. IB illustrates a rear view of the prefabricated window trim and casing
apparatus, in accordance with the instant invention.
FIG. 1 C illustrates an isometric view of the prefabricated window trim and
casing apparatus illustrated in FIGS. lA-B, in accordance with the instant
invention.
FIG. ID illustrates a front view of an alternate embodiment of the
prefabricated window trim and casing apparatus, in accordance with the instant
invention.
FIG. IE illustrates a rear view of an alternate embodiment of the
prefabricated
window trim and casing apparatus, in accordance with the instant invention.
FIG. IF illustrates an isometric view of an alternate embodiment of the
prefabricated window trim and casing apparatus illustrated in FIGS. 1D-E, in
accordance with the instant invention.
FIG. 2 illustrates an isometric view of an exemplary method of measuring the
jamb depth of an existing opening, in accordance with the instant invention.
FIG. 3 illustrates an isometric view of an exemplary method of marking the
jamb depth, as measured in FIG. 2, onto the prefabricated window trim and
casing
apparatus, in accordance with the instant invention.
FIG. 4A illustrates a top view of an adjustable cutting guide apparatus for
installing a prefabricated window trim and casing apparatus, in accordance
with the
instant invention.
FIG. 4B illustrates a side view of the adjustable cutting guide apparatus for
installing a prefabricated window trim and casing apparatus shown in FIG. 4A,
in
accordance with the instant invention.
FIG. 4C illustrates an isometric view of the adjustable cutting guide
apparatus
for installing a prefabricated window trim and casing apparatus shown in FIG.
4A, in
accordance with the instant invention.
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FIG. 5 illustrates a perspective view of an exemplary method of attaching the
adjustable cutting guide apparatus shown in FIGS. 4A-C to a portable power
cutting
tool, in accordance with the instant invention.
FIG. 6 illustrates a perspective view of the portable power cutting tool, with
the adjustable cutting guide apparatus shown in FIGS. 4A-C attached, trimming
the
customizable jamb subassembly of the prefabricated window trim and casing
apparatus shown in FIG. 1 A, in accordance with the instant invention.
FIG. 7 illustrates an exemplary flow chart detailing a method of installing a
prefabricated window trim and casing, apparatus having a customizable jamb
subassembly, in accordance with the instant invention.
FIG. 8 illustrates an exemplary flow chart detailing a method of manufacturing
a prefabricated window trim and casing apparatus, in accordance with the
instant
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Embodiments of the presently disclosed invention provide for a method of and
system for the manufacture and installation of prefabricated window trim and
casing
systems including an adjustable cutting guide.
FIGS. lA-C illustrate various views of a prefabricated window trim and casing
apparatus 100, in accordance with the instant invention. It should be
understood that
the prefabricated window trim and casing apparatus illustrated in FIGS. 1 A-C
is only
one possible embodiment of the prefabricated window trim and casing apparatus
100.
Specifically, FIG. 1 A illustrates a front view of a prefabricated window trim
and casing apparatus 100, in accordance with the instant invention. The front
view
illustrates the portion of the prefabricated window trim and casing apparatus
100
visible from the interior when installed into a window opening. In other
words, when
installed, the front of the window trim and casing apparatus 100, as
illustrated in FIG.
1 A, is the visible portion of the window trim and casing apparatus 100. The
preferred prefabricated window trim and casing apparatus 100 is a decorative
molding
for interior applications and comprises a casing subassembly 110. The casing
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subassembly 110 is configured to cover a window opening 210 (FIG. 2)
comprising a
window unit 220 (FIG. 2) and a window frame 221 (FIG. 2) in a wall 215 (FIG.
2).
The prefabricated window trim and casing apparatus 100 further comprises a
customizable jamb subassembly 120 (FIG. IB). The customizable jamb subassembly
120 (FIG. IB) is coupled to the rear of the casing subassembly 110 by brads,
staples,
glue, nails, screws, dowels, biscuit joints, or any other suitable method well
known to
those skilled in the art. The customizable jamb subassembly 120 (FIG. IB) is
configured to be inserted into the window opening 210 (FIG. 2) comprising a
window
unit 220 (FIG. 2) and window frame 221, and to be fastened to the wall 215
(FIG. 2).
Embodiments of the current invention are also configured to cover the inside
edge of
openings between the window unit 220 (FIG. 2) and the wall 215 (FIG. 2). The
prefabricated window trim and casing apparatus 100 is preferably secured to
the
opening 210 (FIG. 2) by brad-nailing the window trim and casing apparatus 100
into
the wall studs. However, other means of securing the prefabricated window trim
and
casing apparatus 100 are well known to those skilled in the art.
The casing subassembly 110 preferably comprises vertical side casings 11 l,
and a horizontal top casing 112. In yet further alternative embodiments, the
casing
subassembly 110 comprises vertical side casings 11 l, a horizontal top casing
112, and
a horizontal bottom casing 115, with these components being cut and coupled
together to form a rectangular casing frame (otherwise known as a full
surround
configuration) as illustrated in FIGS. 1 D-F. Preferably, the components of
the casing
subassembly 110 are coupled utilizing miter joints. The miter joints are
fastened
using underpinning devices such as V-nails, corrugated inserts, mufti-pronged
spanners, and/or staples, screws, glue, mortise-tenon joints, biscuits, or any
of the
other joining method well known to those skilled in the art. In other
embodiments,
the components of the casing subassembly 110 are coupled together utilizing
butt
joints, decorative joints using plinth blocks, rosette blocks, or any other
such joint
well known to those skilled in the art.
The preferred customizable jamb subassembly 120 comprises vertical frame
jambs 121, a head frame 122, and a stool 113. In alternative embodiments, the
customizable jamb subassembly 120 further comprises an apron 114, as
illustrated in
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FIGS. lA-C. In yet further alternative embodiments, the customizable jamb
subassembly 120 comprises vertical frame jambs 121, a head frame 122 and a
frame
sill 123, as illustrated FIGS. 1D-F. The customizable jamb subassembly 120 and
the
casing subassembly 110 are preferably prefabricated. Further, the customizable
jamb
subassembly 120 comprises a width w~23, a height hlzu and a depth d~22, as
illustrated.
It should be understood that the individual components of the customizable
jamb
subassembly 120 are sized by one skilled in the art so that the customizable
jamb
subassembly 120 has dimensions that matches the width and height requirements
of
the window opening into which the prefabricated window trim and casing
apparatus
100 is to be installed. Further, the components of the customizable jamb
subassembly
120 are preferably square-cut and coupled together by butt joints that are
fastened
together using screws, nails, brads, staples, glue, or any other joining
method well
known to those skilled in the art. Alternatively, the components of the
customizable
jamb subassembly 120 are coupled together by miter joints, mortise-tenon
joints,
dowel joints, dovetail joints, biscuit joints, or any of the other joining
methods well
known to those skilled in the art.
Preferably, the prefabricated window trim and casing apparatus 100 comprises
wood. In alternative embodiments, the prefabricated window trim and casing
apparatus 100 comprises polyvinyl chloride. In yet another alternative
embodiments,
the prefabricated window trim and casing apparatus comprises fiberglass. In
another
embodiment, the prefabricated window trim and casing apparatus comprises
insulating material providing for greater heat gain protection. In yet another
alternative, the prefabricated window trim and casing apparatus is in a hollow
configuration. Further, in alternative embodiments, the customizable jamb
subassembly 120 (FIG. IB) comprises any solid material that can be cut by a
saw.
It should be understood that the configuration of and materials selected for
the
prefabricated window trim and casing apparatus 100, in alternative
embodiments,
vary to meet the needs of the consumer, the particular end-use application, or
the type
of installation to be used.
FIG. IB illustrates a rear view of the prefabricated window trim and casing
apparatus 100, in accordance with the instant invention, as described in
detail above.
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The customizable jamb subassembly 120 is shown coupled to the casing
subassembly
110. The customizable jamb subassembly 120 is configured to be trimmed to a
custom dimension through the use of a adjustable cutting guide apparatus 400
(FIGS.
4A-C), so as to match the jamb depth dimension 230 (FIG. 2) of the window
opening
210 and secured to the window opening 210 as discussed in detail below.
FIG. 1 C illustrates an isometric view of the prefabricated 'window trim and
casing apparatus 100, in accordance with the instant invention, as discussed
in the
description of FIGS. lA and B. The customizable jamb frame subassembly 120 is
shown coupled to the rear of the casing subassembly 110.
FIGS. 1 D-F illustrate various views of an alternative embodiment of the
prefabricated window trim and casing apparatus I OI . Specifically, FIG. ID
illustrates
a front view, FIG. IE illustrates a rear view, and FIG. IF illustrates an
isometric view
of an alternate embodiment of the prefabricated window trim and casing
apparatus
101. The alternative embodiment illustrate in FIGS. 1D-F shows the casing
subassembly 110 comprising vertical side casings 111, a horizontal top casing
112,
and a horizontal bottom casing 1 I 5, with these components being cut and
coupled
together to form a rectangular casing frame (otherwise known as a full
surround
configuration). Further, the stool 113 has been replaced by the frame sill
123. With
the exception of being in a rectangular casing configuration, the discussion
of FIGS.
1 A-C also applies to FIGS. 1 D-F.
It should be understood that in alternative configurations, any combination of
the various components of FIGS. lA-F, are configured and fabricated, so as to
provide a prefabricated window trim and casing apparatus to meet end user
requirements and that the embodiments shown in FIGS. 1 A-F are merely
exemplary.
FIG. 2 illustrates an isometric view of an exemplary method of measuring the
jamb depth of an existing opening, in accordance with the instant invention.
Specifically, an adjustable square 225, or other suitable measuring device, is
used to
measure the deepest jamb depth dimension at multiple points between the window
frame 221 and the wall 215. The deepest measurement measured is preferably the
jamb depth 230. The typical window opening 210 comprises a horizontal stud, a
header, and a plurality of studs and cripples forming the wail 215 and
configured so as
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to accept a window unit 220. The condition of the window opening 210, may be
in
any state, including, but not limited to, a rough state, a finished state, or
any degree of
semi-finished state. It should be understood that when the prefabricated
window trim
and casing apparatus 100 is installed into the window opening 210, the
vertical side
casing 111 and the vertical frame jamb 121 are parallel to and cover, trim,
and finish
the vertical studs (not shown) and/or cripples (not shown) of the window
opening 210
regardless of whether the vertical studs and/or cripples are in rough,
finished, or semi-
finished states, thus eliminating the need for alteration, squaring, or
preparation of the
window opening 210. Similarly, upon installation, the horizontal top casing
112 and
the head frame 122 are parallel to and fully cover, trim, and finish the
window header
(not shown) of the window opening 210, regardless of the state of the window
header.
Further, upon installation, the stool 113 and apron 112 (or alternatively the
horizontal
bottom casing 115 and the frame sill 123) are parallel to and fully cover,
trim, and
finish the lower horizontal stud of the window opening 210, regardless of the
state of
the lower horizontal stud.
FIG. 3 illustrates an isometric view of an exemplary method of marking the
jamb depth, as measured in FIG. 2, onto the customizable jamb subassembly of
the
prefabricated window trim and casing apparatus, in accordance with the instant
invention. Specifically, the adjustable square 225 used to measure the jamb
depth 230
is preferably placed on the head frame 122 of the customizable jamb frame
subassembly 120 and used to mark the jamb depth 230 (using a pencil, pen, or
other
suitable marking device) onto the customizable jamb subassembly 120. This jamb
depth 230 is the depth to which the customizable jamb subassembly 120 is
trimmed
(by using the adjustable cutting guide apparatus 400), allowing the
prefabricated
window trim and casing apparatus 100 to be installed and secured into the
opening
210.
FIGS. 4A-C illustrate an adjustable cutting guide apparatus 400 for installing
a
prefabricated window trim and casing apparatus, in accordance with the instant
invention. The adjustable cutting guide apparatus 400 is used for trimming the
customizable jamb frame subassembly 120 of the prefabricated window trim and
casing apparatus 100 to the desired jamb depth 230.
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Specifically, FIG. 4A illustrates a top view of the adjustable cutting guide
apparatus 400 for installing a prefabricated window trim and casing apparatus,
in
accordance with the instant invention. The preferred adjustable cutting guide
apparatus 400 comprises a guiding region 410. Further, the preferred
adjustable
cutting guide apparatus 400 comprises a planar deck 411, mounting slots 412,
and an
alignment flange 413. The guiding region 410 and alignment flange 413 provide
for
full reversibility of the adjustable cutting guide apparatus 400. The
alignment flange
413, guiding region 410, and planar deck 411 are preferably configured to
align the
adjustable cutting guide apparatus 400 to the customizable jamb subassembly
120 and
slide against the customizable jamb subassembly 120 when the adjustable
cutting
guide apparatus 400 is attached to a portable power cutting tool 510 (FIG. 5).
The adjustable cutting guide apparatus 400 can be coupled to and fiznction
with both left-handed and right-handed portable power cutting tools using
either the
leading or the trailing edge of the base plate S 15 (FIG. 5) of the portable
power
cutting tool 510 (FIG. S). Once coupled to the portable power cutting tool
510, the
guiding region 410 is aligned so as to be substantially parallel to the
cutting blade of
the portable power cutting tool 510 (FIG. 5).
The guiding region 410 is further configured to be positioned against the
exposed edge of the customizable jamb subassembly 120 (FIG. IB) of the
prefabricated window trim and casing apparatus. The planar deck 411 is
fenestrated
(preferably with mounting slots 412) and configured to detachably couple to a
base
plate 515 (FIG, 5) of a portable power cutting tool 510 (FIG. S) comprising a
cutting
region 520 (FIG. S) such that the guiding region 410 is positioned outside of,
and not
interfering with, the cutting region 520 (FIG. 5). The mounting slots 412 are
configured to couple the adjustable cutting guide apparatus 400 to commonly
available portable power cutting tools. Furthermore, the mounting slots 412
are
configured to allow adjustment of the distance between the guiding region 410
and
the cutting blade of the portable power cutting tool S 10, along the full
length of the
mounting slots 412. Once the adjustable cutting guide apparatus 400 is coupled
to the
portable power cutting tool 510, the planar deck 411 and the guiding region
410 allow
configuration of the cutting region 520 (FIG. 5) such that the cutting region
520 aligns
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the blade of the portable power cutting tool 510.(FIG. S) with the jamb depth
230
marked on the customizable jamb subassembly 120 (FIG. IB) of the prefabricated
window trim and casing apparatus 100 (FIG. 1 A). Once aligned, the blade is
configured to evenly trim the customizable jamb subassembly 120 (FIG. IB) to a
desired jamb depth 230.
The adjustable cutting guide apparatus 400 is preferably detachably coupled
through the base plate 515 (FIG. 5) of the portable power cutting tool S10
(FIG. 5) by
at least one butterfly nut 430 and complementary fastener 435 and washer 436.
It
should be understood that the butterfly nut 430 and complementary fastener 435
and
washer 436 are shown coupled with the adjustable cutting guide apparatus 400
in
FIGS. 4A-C for storage purposes only. But the butterfly nut 430 and
complementary
fastener 435 and washer 436 are preferably detachably coupled through the base
plate
515 of the portable cutting tool 510 through the mounting slots 412 of the
adjustable
cutting guide apparatus 400 as shown in FIGS. 5 and 6. In alternative
embodiments,
the adjustable cutting guide apparatus 400 is coupled to the base plate 515
(FIG. 5) by
any appropriate manner including, but not limited to, at least one quick
release nut
and complimentary fastener.
FIG. 4B illustrates a side view of the adjustable cutting guide apparatus 400
for installing a prefabricated window trim and casing apparatus 100, in
accordance
with the instant invention, as described in detail above. Further, FIG. 4C
illustrates an
isometric view of the adjustable cutting guide apparatus 400 for installing a
prefabricated window frame and casing apparatus 100, in accordance with the
instant
invention, as discussed in the description of FIG. 4A above.
FIG. 5 illustrates a perspective view of an exemplary method of attaching the
adjustable cutting guide apparatus 400 shown in FIG. 4A-C to a portable power
cutting tool 510, in accordance with the instant invention. Specifically, the
adjustable
cutting guide apparatus 400 is detachably coupled through the base plate 515
of the
portable power cutting tool 510 by at least one butterfly nut 430 and
complimentary
fastener 435 and washer 436. Alternatively, the adjustable cutting guide
apparatus
400 is detachably coupled to the base plate 515 by any appropriate means,
including,
but not limited to at least one quick release means. The planar deck 411 is
configured
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to couple the adjustable cutting guide apparat>~s 400 to the portable power
cutting tool
510, preferably by the mounting slots 412. Further, the guiding region 410
configures
the cutting region 520 such that the cutting region 520 aligns the blade of
the portable
power cutting tool 510 with the jamb depth 230 as measured (FIG.2) and marked
(FIG. 3) on the customizable jamb subassembly 120 (FIG. IB) of the
prefabricated
window trim and casing apparatus 100 (FIG. I A) such that the blade evenly
trims the
customizable jamb subassembly 120 (FIG. IB) to the desired jamb depth 230
(FIG. 2).
When coupled, the inside edge of the alignment flange 413 is in contact with
either
the leading or trailing edge of the base plate 515 of the portable power
cutting tool
510. This contact configures the guiding region 410 of the adjustable cutting
guide
apparatus 400 to be substantially parallel to the cutting blade of the
portable power
cutting tool 510.
The mounting slots 412 allow fine adjustments such that the cutting region
520 is configured to match the desired depth such that once the exposed edge
of the
jamb frame subassembly 120 is trimmed, the resulting customizable jamb
subassembly depth d~2z is equivalent to the jamb depth dimension 230 as
measured in
FIG. 2.
FIG. 6 illustrates a window trim and casing system 600. Specifically, FIG. 6
illustrates a perspective view of the system 600 with a portable power cutting
tool 510
and an attached adjustable cutting guide apparatus 400, trimming the
prefabricated
window frame and casing apparatus 100. The system 600 comprises a customizable
jamb subassembly 120 of the prefabricated window frame and casing apparatus
100
and an adjustable cutting guide apparatus 400. The customizable jamb
subassembly
depth d~22 is configured to be trimmed to a custom size, inserted into an
opening in a
wall 215, and fastened to the opening in the wall 215. The customized depth
d~22
preferably is equal to the jamb depth dimension 230 as measured in FIG.2 and
marked
in FIG. 3. Before installation, all sides of the customizable jamb subassembly
120 are
trimmed to this custom size. However, it should be noted that the custom size
depends on the particular end use application and field dimensions.
The adjustable cutting guide apparatus 400 is configured to mount to abase
plate S 15 of the portable power cutting tool 510. The preferred portable
power
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cutting tool is an electric circular saw. Further the adjustable cutting guide
apparatus
400 is configured to allow the portable power cutting tool 510 to trim the
customizable jamb subassembly 120 to the custom size. As seen in FIG. 6, the
guiding region 410 is positioned outside of, and not interfering-with, the
cutting
region 520. Once coupled, the guiding region 410 (FIG. 4C) configures the
cutting
region 520 such that the blade of the portable power cutting tool 510 is
aligned with
the jamb depth 230 as measured (FIG.2) and marked (FIG. 3) on the customizable
jamb subassembly 120. This allows the blade to evenly trim the customizable
jamb
subassembly 120 to the customizable jamb subassembly depth d,z2, that is
preferably
approximately equal to the jamb depth 230 as measure in FIG. 2.
FIG. 7 illustrates an exemplary flow chart 700 detailing a method of
installing
a prefabricated window trim and casing apparatus having a customizable jamb
subassembly with a depth, in accordance with the instant invention. At the
step 701, a
jamb depth dimension is determined. Preferably, the jamb depth dimension
comprises a deepest of depth measurements from a window to a wall. At the step
702, a jamb depth mark is marked on the customizable jamb subassembly of the
prefabricated window frame and casing apparatus. At the step 703, an
adjustable
cutting guide apparatus with a guiding region comprising a planar deck is
mounted to
a portable power cutting tool with a blade. The portable power cutting tool
with a
blade is preferably an electric circular saw and the preferred blade is a
finish blade.
At the step 704, the adjustable cutting guide apparatus is aligned such that
the blade of
the portable power cutting tool is aligned with an outside edge of the jamb
depth mark
and is configured to cut the customizable jamb subassembly to a customized
depth.
The blade is preferably adjusted to a blade depth not more than 1/16 of an
inch greater
than the thickness of the customizable jamb subassembly. The blade depth
should be
adjusted such that when trimming the customizable jamb subassembly, the blade
does
not protrude too far from the bottom of the customizable jamb subassembly.
This
blade depth adjustment allows the blade to evenly trim the customizable jamb
subassembly and restricts the blade from incorrectly trimming portions of the
customizable jamb assembly when at the corners/joints of the customizable jamb
subassembly, for example. At the step 705 the guide region of the adjustable
cutting
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guide apparatus 400 is positioned against the exposed edge of the customizable
jamb
subassembly. At the step 706, the portable power cutting tool is used to trim
all sides
of the customizable jamb subassembly to the jamb depth. At the step 707, the
prefabricated window trim and casing apparatus is positioned into a window
opening
and secured into the window opening. The method of installing a prefabricated
window trim and casing apparatus having a customizable jamb subassembly ends
at
the step 708.
FIG. 8 illustrates an exemplary flow chart 800 detailing a method of
manufacturing a prefabricated window trim and casing apparatus, in accordance
with
the instant invention. The prefabricated window trim and casing apparatus is
preferably configured to cover an opening in an interior wall. At the step
801, a jamb
subassembly comprising vertical frame jambs; a head frame, and a frame sill is
fabricated. In alternative embodiments, a jamb subassembly comprising a stool
instead of the frame sill is fabricated. At the step 802 .a casing subassembly
is
fabricated. The casing subassembly preferably comprises vertical side casings,
a
horizontal top casing, and a horizontal bottom casing. In the step 803 the
casing
subassembly is coupled to the customizable jamb subassembly to form the
prefabricated window trim and casing apparatus. The method of manufacturing a
prefabricated window trim and casing system ends at the step 804.
The current invention provides a high speed, high quality, and low cost way to
mass manufacture window trim and casings at a manufacturing facility. These
prefabricated window trim and casings can be quickly installed by low skilled
laborers, yet still achieve a consistent carpentered look. Further, the
current invention
provides ease of installation, lower manufacturing cost, reduced labor costs,
ease in
cleaning and maintenance, as well as a wide choice of colors, materials, and
designs.
Other advantages of the current invention include compatible and customizable
window trim and casings and installation methods for both new construction and
replacement (retrofit) applications. The prefabricated window trim and casing
apparatus is versatile in design and flexible in configuration parameters so
as to meet
both the infinite variation of window opening dimensions which exist and the
broad
range of features/aesthetics/materials which are demanded in the marketplace.
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The prefabricated window trim and casing system and corresponding method
for Installation do not require the skills of a finish carpenter but instead
can be readily
installed by the typical lower wage window installer or any equivalent lower
skilled
worker. Further, the method of installing the prefabricated window trim and
casing
apparatus applies for any window opening regardless of whether the window
opening
is in a rough, semi-finished, or finished state and with no need for
smoothing,
squaring, or other preparation of the side surfaces or front surfaces of the
window
opening.
Further, the adjustable cutting guide apparatus disclosed is sturdy,
inexpensive, and readily adaptable to the broad range of portable power
cutting tools
that currently exist in the construction industry. Use of the adjustable
cutting guide
apparatus, in conjunction with the system, is simple for the typical window
installer to
understand with the aid of only cursory directions or a simple instruction
sheet. Also,
the adjustable cutting guide apparatus is easily removable from the portable
power
I S cutting tool so as not to require the installer to dedicate a tool
exclusively for a single
use.
Unlike existing adjustable cutting guide apparatuses, the current adjustable
cutting guide apparatus provides a power cutting tool with a guide surface
located on
the inboard side of the cutting blade of the portable power cutting tool. In
other
words, existing adjustable cutting guide apparatuses provide a portable power
cutting
tool with a guide surface located on the outboard side of the cutting blade of
the
portable power cutting tool. Existing adjustable cutting guide apparatuses
with guide
surfaces located on the outboard side of the cutting blade of the portable
power
cutting tool limit the usefulness of the guide and the power cutting tool
because the
motor and its associated housing extend outwardly from the inboard side of the
portable power cutting tool. This outward extension acts as an obstruction and
hinders or eliminates the cutting of an exposed edge of a surface in close
proximity to
any obstruction protruding from that surface, such as a flange or a wall.
Another advantage of the current adjustable cutting guide apparatus is that it
is
configured to allow a user to reverse the conventional orientation of a
portable power
cutting tool relative to the item being cut, eliminating any problem of
interference
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between the motor and,its associated housing.of the portable power cutting
tool with
an object to be trimmed.
The method, apparatus, system, and associated adjustable cutting guide
apparatus offer substantial benefits and significant reduction in the amount
of
material, time, and cost required for a wide range of window trim and casing
installations. The current invention provides for low cost production and
installation,
and allows for a method of rapid, repeatable, high quality fabrication
employing
typical methodology and industrial machinery that is commonly, readily, and
economically available in the woodworking, plastics, and metals industries.
The present invention has been described in terms of specific embodiments
incorporating details to facilitate the understanding of the principles of
construction
and operation of the invention. Such reference herein to specific embodiments
and
details thereof is not intended to limit the scope of the claims appended
hereto. It will
be apparent to those skilled in the art that modifications may be made in the
I 5 embodiment chosen for illustration without departing from the spirit and
scope of the
invention.
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