Replacement window cladding method and system
09644380 ยท 2017-05-09
Assignee
Inventors
Cpc classification
E06B2001/628
FIXED CONSTRUCTIONS
International classification
E04G23/02
FIXED CONSTRUCTIONS
E06B3/30
FIXED CONSTRUCTIONS
E06B3/00
FIXED CONSTRUCTIONS
Abstract
A window unit and replacement window cladding method and system which is provided as a single unit to be installed as a complete new window that fits over the head, side jamb and sill of an existing window frame and the old window frame that is cladded with head jamb, side jamb, and sill cover assemblies defining an opening in which one or more sash units is pivotally secured forming a replacement window unit, without any loss of glass size and egress, and without disturbing the building interior.
Claims
1. A replacement window cladding system comprising: a) a head jamb assembly; b) a pair of side jamb assemblies, said head jamb and side jamb assemblies configured to be installed as a single unit in a building window opening directly over an already installed window frame, the head and side jamb assemblies each including inner and outer balance system channels and having a rearwardly facing surface to be positioned against an outwardly facing surface of the window frame, and an extension member connected to the head and side jamb assemblies which upon installation extends behind the already installed window frame; c) a head adapter adapted to be connected to said head jamb assembly hi a position covering the inner balance system channel; d) a frame adapter adapted to be connected to said side jamb assemblies at a location between the inner and outer balance system channels; and e) a sill assembly; f) said head jamb assembly, side jamb assemblies, and sill assembly, defining an opening in which one or more sash units is securable forming a replacement window unit.
2. The replacement window cladding system of claim 1 additionally comprising an inside trim member adapted to be connected to said head and side jamb assemblies having a first leg, and a second leg with a reduced end portion.
3. The replacement window cladding system of claim 1 in which said sill assembly includes a sill cover having a main cap section, an offset ledge on one end, a nose section on the other end, and a sill cover extension having a lip on one end and another end which is supported on the offset ledge, the sill cover extension allowing for the angle of the sill cover to be adjusted to fit or modify the angle of an existing sill.
4. The replacement window cladding system of claim 3 additionally comprising an upper window sash and lower window sash which are slidably mounted to said head jamb and side jamb assemblies.
5. The replacement window cladding system of claim 4 in which the side jamb assemblies, head jamb assembly, and sill assembly are connected together to form a single unit.
6. The replacement window cladding system of claim 4 wherein at least one of the side jamb assemblies, head jamb assembly, and sill assembly is made of a synthetic material.
7. The replacement window cladding system of claim 4 wherein at least one of the side jamb assemblies, head jamb assembly, and sill assembly is made by extrusion.
8. A replacement window unit comprising: a clad jamb assembly (40) including a back wall having opposite inwardly and outwardly (42) facing surfaces, a first arm (44) connected to the back wall and having an outwardly extending portion and an inwardly extending portion, an extension arm (46) connected to the outwardly extending portion of the first arm (44) and projecting over a portion of the outwardly facing surface (42) of the back wall, a pair of aligned balance system channels (76 and 78) extending from the inwardly facing surface of the back wall, a slot (80) defined between the channels, and an exterior window casing structure (50) attached to the first arm (42), said casing structure including an accessory kerf and configured for attachment of one or more trim components to the window unit; said clad jamb assembly (40) forming at least a pair of oppositely disposed side jamb sections and a top jamb section extending between the side jamb sections, and configured to be secured to a previously installed window frame having an inwardly directed surface, a rear surface, an exterior directed surface and an interior directed surface, with the outwardly facing surface (42) of the back wall seated against the window frame inwardly directed surface, the outwardly extending portion of the first arm seated against the window frame exterior directed surface, and the extension arm abutting against the window frame rear surface; and a sill section (160) connected between the side jamb sections of the clad jamb assembly.
9. The replacement window unit of claim 8 in which the exterior window casing structure (50) includes an internal screw boss.
10. The replacement window unit of claim 9 in which the first arm perpendicularly intersects with an end of the back wall.
11. The replacement window unit of claim 10 additionally comprising a head adapter (100) having a pair of clip members for securing the head adapter in the slot (80) between the channels of the head jamb section of the jamb assembly, a sash guide section, and a channel cover section.
12. The replacement window unit of claim 11 additionally comprising a frame adapter having a pair of clip members for securing the frame adapter in the slot (80) between the channels of a side jamb section of the jamb assembly and covering the sash balances of the replacement window unit.
13. The replacement window unit of claim 8 additionally comprising a nail fin (49) extending outwardly from the first arm.
14. The replacement window unit of claim 8 additionally comprising a second arm (72) extending inwardly from the back wall and having a distal lip.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
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DETAILED DESCRIPTION OF THE INVENTION
(11) The following detailed description is of the best mode or modes of the invention presently contemplated. Such description is not intended to be understood in a limiting sense, but to be an example of the invention presented solely for illustration thereof, and by reference to which in connection with the following description and the accompanying drawings one skilled in the art may be advised of the advantages and construction of the invention. The components in the drawings are not necessarily drawn to scale, the emphasis instead being placed upon clearly illustrating the principles and manner of use of the invention. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. Wherever possible, the same reference numbers are used throughout the drawings to refer to the same or like elements of an embodiment.
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(13) Unlike other replacement window installations where either the old frame is completely removed or the new window including a new frame is installed in the old frame, in the present system the old window is replaced by a new complete window that fits over the old frame, and includes a new clad frame with built-in sashes and counter balances which have been precisely measured to fit over the old wood frame, such that the old window frame is converted into a clad window. In a limited number of circumstances, particularly in the case of historic windows or for personal reasons, the old sashes could be retrofitted for use with the present old frame cladding method and system, although in general this is likely to be more costly and labor intensive than installing a complete new replacement window unit 10. The new sashes of the replacement window unit 10 may need to be removed from the window unit 10 temporarily after the unit is inserted in the old frame, in order for the new window and cladding system to be properly anchored to the old frame as described in detail below, after which the new sashes are put back in place. In one embodiment, the new windows are deep, having a width of about 4 and abut against the old inside trim that was nailed on when the old windows were originally installed.
(14) The replacement window installation method and system of the present invention has numerous advantages over existing systems, and eliminates problems and complaints associated with current stile replacement windows, including loss of glass area. For example, a current window replacement system resulted in a reduction of the glass width from 26 to 23 and in the overall glass height from 52 to 46 (per sash height of glass lost from 25 to 22, or about 10%). In contrast, loss of glass area in the present inventor's replacement window system ranges from 0% to possibly 1%. In addition, a double frame system gives the window a thicker frame look, since the ratio of glass to frame has a dramatic primarily negative change in appearance. In contrast, the present system maintains more of the original architectural look and feel of the building structure, as the same look to the interior and exterior is provided. The new system also gives the appearance of a new construction window and can closely match any new construction that may be added to a construction project.
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(16) The exterior frame cladding can be manufactured from materials such as aluminum, vinyl or fiberglass, synthetic materials, or wood. The cladding with or without a jamb liner/sleeve is connected to the old jamb after the old exterior casings/moldings, blind stops, and head stops are removed. The new window cladding with the jamb strut attached and balance system slide in to the old frame and connect with the old frame. The exterior clad side, head jamb and full sill cover need to fit tightly to the inside stops or side extender 20, and as seen in
(17) A drip cap nailing fin 21 is secured to the new side and head jam assemblies, as well as a new head parting stop or polystyrene strut 22b which replaced old strut 22a, while head brickmold 23 is also removed. In addition, a dripcap nailing fin 24 is provided on the new clad side jamb assemblies, while side brickmold 25 is removed from the old side jambs. Once installed, a frame corner key 26 is secured to the upper corners of the new side jamb assemblies. One of the jamb balance assemblies 27 is shown behind head jamb assembly 13 in
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(19) Structure 50 is formed as part of assembly 40, and includes outwardly turned leg 52 which extends from arm 44 opposite inwardly turned arm 44, and has a rounded tip 54. Depending on the dimensions of the old window frame, in some embodiments, arm 46 and leg 52 are connected to arm 44 extending directly outwardly from each other or offset from each other. A short extension 56 extends downwardly from leg 52, and another extension 58 extends outwardly from short leg 56 to a position slightly beyond tip 54, forming outwardly facing groove 59. Another leg 60 extends downwardly from the outer end of extension 58, and the lower end of leg 60 is connected to angled extension 62 which extends downwardly and inwardly from leg 60. Angled extension 62 is connected on its other end to extension 64, which is also connected to short downward leg 66 and in turn to leg 68 which extends outwardly from the downwardly directed section of arm 44. A longitudinal track 71 is formed between leg 68 and rounded finger extension 70 which extends upwardly from leg 64. Longitudinal track 71 serves as a screw boss that enables screwing of the mitered parts together. When the old brickmold, and blind stop are removed from around the old window frame, a space or is left between the house exterior materials (siding, block, stone, stucco) that is filled by structure 50 and components to be connected to structure. This includes attachment or application of a nail fin, commercial backer rod, caulking, flashing, and nail or screw anchoring. Structure 50 therefore is the exterior window casing included in the clad system. Lip 54 is an accessory kerf used to help hold in place any clad trim accessories applied to make the face of the window wider. Increasing the width helps close any gaps between the building and the exterior window casing. There is also a corner key (see
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(25) As shown in the side diagrammatic sectional view of the replacement double hung window unit 10 in
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(28) Assembly 40 is secured to side jambs 220 and 222 by nail fins 50, and in addition screws can be passed through wall 94 between channel 76 and 78 directly into the side jambs (in one embodiment the same is true with respect to the head jamb). Once the old frame cladding has been completely installed, then the counter balances and the sash are installed.
(29) As indicated above, replacement window unit 10 is shipped completely assembled and dimensioned so that the unit slips over the old wood window jamb, sill and head, including the new sashes, sash locks and insect screen installed. When the window arrives at the project, it is ready to be installed. The sashes may be removed after installing for the purpose of accessing the area of the frame adapter, which can be removed so that anchor screws can be directed through wall 84 of the new side jamb assemblies 40, after which the frame adapter 130 is replaced. Sealant is applied behind the nail fin, and in the area where the interior of the replacement window unit 10 meets the inside stops, as well as at the exterior of the head, side jambs and sill. A polystyrene strut may be inserted behind the head and side jambs which are used as a tunnel pad to block air and water from leaking into the replacement window unit structure 10. In one embodiment, the clad sill assembly is connected to the new side jamb assemblies by a screw boss channel which is built into the side jamb system in the spaces formed structural members 82 in assembly 40. In this arrangement, screws will be directed up through the underneath of the sill and into the screw boss channel in the side jamb.
(30) In one method of practicing the present invention, first the installer will inspect the condition of the old window and take exact measurements of the old window, which are to be provided to the manufacturer of the window, since proper sizing of the new window is very important. When the new window arrives, it is completely assembled with the assembly configured to slip over the old wood window jamb, sill and head, and with the sash, sash locks and an insect screen installed. When the window arrives at the project, it is therefore already properly sized and ready to be installed. As indicated above, the sash may be removed after installing for the purpose of accessing the area of the frame adapter, which is temporarily removed to install anchor screws, after which the frame adapter is replaced. To prepare the old opening to receive the new window, the old brick molding or exterior casing and exterior blind stop are removed. Next, the cavity space between the remaining window frame, sill, and head is inspected for any wood rot, old insulation, or insect infestations. Using a good quality insulation, low expanding foam, fiberglass batt type insulation and window and door graded caulking, is applied to the exterior edge of the old jamb, head and sill. The new replacement window unit 10 is then fitted over the old window frame by placing the head exterior open receptor slot over the old head jamb while rotating down on the side jambs. As the new side jambs slide over the old side jamb, the window unit is pressed evenly inwardly until the sill connects the old sill at the back stop. The installer will then plumb, level, and square the new window with respect to the old window frame, with shims being made available so the installer can adjust the frame to square up. Shims can also be used on the outside perimeter on the frame to square, plumb and level the new window. Once this is completed, 1roofing nails are used to nail into the nail fin and anchor the new window. A drip cap is applied over the head of the new window unit, and the set of the window to the interior is checked. Further shims and caulk are used if necessary to achieve a proper appearance. When secured to the side jamb and connected on all four corners the unit becomes a fully assembled window in need of the wood side jamb of the old window. It is then married to the old wood side jamb, head jamb and sill. The unit is secured with the nail fin and or anchored through the side jamb. Anchoring through the side jamb is best done by removing the frame adapter.
(31) While the present invention has been described with respect to the installation of double hung replacement windows, in another embodiment the invention may be used with casement and awning windows. The present system requires eight sash parts for a double hung window and four sash parts for a casement/awning window. This present design can be used for replacement of casements and awnings with modifications to a casement/awning sill cover and no frame blind stop inside or out, and a sash stop will be added to the location of the parting bead and head stop.
(32) As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by referenced in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.
(33) While the present invention has been described at some length and with some particularity with respect to the several described embodiments, it is not intended that it should be limited to any such particulars or embodiments or any particular embodiment, but it is to be construed with references to the appended claims so as to provide the broadest possible interpretation of such claims in view of the prior art and, therefore, to effectively encompass the intended scope of the invention.