Note: Descriptions are shown in the official language in which they were submitted.
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WINDOW AND METHOD
Field of Invention
This invention relates generally to a window and a method of installing a
window.
Background of the Invention
A conventional window frame has an upper flange, a lower flange, and two side
flanges that are generally fastened directly on to plywood sheathing of a wall
of a
building during installation. Insulation sheets are usually disposed directly
on the
outer surface of the upper flange and plywood is used to cover the outer
surface of the
insulation sheets. Traditionally, a lower (river) flashing is disposed
adjacent the lower
edge of the window frame, on the outer surface of the lower flange. An upper
flashing
is generally fastened to the plywood sheathing of the wall through the upper
flange.
Buildings, including their windows, are exposed to water under various weather
conditions. The water that buildings are exposed to includes for example rain
water
and water from condensation, melted ice, snow, and frost. With the
conventional
window and method of window installation, water can seep behind the upper
flange
and will trickle down between the flashing/upper flange and the plywood at the
top of
the window, which can cause the plywood to deteriorate. Further water can seep
behind the lower flashing through the lower flange, into the plywood
sheathing, which
can also cause the plywood to deteriorate.
Further, the placement of the insulation sheets can prevent water from flowing
down
the flange, causing water to seep into the plywood behind the flange and the
plywood
covering the insulation sheets. Water from the plywood sheathing can also seep
into
other parts of the wall, such as studs and insulation materials. Water damage
to the
wood components of the wall can compromise the strength and integrity of the
wall.
Further, mould can easily develop in damp areas inside the wall, which can
pose a
serious health threat.
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Summary of Invention
The present invention provides a window and a method of installing a window.
In one aspect, a window unit is provided, comprising:
= a frame body having an upper edge, a bottom edge and two side edges
defining the perimeter of the frame;
= a pair of side mounting flanges, each comprising a substantially vertical
plate
and each secured along a respective side edge of the frame;
= an upper mounting flange comprising a substantially vertical plate and a
ledge
extending outwardly from a lower edge of the vertical plate;
whereby the upper mounting flange is secured along the upper edge of the frame
by
means of the ledge such that the vertical plate of the upper mounting flange
is in a
first vertical plane behind a second vertical plane of the vertical plates of
the side
mounting flanges.
In another aspect, a method is provided for installing a window of the present
invention, comprising;
= attaching the frame body of the window to a first material by means of
the
upper mounting flange such that the ledge of the upper mounting flange rests
on a top edge of a second material;
= attaching each side flange to the second material;
whereby the first material is recessed from the second material by a distance
about the
same as the width of the ledge of the upper mounting flange.
Brief Description of the Drawings
Drawings are included for the purpose of illustrating certain aspects of the
invention.
Such drawings and the description thereof are intended to facilitate
understanding and
should not be considered limiting of the invention. Drawings are included, in
which:
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FIG. 1 is a planar view of a conventional prior art window.
FIG. 2 is a perspective and partially exploded view of an embodiment of a
window of
the present invention.
FIG. 3 is a magnified cross-sectional view of the window of FIG. 2, along the
line of
A-A.
FIG. 4 is a planar view of an embodiment of a window of the present invention
where
portions of the finished installed window are broken away to show installation
of the
window.
Detailed Description of Various Embodiments
The detailed description set forth below in connection with the appended
drawings is
intended as a description of various embodiments of the present invention and
is not
intended to represent the only embodiments contemplated by the inventor. The
detailed description includes specific details for the purpose of providing a
comprehensive understanding of the present invention. However, it will be
apparent
to those skilled in the art that the present invention may be practiced
without these
specific details.
In the description, "up," "upward," "above" and "upper" denote a position that
is
further away from the ground than "down," "downward," "below" and "lower";
"front," "outward" and "outer" denote a position that is further away from the
interior
space of a wall and/or building than "behind" and "inner".
FIG. 1 shows a conventional window 50 (prior art). Window 50 comprises a frame
51 and extending from or attached to the frame 51 are an upper mounting flange
52, a
lower mounting flange 54 and two side mounting flanges 56. Each flange is
provided
with a plurality of holes 58 through which a nail, screw, etc. can be used to
fasten the
window 50 directly to the plywood 60. Additionally, upper flashing (not shown)
can
be attached to upper flange 52 and lower flashing (not shown), also referred
to as river
flashing, can be attached to lower flange 54 for directing water away from the
window. Nevertheless, it was discovered that any water/moisture which trickles
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down the plywood 60 (shown as arrows 62) will still be able to find its way
into space
64 formed between upper flange 52 and plywood 60. Furthermore, any moisture
which may pour off the sides of the upper flashing (not shown) may also be
able to
seep into space 66 formed between side flanges 56 and plywood 60.
The present invention attempts to address one or all of the moisture related
problems
associated with prior art windows. Referring to FIGS 2 and 3, a window 10 of
the
present invention has a frame 9 and extending from or attached to the frame 9
are an
upper mounting flange 7 and two side mounting flanges 7a. In this particular
embodiment, the lower portion of frame 9, referred to as lower frame 9a, has
been
adapted to fasten directly to a surface, eliminating the need for a lower
mounting
flange. There are advantages in not having a lower flange, which will be
discussed in
more detail below. It is understood, however, that a lower mounting flange can
be
used while still enjoying many of the benefits of the present invention.
Some or all of upper flange 7, side flanges 7a, and frame 9 may be formed as a
single
part from one piece of material or may be formed separately as individual
components
and subsequently joined together. The separate components may be joined
together in
various ways including for example welding, adhesives, fasteners, etc. Window
10 is
preferably made of materials that are suitable for indoor and outdoor use and
can
withstand ordinary temperature differentials between indoor and outdoor spaces
and
between seasons. Window 10 may be made of various materials including for
example aluminum, vinyl, composite, fiberglass, and wood, or a combination
thereof.
The components of window 10 may be made by extrusion, machining, and the like.
Upper flange 7 provides an area for connecting the window to the sheathing
and/or
studs of the wall, which is shown in FIG. 4 and will be discussed in more
detail
below. In one embodiment, upper flange 7 includes a substantially vertical
plate 12
and apertures 14 therein for receiving fasteners or the like therethrough.
Upper flange
7 may assist in preventing water from its outer surface from seeping in to a
surface on
to which upper flange is to be mounted. Upper flange 7 further comprises an
outwardly extending ledge 1, which extends outwardly from the plane of the
vertical
plate 12 of flange 7. The ledge 1 is preferably connected to the bottom of
vertical
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plate 12 and is also connected to the upper ends of side flanges 7a and frame
9a. Thus,
the upper ends of side flanges 7a and the upper edge of frame 9 are connected
to the
upper flange 7 via ledge I. Width W denotes the perpendicular distance by
which
ledge 1 extends from the outer surface of upper flange 7.
The magnitude of W is approximately the same as the thickness of a wall
sheathing
(e.g., plywood) on to which side flanges 7a are to be mounted. The presence of
ledge
1 offsets upper flange 7 and side flanges 7a by a distance W such that upper
flange is
in a first vertical plane behind a second vertical plane in which the side
flanges are
positioned. It is not necessary that the upper surface of ledge I be
perpendicular to the
outer surface of upper flange 7. In one embodiment, ledge 1 is sloped
downwardly
towards the outer surface of window 10. The sloping in ledge I may direct any
water
flowing down from above to flow down side flanges 7a.
Ledge 1 may include a ridge 8 at or near the edge on each end. A "ridge" used
herein
refers to a raised portion relative to a substantially planar surface, which
may function
to block and/or redirect the flow of water. One end of ridges 8 may be
connected to
the outer surface near the lower edge of upper flange 7. The other end of
ridges 8
extend towards the upper ends of side flanges 7a. Ridges 8 may prevent water
from
flowing out the ends of ledge 1 and may direct any water on ledge 1 to flow
down
side flanges 7a.
Each side flanges 7a provides an area for attaching the window to a wall
sheathing
(e.g., plywood) and comprises a substantially vertical plate 16. In one
embodiment,
each side flange 7a includes apertures 5 for receiving fasteners such as
nails, screws,
bolts or the like therethrough located on the vertical plate 16. Side flanges
7a may
direct water to flow downwards on their outer surface and may prevent water
from
their outer surface from seeping into a surface on which the side flanges are
to be
supported. Side flanges 7a each extend laterally away from frame 9, along the
length
of either side of frame 9. Each side flange 7a is connected on a first side
along its
length to frame 9. In one embodiment, a second side of each side flange 7a
(which is
not connected to frame 9) includes a ridge 8a along the length thereof. Ridge
8a
assists in preventing water from flowing out past the second side of side
flange 7a.
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Ridge 8a may be at or near the edge of the second side of each side flange 7a.
In a
further embodiment, the upper end of ridge 8a connects to one end of ridge 8.
Ridge
8a may run substantially continuously along the length of the second side of
each side
flange 7a. In another embodiment, ridge 8a may comprise of a plurality of
spaced-
apart ridge segments.
In one embodiment, each side flange 7a further includes at least one ridge 8b
on the
front face of vertical plate 16. Ridge 8b is positioned just above aperture 5
to help any
water flowing down the outer surface of side flanges 7a to circumnavigate the
aperture 5, thereby preventing water from flowing into the aperture 5 and
seeping into
the area behind side flanges 7a. In another embodiment, the upper end of ridge
8b
connects to ridge 8a to form a shield above aperture 5. In a further
embodiment, side
flanges 7a each include at least one ridge 4, an upper end of which may
connect to a
lower end of ridge 8b. Ridge 4 helps to guide any water on the outer surface
of side
flanges 7a, especially any water bypassing aperture 5 via ridge 8b, to flow
downwards. Each of side flanges 7a may further include a ridge 4a, which may
be
positioned lengthwise on the outer surface of flanges 7a near the first side.
Ridge 4a
helps to direct water on the outer surface of flange 7a to flow downwards.
Ridge 4a
may run substantially continuously along the length of the first side of each
side
flange 7a. In another embodiment, ridge 4a may comprise of a plurality of
spaced-
apart ridge segments.
Ridges 8a, 8b, 4 and 4a form raised channels for directing the water down the
outer
surface of the vertical plates 16 of the side flanges 7a. It is understood
that other
methods for forming raised channels can be used.
Any of ridges 8a, 8b, 4 and 4a may further assist in preventing any materials
covering
side flanges 7a from being in direct contact with the outer surface of side
flanges 7a,
thereby maintaining a clear flow path and preventing any potential blockage of
water
flow down the outer surface of the side flanges.
In one embodiment, some or all of the above-mentioned ridges may be replaced
with
grooves, which are recessed portions relative to a substantially planar
surface that
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may function to redirect the flow of water. The ridges and grooves may have
various
shapes, including example substantially linear, curved, wavy, etc.
Frame 9 is connected at the upper end to upper flange 7 and, in some
embodiments, to
ledge 1. Frame 9 may have an outer surface that is substantially flush with
that of side
flanges 7a. In another embodiment, frame 9 may protrude outwardly from ledge 1
and
the vertical plane of side flanges 7a. In yet another embodiment, the outer
surface of
side flanges 7a is substantially perpendicular to the side edges of frame 9.
Frame 9
may include, preferably at its center, at least one layer of substantially
transparent
material, such as for example glass, plastic, etc., to allow light to travel
between an
exterior space and an interior space.
Lower frame 9a provides an area for connecting the window to a wall sheathing
(e.g.,
plywood). In one embodiment, lower frame 9a includes apertures 5a for
receiving
fasteners or the like therethrough. As previously mentioned, however, a lower
mounting flange could be added for securing the bottom of the frame to wall
sheathing.
An upper flashing 2 and a lower (river) flashing 3 may be placed above and
below
window 10, respectively, during installation. Flashings 2 and 3 are each a
strip of
metal or other impervious material installed with the window to help prevent
the
passage of water into the wall at the joints. Flashings 2 and 3 may be
similarly shaped,
each having a substantially planar middle section (2a and 3a, respectively)
with a back
extension (2b and 3b, respectively) extending substantially vertically
upwardly on one
side and a front extension (2c and 3c, respectively) extending substantially
vertically
downwardly on the other side. The back and front extensions extend
substantially
along the entire length of either side of the planar middle section. The
planar middle
sections 2a and 3a may further include end extensions (2d and 3d,
respectively) that
extend substantially vertically upwardly at both ends of the section. The
planar middle
section may be sloped downwardly from the back extension to the front
extension,
such that when the back extension is substantially vertical, any water on the
planar
middle section tends to flow towards and down the front extension.
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Window 10 may be installed in a wall in various ways. The method described
below
with reference to FIGS. 2, 3 and 4 is one example of how window 10 may be
installed. A hole is provided in the wall where window 10 is to be installed.
The hole
is sized and shaped to accommodate the window and may be of various shapes
depending on the shape of the window to be installed. In one embodiment, the
hole is
rectangular in shape and is framed by wall components such as studs and
sheathing.
In a further embodiment, an upper stud, which may be substantially horizontal,
frames
the upper edge of the hole. Framing the side edges and the lower edge of the
hole is
wall sheathing, e.g., plywood, which is supported on studs.
FIG. 4 shows window 10 and the various steps of installation. The upper flange
7 of
window 10 is fastened to upper stud 140, which upper stud 140 is positioned
over the
top portion of window opening or hole. Upper flange 7 is fastened/attached to
upper
stud 140 by fastening devices being inserted into apertures 14 and forced
through
upper stud 140. Side flanges 7a are fastened to plywood 160, which plywood 160
surrounds the other three sides of the window opening or hole. Side flanges 7
are
fastened/attached to plywood 160 by fastening devices being inserted into
apertures 5
and forced through plywood 160.
As shown in FIG. 2, window 10 may have lower (river) flashing 3 placed at a
lower
portion of window 10. In this instance, back extension 3b of lower flashing 3
is
placed between plywood 160 and the lower frame 9a of window 10 such that the
back
extension 3b of flashing 3 is disposed between the inner surface of the lower
portion
9a of window 10 and the outer surface of the sheathing (e.g., plywood) framing
the
lower edge of the hole ("lower sheathing"). The upper surface of the planar
middle
section 3a of flashing 3 is adjacent to the lower ends of side flanges 7a and
the lower
edge of lower frame 9a. Window 10 is aligned with the hole such that upper
flange 7
is substantially flush with the outer surface of the upper stud, and that the
ends of
ledge 1 cover a portion of the upper edge of the sheathing (e.g., plywood)
framing the
sides of the hole ("side sheathing"). The magnitude of width W of ledge 1 is
preferably sufficient to accommodate the thickness of the side sheathing, such
that
side flanges 7a are substantially flush with the outer surface of the side
sheathing.
However, the side sheathing may be trimmed and/or cut to fit behind side
flanges 7a
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such that when upper flange 7 is substantially flush with the outer surface of
the upper
stud, side flanges 7a are also substantially flush with the outer surface of
the side
sheathing.
Window 10 may be secured to the frame of the hole in various ways, including
for
example by fasteners, adhesives, or a combination thereof. Fasteners include
for
example screws, nuts and bolts, nails, staples, rivets, snap fittings, etc.
Adhesives
include hot adhesives, cold adhesives, chemical reaction bonding, etc.
In one embodiment, lower frame 9a is secured to the lower sheathing, with the
back
extension 3b of lower flashing 3 wedged therebetween, by fasteners through
apertures
5a and the back extension. As can be seen in FIG. 2, placement of the lower
flashing 3
such that the planar middle section 3a is adjacent to the lower ends of side
flanges 7a
allows any water that may fall from ledge 1 to be directed by the ridges of
the side
flanges 7a and fall directly on the planar middle section 3a. Further, if any
water
accumulates on planar middle section 3a, the water will not be able to damage
the
wall behind as a result of back extension 3b.
In a further embodiment, side flanges 7a is secured to the side sheathing by
fasteners
through apertures 5. In a still further embodiment, upper flange 7 is secured
to the
upper stud by fasteners through apertures 14. In another embodiment, any of
the
apertures 5a, 5, and 14 may be covered with a plug 6, whether the aperture has
received a fastener. Plug 6 may be secured to the aperture in various ways
including
for example adhesives, friction fitting, threaded connections, snap fitting,
etc.
After upper flange 7 is secured to the upper stud, flashing 2 may be supported
thereon
to substantially cover upper flange 7 and ledge 1. Flashing 2 is disposed such
that its
back extension 2b is adjacent to the outer surface of upper flange 7 and its
planar
middle section 2a is adjacent to the upper surface of ledge 1. Flashing 2 may
be
secured to upper flange 7 by fasteners and/or adhesives.
As shown in FIG. 4, wall sheathing, in this case, plywood 160, can then be
placed
over the outer surface of flange 7, or if flashing 2 is used, plywood 160 can
be placed
over the outer surface of the back extension 2b of flashing 2, and the wall
sheathing
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may be secured to window 10, the upper stud, and/or other components of the
wall. In
one embodiment, insulation sheets 180 are disposed on the wall sheathing to
substantially cover the outer surface thereof. In a further embodiment,
insulation
sheets 180 are placed over side flanges 7a to substantially cover the outer
surface
thereof. Outer wall material (such as for example stucco, vinyl, stone,
SmartboardTM,
etc.) may be disposed on the outer surface of the insulation sheets.
The above-described window and method of installation thereof may help prevent
water leakage into wall components. For example, water flowing down the wall
sheathing (plywood) from above the window or from the outer wall would first
encounter the planar middle section 2a of flashing 2 and then flow off the
front
extension 2a of flashing 2. If flashing is not used, water would still flow
away from
the wall due to flange 7 and ledge 1. Any water that finds its way onto ledge
1 would
be directed away via ridges 8a, 8b, 4 and 4a on side flanges 7a.
Any water on the outer surface of frame 9 would flow downwards on to the
planar
middle section 3a of flashing 3 and then past the front extension 3a of
flashing 3. Any
water that may have accumulated on the outer surface of upper flange 7 would
flow
down on to ledge 1 and then down side flanges 7a on to the planar middle
section 3a
of flashing 3. Flashing 3 would then direct the water to flow off the front
extension 3c
thereof. Similarly, any water that may have accumulated on side flanges 7a or
the side
edges of frame 9 would flow downwards on to flashing 3 and then past the front
extension thereof. The window and installation thereof disclosed herein assist
in
minimizing water exposure and accumulation at the joints between the window
and
the wall components.
The previous description of the disclosed embodiments is provided to enable
any
person skilled in the art to make or use the present invention. Various
modifications
to those embodiments will be readily apparent to those skilled in the art, and
the
generic principles defined herein may be applied to other embodiments without
departing from the spirit or scope of the invention. Thus, the present
invention is not
intended to be limited to the embodiments shown herein, but is to be accorded
the full
scope consistent with the claims, wherein reference to an element in the
singular, such
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as by use of the article "a" or "an" is not intended to mean "one and only
one" unless
specifically so stated, but rather "one or more". All structural and
functional
equivalents to the elements of the various embodiments described throughout
the
disclosure that are known or later come to be known to those of ordinary skill
in the
art are intended to be encompassed by the elements of the claims. Moreover,
nothing
disclosed herein is intended to be dedicated to the public regardless of
whether such
disclosure is explicitly recited in the claims. For US patent properties, it
is noted that
no claim element is to be construed under the provisions of 35 USC 112, sixth
paragraph, unless the element is expressly recited using the phrase "means
for" or
"step for".
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