Adaptable fenestration frame members and methods
10604988 ยท 2020-03-31
Assignee
Inventors
Cpc classification
E06B1/10
FIXED CONSTRUCTIONS
E06B2003/4484
FIXED CONSTRUCTIONS
E06B3/4415
FIXED CONSTRUCTIONS
E06B9/52
FIXED CONSTRUCTIONS
E06B1/20
FIXED CONSTRUCTIONS
E06B2003/4476
FIXED CONSTRUCTIONS
E06B1/342
FIXED CONSTRUCTIONS
E06B1/30
FIXED CONSTRUCTIONS
International classification
E06B1/20
FIXED CONSTRUCTIONS
Abstract
Adaptable fenestration frame members, fenestration units using the frame members, and methods of adapting the fenestration frame members. The adaptable fenestration frame members provide a construction that is adaptable for use in both pocket and non-pocket installations by including an adaptation channel forming an outside corner along one edge of the fenestration frame member. Removal of the outside corner converts that portion of the frame member from an outside corner to an inside corner, thus adapting the frame member for use in a pocket installation.
Claims
1. An adaptable fenestration frame member extending along a frame member length, the frame member comprising: a body extending along the frame member length, the body comprising a jamb face and a sash face, wherein the jamb face is configured to face a jamb defining an edge of a building opening in which a fenestration unit including the frame member is installed and the sash face is located opposite the jamb face and configured to face a sash of a fenestration unit including the frame member, the body further comprising a first side and a second side, wherein the first side extends between the jamb face and the sash face and the second side extends between the jamb face and the sash face, and further wherein the first and second sides are located on opposite sides of the frame member such that the first side faces away from the body in a first direction and the second side faces away from the body in a second direction, wherein the first and second directions face in opposite directions from each other; and an adaptation channel extending along the first side of the body between the jamb face and the sash face, wherein the adaptation channel extends over the frame member length, wherein the adaptation channel comprises: a first wall forming a portion of the jamb face; a second wall forming a portion of the first side of the body; an outside corner formed by the first wall and the second wall at a junction between the jamb face and the first side of the body; a first interior wall extending along a direction between the first side and the second side of the frame member; a second interior wall generally perpendicular to the first interior wall, the second interior wall extending along a direction between the sash face and the jamb face of the frame member; and an inside corner formed within the adaptation channel at a junction of the first interior wall and the second interior wall, the inside corner facing away from the sash face and opening towards the jamb face of the frame member; wherein removal of at least a portion of the first wall and at least a portion of the second wall removes the outside corner formed by the first wall and the second wall at the junction between the jamb face and the first side of the body and exposes the inside corner located within the adaptation channel; an open trim channel extending along the frame member length adjacent the adaptation channel, wherein the open trim channel is formed between the first interior wall and the sash face, and wherein the open trim channel opens in the first direction and is sized and configured to receive and retain a trim member extending along the frame member length before and after removal of the outside corner formed by the first wall and the second wall at the junction between the jamb face and the first side of the body; and a screen frame retaining channel formed at a junction between the sash face and the first side of the body, the screen frame retaining channel comprising an interior stop and an exterior stop mutually defining the screen frame retaining channel opening towards the first side and the sash face of the frame member, wherein the open trim channel is located between the screen frame retaining channel and the jamb face of the frame member.
2. A fenestration frame member according to claim 1, wherein the adaptation channel comprises a generally rectangular inner cross-sectional shape before removal of the outside corner formed by the first wall and the second wall at the junction between the jamb face and the first side of the body.
3. A fenestration frame member according to claim 1, wherein the adaptation channel comprises a closed adaptation channel.
4. A fenestration frame member according to claim 1, wherein the frame member further comprises an extension jamb channel extending along the second side of the body between the jamb face and the sash face, wherein the extension jamb channel extends over the frame member length; and wherein the extension jamb channel comprises a sacrificial wall forming a portion of the second side of the body between the jamb face and the sash face, wherein removal of the sacrificial wall opens the extension jamb channel such that the extension jamb channel is configured to receive a portion of an extension jamb oriented generally parallel with the jamb defining an edge of a building opening in which a fenestration unit including the frame member is installed.
5. A fenestration unit that is adaptable from a first configuration suitable for installation in a rough opening to a second configuration suitable for pocket installation within an existing fenestration frame located in a building opening, the fenestration unit comprising: a sash; a frame surrounding the sash, wherein the frame comprises a plurality of frame members connected to form the frame, wherein the plurality of frame members comprises a left frame member and a right frame member located on opposite sides of the sash, wherein each of the left frame member and the right frame member comprise: a body extending along a frame member length, the body comprising a jamb face and a sash face, wherein the jamb face is configured to face a jamb defining an edge of a building opening in which the fenestration unit is installed and the sash face is located opposite the jamb face and configured to face the sash of the fenestration unit, the body further comprising a first side and a second side, wherein the first side extends between the jamb face and the sash face and the second side extends between the jamb face and the sash face, and further wherein the first and second sides are located on opposite sides of the frame member such that the first side faces away from the building opening in a first direction and the second side faces away from the building opening in a second direction, wherein the first and second directions face in opposite directions from each other; and an adaptation channel extending along the first side of the body between the jamb face and the sash face, wherein the adaptation channel extends over the frame member length, wherein the adaptation channel comprises: a first wall forming a portion of the jamb face; a second wall forming a portion of the first side of the body; an outside corner formed by the first wall and the second wall at a junction between the jamb face and the first side of the body; a first interior wall, the first interior wall extending along a direction between first side and the second side of the frame member; a second interior wall generally perpendicular to the first interior wall, the second interior wall extending along a direction between the sash face and the jamb face of the frame member; and an inside corner formed within the adaptation channel at a junction of the first interior wall and the second interior wall, the inside corner located within the adaptation channel, the inside corner facing away from the sash face and opening towards the jamb face of the frame member; wherein removal of at least a portion of the first wall and at least a portion of the second wall removes the outside corner formed by the first wall and the second wall at the junction between the jamb face and the first side of the body and exposes the inside corner located within the adaptation channel such that the fenestration unit is adapted from the first configuration suitable for installation within a rough opening to the second configuration suitable for pocket installation within an existing fenestration frame located in a building opening; an open trim channel extending along the frame member length adjacent the adaptation channel, wherein the open trim channel is formed between the first interior wall and the sash face, and wherein the open trim channel opens in the first direction and is sized and configured to receive and retain a trim member extending along the frame member length before and after removal of the outside corner formed by the first wall and the second wall at the junction between the jamb face and the first side of the body; and a screen frame retaining channel formed at a junction between the sash face and the first side of the body, the screen frame retaining channel comprising an interior stop and an exterior stop mutually defining the screen frame retaining channel opening towards the first side and the sash face of the frame member, wherein the open trim channel is located between the screen frame retaining channel and the jamb face of the frame member.
6. A fenestration unit according to claim 5, wherein the adaptation channel in each of the left frame member and the right frame member comprises a generally rectangular inner cross-sectional shape before removal of the outside corner formed by the first wall and the second wall at the junction between the jamb face and the first side of the body.
7. A fenestration unit according to claim 5, wherein the adaptation channel in each of the left frame member and the right frame member comprises a closed adaptation channel.
8. A fenestration unit according to claim 5, wherein each of the left frame member and the right frame member further comprises an extension jamb channel extending along the second side of the body between the jamb face and the sash face, wherein the extension jamb channel extends over the frame member length; and wherein the extension jamb channel comprises a sacrificial wall forming a portion of the second side of the body between the jamb face and the sash face, wherein removal of the sacrificial wall opens the extension jamb channel such that the extension jamb channel is configured to receive a portion of an extension jamb oriented generally parallel with the jamb defining an edge of a building opening in which the fenestration unit is installed.
9. An adaptable fenestration frame member extending along a frame member length, the frame member comprising: a body extending along the frame member length, the body comprising a jamb face and a sash face, wherein the jamb face is configured to face a jamb defining an edge of a building opening in which a fenestration unit including the frame member is installed and the sash face is located opposite the jamb face and configured to face a sash of a fenestration unit including the frame member, the body further comprising a first side and a second side, wherein the first side extends between the jamb face and the sash face and the second side extends between the jamb face and the sash face, and further wherein the first and second sides are located on opposite sides of the frame member such that the first side faces away from the body in a first direction and the second side faces away from the body in a second direction, wherein the first and second directions face in opposite directions from each other; and an adaptation channel extending along the first side of the body between the jamb face and the sash face, wherein the adaptation channel extends over the frame member length, wherein the adaptation channel comprises: a first wall forming a portion of the jamb face; a second wall forming a portion of the first side of the body; an outside corner formed by the first wall and the second wall at a junction between the jamb face and the first side of the body; a first interior wall extending along a direction between the first side and the second side of the frame member, the first interior wall forming a portion of the sash face configured to receive a window sash; a second interior wall generally perpendicular to the first interior wall, the second interior wall extending along a direction between the sash face and the jamb face of the frame member; and an inside corner formed within the adaptation channel at a junction of the first interior wall and the second interior wall, the inside corner facing away from the sash face and opening towards the jamb face of the frame member; wherein removal of at least a portion of the first wall and at least a portion of the second wall removes the outside corner formed by the first wall and the second wall at the junction between the jamb face and the first side of the body and exposes the inside corner located within the adaptation channel; an open trim channel extending along the frame member length adjacent the adaptation channel, wherein the trim channel opens in the first direction and is sized and configured to receive and retain a trim member extending along the frame member length before and after removal of the outside corner formed by the first wall and the second wall at the junction between the jamb face and the first side of the body; wherein the open trim channel is located between the adaptation channel and the sash face of the body of the frame member; and further wherein the first interior wall is located between the open trim channel and the second side of the frame member; and a screen frame retaining channel formed at a junction between the sash face and the first side of the body, the screen frame retaining channel comprising an interior stop and an exterior stop mutually defining the screen frame retaining channel opening towards the first side and the sash face of the frame member, wherein the open trim channel is located between the screen frame retaining channel and the jamb face of the frame member.
10. A fenestration frame member according to claim 9, wherein the adaptation channel comprises a generally rectangular inner cross-sectional shape before removal of the outside corner formed by the first wall and the second wall at the junction between the jamb face and the first side of the body.
11. A fenestration frame member according to claim 9, wherein the adaptation channel comprises a closed adaptation channel.
12. A fenestration frame member according to claim 9, wherein the frame member further comprises an extension jamb channel extending along the second side of the body between the jamb face and the sash face, wherein the extension jamb channel extends over the frame member length; and wherein the extension jamb channel comprises a sacrificial wall forming a portion of the second side of the body between the jamb face and the sash face, wherein removal of the sacrificial wall opens the extension jamb channel such that the extension jamb channel is configured to receive a portion of an extension jamb oriented generally parallel with the jamb defining an edge of a building opening in which a fenestration unit including the frame member is installed.
Description
(1) The above summary is not intended to describe each embodiment or every implementation of the adaptable fenestration frame members, fenestration units using the frame members, and methods of adapting the fenestration frame members as described herein. Rather, a more complete understanding of the invention will become apparent and appreciated by reference to the following Description of Illustrative Embodiment and claims in view of the accompanying figures of the drawing.
BRIEF DESCRIPTIONS OF THE DRAWING
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(8) For reference, each of the figures includes Cartesian coordinate system axes to assist in description of the various components of the adaptable fenestration frame members, fenestration units using the frame members, and methods of adapting the fenestration frame members between the different figures as described herein.
DETAILED DESCRIPTION
(9) In the following description, reference is made to the accompanying figures of the drawing which form a part hereof, and in which are shown, by way of illustration, specific embodiments. It is to be understood that other embodiments may be utilized and changes may be made without departing from the scope of the present invention.
(10) One illustrative embodiment of an adaptable frame member for use in manufacturing fenestration units as described herein is depicted in
(11) The frame member 10 may include a variety of features such as, cavities, walls, webs, etc. designed to provide structural integrity to the frame member 10 and/or to allow for the connection or interaction of other components with the frame member 10 when incorporated into a fenestration unit as described herein. For example, frame member 10 may include a main cavity 11 occupying a substantial portion of the body of frame member 10 along with other smaller cavities located within the body of frame member 10. The cavities and other internal structures within a frame member 10 may also be provided to improve the manufacturing process, reduce the amount of material needed to form frame member 10, etc. For example, in one or more embodiments, the smaller cavities located on opposite ends of the main cavity 11 may be sized to receive a fastener such as a screw, nail, etc. for use in securing the frame member 10 either to the fenestration unit itself and/or to the side of a building opening in which the fenestration unit is installed. Such features will be known to those skilled in the art and will not be further described herein.
(12) The body of the frame member 10 defines a jamb face 12 and a sash face 14. The jamb face 12 is configured to face a jamb defining an edge of a building opening (sometimes referred to as a rough opening) in which a fenestration unit including the frame member 10 is installed. The sash face 14 is located opposite from the jamb face 12 and is configured to face a sash (or sashes) of a fenestration unit including the frame member 10.
(13) The body of the frame member 10 may further be described as including a first side 16 and a second side 18. The first side 16 extends between the jamb face 12 and the sash face 14, while the second side 18 extends between the jamb face 12 and the sash face 14 on the opposite side of the body of the frame member 10. The first and second sides 16 and 18 are located on opposite sides of the frame member 10 such that the first side 16 faces away from a building opening in a first direction and the second side faces away from the building opening in a second direction, where the first and second directions are opposite from each other and extend along the y-axis as depicted in
(14) In the depicted illustrative embodiment of frame member 10, the first side 16 of the body of frame member 10 will typically be oriented towards an exterior of a building in which a fenestration unit using the frame member 10 is installed, while the second side 18 of the body of frame member 10 will typically be oriented towards an interior of the building, although such an arrangement is not required.
(15) The depicted illustrative embodiment of frame member 10 also includes a sash liner pocket 15 on the sash face 14 of the body of the frame member 10. The sash liner pocket 15 may, in one or more embodiments, be configured to receive a sash liner of a fenestration unit as described herein. In one or more alternative embodiments, a sash liner may be formed integrally with the frame member, such that a sash liner pocket is not required.
(16) The depicted illustrative embodiment of frame member 10 also includes an adaptation channel 20 that extends along the first side 16 of the body of frame member 10 and is located between the jamb face 12 and the sash face 14. The depicted illustrative embodiment of the adaptation channel 20 extends over the frame member length, i.e., along a z-axis as discussed herein. In one or more embodiments, the adaptation channel 20 preferably extends along the entire length of the body of frame member 10 such that it is coextensive with the frame member 10.
(17) In one or more embodiments, the adaptation channel 20 may be described as a closed adaptation channel which, as used herein, means that the only openings into the adaptation channel are found at the ends of the frame member 10 such that the closed adaptation channel 20 essentially forms a closed, tubular structure along the first side 16 of the body of frame member 10.
(18) The adaptation channel 20, when in its closed configuration as depicted in
(19) The adaptation channel 20, in its closed configuration as depicted in
(20) The adaptation channel 20 includes, in the depicted illustrative embodiment an inside corner 27 located within the adaptation channel 20. In the depicted embodiment, the inside corner 27 is formed at a junction between interior walls 26 and 28 which also define the boundaries of the adaptation channel 20.
(21) In one or more embodiments, and adaptation channel such as the depicted illustrative embodiment of adaptation channel 20 may have a generally rectangular inner cross-sectional shape before removal of the outside corner 23 formed by the first wall 22 and the second wall 24 at the junction between the jamb face 12 and the first side 16 of the body of frame member 10.
(22) Removal of at least a portion of the first wall 22 and at least a portion of the second wall 24 forming the adaptation channel 20 removes the outside corner 23 at the junction between the jamb face 12 and the first side 16 of the body of frame member 10 and, further, exposes the inside corner 27 located within the adaptation channel 20. Removal of the outside corner 23 and exposure of the inside corner 27 forms a notch in the body of the frame member 10 at the junction between the jamb face 12 and the first side 16, with that notch being useful for adapting the frame member 10 for use in a pocket type installation as will be described herein.
(23) Another optional feature which may be found in one or more embodiments of frame members as described herein include an open trim channel 30 which opens towards the first side 16 of the body of frame member 10 and extends along the frame member length adjacent to the adaptation channel 20. In one or more embodiments, the trim channel 30 preferably is coextensive with the body of frame member 10. In one or more embodiments, the trim channel 30 may be described as opening in the first direction along with the first side 16 of the body of frame member 10. In one or more embodiments, the trim channel 30 is sized and configured to receive and retain a trim member that may also extend along the frame member length both before and after removal of the outside corner 23 formed by the first wall 22 and the second wall 24 at the junction between the jamb face 12 and the first side 16 of the body of frame member 10.
(24) In one or more embodiments of a frame member as described herein, the trim channel 30 may be described as being located between the adaptation channel 20 and the sash face 14 of the body of frame member 10. As a result, removal of the outside corner 23 and the walls of the adaptation channel 20 forming that outside corner 23, does not adversely impact the integrity of the trim channel 30. In the depicted illustrative embodiment, the trim channel 30 is defined by interior wall 26 forming a portion of the adaptation channel 20 as well as wall 32 located opposite from interior wall 26, with the trim channel 30 being located between wall 32 and interior wall 26.
(25) The depicted illustrative embodiment of frame member 10 also includes a closed extension jamb channel 40 that extends along the second side 18 of the body of frame member 10. The closed extension jamb channel 40 may, in one or more embodiments, be coextensive with the length of the frame member 10. In one or more embodiments, the extension jamb channel 40 includes a sacrificial wall 42 that, in the depicted embodiment, forms a portion of the second side 18 of the body of frame member 10 between the jamb face 12 and the sash face 14. Removal of the sacrificial wall 42 opens the extension jamb channel 40 such that the extension jamb channel 40 is configured to receive a portion of an extension jamb as will be described herein. Generally, any such extension jamb may be described as oriented generally parallel with a jamb defining an edge of a building opening in which the fenestration unit including frame member 10 is installed.
(26) Another optional feature included in the depicted illustrative embodiment of frame member 10 as seen in
(27) As discussed herein, the adaptable frame members for fenestration units may be used to reduce inventory by providing a common profile that may be used to manufacture fenestration units configured for installation in building openings that have different shapes or profiles. In particular, the adaptable frame members described herein, while designed for installation in a building opening having flat surfaces (such as, e.g., conventional rough openings into which fenestration units may be installed), may be easily adapted for use in a pocket type installation in which a pocket is formed along the left and right sides and, typically, the header or top of the building opening.
(28) Two building openings having different edge profiles are depicted in cross-section views in
(29) The rough opening 70 depicted in
(30) Also depicted in
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(32) The existing window sashes are typically removed from the window frame as seen in
(33) The frame members of fenestration units installed in building opening 170 from the exterior side typically rest against the stops 175 while exterior stops 176 may or may not be replaced. In those installations in which no exterior stop 176 is replaced after locating the fenestration unit in the opening 170, the adaptation channel of a frame member of the installed fenestration unit as described herein may remain intact.
(34) As an alternative to an exterior installation approach, the interior stop 175 and the interior trim piece 173 (typically casing) may be removed to allow for installation of the fenestration unit without removing the exterior stop 176. If present, parting stops may also be removed, leaving the jambs 177 and exterior stops 176 in position. After placement of a fenestration unit in the opening 170 such that the frame members of the fenestration unit are located adjacent the jambs 177, the interior stop 175 may be replaced along with the trim piece 173 (if the trim piece 173 was removed).
(35) In those installations in which the stop 176 is left intact, the adaptable frame members described herein may be modified or adapted to allow for placement of the outermost frame member of a fenestration unit in the pocket 178. That modification may involve removal of at least a portion of the walls forming an outside corner of an adaptable frame member as described herein, such that the stop 176 can occupy a portion of the adaptation channel in the frame member.
(36) A cross-sectional view of one illustrative embodiment of an adaptable frame member 10 as described herein along with the other components of a fenestration unit incorporating the adaptable frame member 10 is depicted in
(37) The portion of the fenestration unit incorporating adaptable frame member 10 includes a pair of sashes, with a stile 60 and glazing unit 62 of a first sash being depicted in combination with a stile 64 and corresponding glazing unit 66 of a second sash. Both the first and second sashes are connected to a sash liner 68 which is, in the depicted embodiment, located within liner pocket 15 (see, e.g.,
(38) Many other conventional features of the fenestration unit are also depicted in the cross-sectional view of
(39) In addition to depicting components of one illustrative embodiment of a fenestration unit in which the illustrative embodiment of adaptable frame member 10 may be used,
(40) Removal of the outside corner portion 123 of the adaptation channel 20 will, as described herein, expose inside corner 27 in adaptation channel 20 to allow the jamb face 12 of adaptable frame member 10 to be positioned within a pocket in a building opening as described herein. Lines 22 and 24 along which the outside corner portion 123 of adaptable frame member 10 is removed are illustrative examples and more or less of the first wall 22 and/or second wall 24 may be removed to open the adaptation channel 22 convert frame member 10 for use in a pocket type installation. Suitable techniques for removing the outside corner portion 123 of the adaptation channel 20 will depend on the composition of the adaptable frame member 10, but may include, e.g., routing, grinding, cutting, etc.
(41) Also depicted in connection with
(42)
(43) The first side of the body of frame member 10 is, in the illustrative embodiment of
(44) The second side 18 of the body of adaptable frame member 10 is depicted as being generally aligned with the drywall or other interior finish sheet material 71, with any gap between sheet material 71 and frame member 10 being covered by trim piece 73 which, in the depicted illustrative embodiment, is in the form of casing.
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(46) In particular, the frame member 10 as depicted in
(47) In the depicted installation, the fenestration unit including frame member 10 could be installed in the depicted building opening after removing both brick mold 179 and all or a portion of stop 176, allowing an installer to slide fenestration unit into the building opening such that the frame member 10 is positioned with its jamb face against jamb 177. After securing the fenestration unit in place, stop 176 may be re-secured, along with brick mold 179. Alternatively, however, the fenestration unit could be installed from the opposite side through removal of stop 175. Although not depicted in
(48) Alternatively, the fenestration unit including frame member 10 could be installed in the depicted building opening after removing only the stop 175, allowing an installer to slide the fenestration unit into the building opening such that the frame member 10 is positioned with its jamb face 12 against jamb 177. After securing the fenestration unit in place, stop 175 may be re-secured.
(49) Removal of the outside corner of a frame member of a fenestration unit as described herein may, in one or more embodiments, occur before assembly of the frame members into a frame for a fenestration unit for those instances in which the fenestration unit is specifically being manufactured for installation in a building opening having a pocket as described herein. Alternatively, however, fenestration units including an adaptation channel as described herein on their frame members may be adapted after assembly of the fenestration unit for use in a pocket type installation.
(50) As used herein, the terms comprises, comprising, includes, including, has, having, contains, containing, characterized by or any other variation thereof, are intended to encompass a non-exclusive inclusion, subject to any limitation explicitly indicated otherwise, of the recited components. For example, a system or method that comprises a list of elements (e.g., components or features or steps) is not necessarily limited to only those elements (or components or features or steps), but may include other elements (or components or features or steps) not expressly listed or inherent to the method.
(51) As used herein, the singular forms a, an, and the include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a or the component may include one or more of the components and equivalents thereof known to those skilled in the art. Further, the term and/or means one or all of the listed elements or a combination of any two or more of the listed elements.
(52) Further, the term comprises and variations thereof do not have a limiting meaning where these terms appear in the accompanying description. Moreover, a, an, the, at least one, and one or more are used interchangeably herein.
(53) The complete disclosure of the patents, patent documents, and publications identified herein are incorporated by reference in their entirety as if each were individually incorporated. To the extent there is a conflict or discrepancy between this document and the disclosure in any such incorporated document, this document will control.
(54) From the above disclosure of the general principles of the present invention and the preceding detailed description, those skilled in this art will readily comprehend the various modifications, re-arrangements and substitutions to which the present invention is susceptible, as well as the various advantages and benefits the present invention may provide. Therefore, the scope of the invention should be limited only by the following claims and equivalents thereof. In addition, it is understood to be within the scope of the present invention that the disclosed and claimed articles and methods may be useful in applications other than surgical procedures. Therefore, the scope of the invention may be broadened to include the use of the claimed and disclosed methods for such other applications.