Installation method

Abstract

Needless repairs can be avoided, and energy savings can be achieved, through installation of windows using methods that incorporate the use of extruded water-resistant foam, bonding tape covering the flanges and fasteners or windows and building wrap covering the bonding tape. This system becomes part of the window, system to improve strength, air and moisture penetration Also eliminating the building wrap bonding tape at the head prevents trapping moisture behind build bonding tape. This system eliminates all voids around the window and frame and becomes part of the structure of the window, etc.

Claims

1. A method for installing a window in a building comprising: a) providing an exterior wall having an interior side, an exterior side and a rough opening of a first shape and a first predetermined size, said first shape and first predetermined size defined by a rough opening frame, the exterior side of the exterior wall having a sheathing layer; b) providing a window having a perimeter of a second predetermined shape and of a second predetermined size defined by a window frame having a plurality of sides, wherein said second predetermined shape and said second predetermined size are selected so that the window substantially fills the rough opening leaving a gap in the range of inch to inch surrounding the window frame on all sides between the window frame and the rough opening frame, the window having a plurality of planar flanges, a separate one of the plurality of planar flanges extending radially outward from each one of the plurality of sides of the window frame; c) inserting the window frame into the rough opening with the plurality of flanges abutting the sheathing layer of the wall and attaching the window frame to the exterior wall with a plurality of rust-proof fasteners while maintaining said gap between the window frame and the rough opening frame; d) installing a bonding tape so that it extends over an exterior surface of each of the plurality of flanges and a portion of the sheathing layer at least one inch wide surrounding the flanges; e) installing a building wrap over the exterior side of the wall so that the building wrap extends over an exterior surface of the window bonding tape and the flanges; and f) filling the gap with a sprayed extruded closed cell water-resistant foam, wherein said sprayed extruded closed cell water-resistant foam is adapted to assist in supporting the window in the rough opening and prevent air and moisture migration in or out of the building.

2. The method of claim 1 wherein the rust proof fasteners comprise screws.

3. The method of claim 1 wherein the rust proof fasteners comprise nails.

4. The method of claim 1 wherein the building wrap is held in place over the flange and bonding tape using at least one piece of exterior trim.

5. The method of claim 1 wherein the building wrap is held in place over the flange and rubber bonding tape using wrap fasteners, each of said wrap fastener comprising a nail and a plastic washer.

6. The method of claim 1 wherein the sprayed extruded water-resistant foam is an extruded polystyrene foam.

7. The method of claim 1 wherein bonding tape comprises a substrate and an adhesive layer.

8. The method of claim 7 wherein the substrate is made of a material selected from a group consisting of silicone rubber and ethylene propylene diene monomer (EPDM) rubber.

9. The method of claim 1 wherein the building wrap is selected from a group consisting of asphalt-saturated felt, asphalt-saturated kraft paper, a woven polymeric sheet, a non-woven polymeric sheet, and a liquid-applied polymer-asphalt membrane.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The foregoing features, objects and advantages of the invention will become apparent to those skilled in the art from the following detailed description and with reference to the following drawings in which like numerals in the several views refer to corresponding parts.

(2) FIG. 1 is a plan view framing of a rough opening made using a standard prior art technique.

(3) FIG. 2 is a plan view of a prior art window having a window frame and flanges extending therefrom.

(4) FIG. 3 is a cross-section view through line 3-3 in FIG. 1 after a window has been positioned in the rough opening.

(5) FIG. 4 is a flow chart of steps carried out in accordance with the present invention to install a window of a type made in accordance with FIG. 2 in a rough opening framed in accordance with FIG. 1.

DETAILED DESCRIPTION

(6) This description of the preferred embodiment is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description of this invention. In the description, relative terms such as lower, upper, horizontal, vertical, above, below, up, down, top and bottom, under, as well as derivatives thereof (e.g., horizontally, downwardly, upwardly, underside, etc.) should be construed to refer to the orientation as then described or as shown in the drawings under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms such as connected, connecting, attached, attaching, joined, and joining are used interchangeably and refer to one structure or surface being secured to another structure or surface or integrally fabricated in one piece unless expressly described otherwise.

(7) As illustrated in FIGS. 3 and 4, the process of the present invention begins by selecting a window of a desired shape and size at step 50 and framing a rough opening at step 52 adapted to receive the selected window. Again, and as shown in FIG. 1, a rough opening frame 12 defines a rectangular rough opening 10. Rough opening frame 12 includes a pair of vertical king studs 17/18. Extending between the king studs are a sill plate 15 and header 16a/b. Two jack studs 13 and 14 are positioned to the inside of and abut the king studs 17 and 18. The jack studs 13 and 14 are also extending between the header 16 and the sill plate 15 and help hold the header 16a/b in place. The sill plate is also supported by a plurality of cripple studs 19/20/21/22/23. Other rough opening framing arrangements are used when the rough opening 10 is to be of a different shape. One skilled in the art will appreciate that the shape and size of the rough opening are dictated by the size, shape and type of the window employed.

(8) The window selected when performing the method of the present invention will have a perimeter of a first predetermined shape matching the predetermined shape of the rough opening and sized to fit in the rough opening. The size and shape of the window perimeter are defined to be a window frame. FIG. 2 shows an exemplary window 30 of a type suitable installed using the method of the present invention. As shown in FIG. 2, the window 30 includes a frame 32. The frame includes a top frame member 34 and a top flange 35 extending from the top frame member 34. The window frame 32 also includes a bottom frame member 36 and a bottom flange 37 extending from the bottom frame member 36. Extending between the top and bottom frame members are a pair of side frame members 38 and 40. A first side flange 39 extends from side frame member 38 and a second side flange 41 extends from side frame member 40. Other window framing arrangements are used when the window is to be of a different shape. Also, as shown in FIG. 1, the exterior of the framing members (i.e., jack studs 13/14) are typically covered with sheathing 24 while the rough opening is not so covered.

(9) When the present invention is employed, the window frame 32 and/or the rough opening 10 should be adapted such that window frame 32 fits into the rough opening 10 leaving a gap in the range of inch to inch surrounding the window frame on all sides between the window frame and the rough opening framing. Also, the flanges and rough opening should be adapted so the flanges extend over a portion of the jack studs 13/14, sill plate 15 and header 16a/16b.

(10) As indicated at step 54 in the flow chart of FIG. 3, the window 30 is positioned in the rough opening with the requisite gap about the entire perimeter of the window between the window frame and the rough opening frame. Shims are used to maintain the gap during framing. Using XPS shims is preferred, but other shims may be used. Further, the flanges of the window extend over the members used to construct the rough opening frame 12.

(11) At step 56, the window frame is secured in place to the rough opening frame while maintaining a gap in the range of inch to inch surrounding the window frame between the window frame and the rough opening frame. The window is so secured to the rough opening frame by securing top flange 35 to the header 16a, the bottom flange 37 to the sill plate 15 or the cripple studs 19/20/21/22/23, and the side flanges 39 and 41 to the jack studs 13/14 or king studs 17/18. The flanges are so secured using a plurality of rust-proof fasteners (e.g., flat head screws or nails) 70 while maintaining the requisite gap in the range of inch to inch between the window frame and the rough opening frame. The flanges may be provided with spaced slots (not shown) through which such screws or nails may pass through the underlying sheathing and into the underlying framing member. The flanges may be preinstalled at the window factory or installed at the job site depending on the window selected.

(12) The process of the present invention further entails three key steps identified as steps 58, 60 and 62 in FIG. 4. As step 58, rubber pressure sensitive bonding tape 72 is installed so that it extends over (a) each of the plurality of flanges (e.g., flange 41 as shown in FIG. 3), including the corners where the flanges meet, (b) each of the plurality of rust proof fasteners 70, and (c) a portion of the sheathing 24 of the wall at least one inch wide surrounding the flanges. As explained above, various types of bonding tape 72 may be employed. Such bonding tapes typically include a first layer (i.e., a substrate) of a suitable material and an adhesive layer. The first layer or substrate may be silicone rubber or ethylene propylene diene monomer (EPDM) rubber, for example. The bonding tape must be suitable for exterior applications given the climatic conditions in the region of the installation and have the capability of being installed over a wide range of temperatures and have even a wider range of service temperatures. A wider range of service temperatures is particularly necessary when the installation is in a climate having temperature extremes ranging from well below 0 F. and peaking at over 100 F. Both the substrate and the adhesive layer selected should have excellent resistance to moisture and ultraviolent (UV) light and be non-reactive to solvents and other chemicals. A pressure sensitive adhesive will make installation of the bonding tape simpler and quicker than other types of adhesives.

(13) Step 59 shown in FIG. 4 involves installing any separate drip edges supplied by the window manufacturer in accordance with the manufacturer's instructions.

(14) At step 60, a building wrap (74 in FIG. 3) applied to the exterior of the wall is extended over the window bonding tape on the jam and sill sides 37, 39 and 41 of the window. As explained above, building wraps in use today include asphalt-saturated felt or kraft paper, woven or nonwoven polymeric sheets, and liquid-applied polymer-asphalt membranes. Any such wraps may be employed when practicing the present invention. Woven polymeric wraps work particularly well. Woven polymeric wraps are made of crisscrossing plastic bonding tapes coated with a waterproof film and may be micro-perforated to allow vapor to pass. Polymeric wraps are suitable for use behind fiber cement siding, wood, and vinyl, brick, brick veneer, and stucco. The film can also include UV inhibitors if prolonged exposure during construction of the building is contemplated.

(15) At step 62, the gap between the window frame 32 and the rough opening frame 12 is filled with a sprayed extruded water-resistant foam 76. Use of such a sprayed extruded water-resistant foam (e.g., XPS foam) to fill this gap 100% serves several purposes. First, the foam is relatively stiff and firm after it sets up. As such, the foam assists with supporting the window 30 in the rough opening 10. Second, the foam prevents air and moisture migration in or out of the building. Third, the foam reduces conductive flow of heat around the window. The sprayed extruded water-resistant foam is preferably an extruded polystyrene foam. It can be used at the jams and sill bonding tape (same as the bonding tape used for the window to prevent tearing of the wrap before the outside studding is installed), at the head of the washer nail and nail or screw with the washer to prevent moisture from penetrating the substrate. This is a significant step that is not being done.

(16) In addition to the foregoing, installation of the window 30 in the rough opening 10 may include having a building wrap 74 held in place over the rubber bonding tape 72 and flanges (e.g., 41) using one or more pieces of exterior trim or wrap fasteners. Such wrap fasteners typically comprise a flat head nail passing through a plastic washer.

(17) Once the foregoing steps are completed, the interior and exterior portions of the wall are completed in any well-known manner at step 64. For example, sheetrock and window trim may be applied to the interior of the wall and window flashing, trim and siding may be applied to the exterior of the wall.

(18) Within the scope of the following claims, the invention may be practiced otherwise than as specifically shown in the drawings and described above. The methods may be used in connection with all buildings, new or old, residential or commercial. Likewise, the framing and sheathing may be made of any suitable material, for example, block concrete, poured concrete, wood, plastic, or other synthetic materials. The foregoing description is intended to explain the various features and advantages but is not intended to be limiting. From the foregoing, one skilled in the art will appreciate that the same methods may be used when installing doors and other devices on rough openings in walls. The methods of the present invention are likewise applicable to residential, commercial, and other buildings. The scope of the invention is defined by the following claims which are also intended to cover a reasonable range of equivalents.