Abstract
Installation systems and methods for fenestration units configured to be set into a rough opening (RO) from interior side of a building structure or wall. The fenestration units may include a retention system coupled to the frame and operable to exert a retention force on the fenestration unit to maintain positive engagement of the fenestration unit with the rough opening framing and resist extraction of the fenestration unit from the rough opening upon insertion of the fenestration unit in the rough opening from the interior side of the rough opening.
Claims
1. A method of installing a fenestration unit, the method comprising: performing an interior installation phase from an interior of a building structure having an exterior opposite the interior of the building structure, the building structure including a rough opening having a rough opening frame, the rough opening frame having a center, a perimeter extending around the center, and a support surface facing toward the center and substantially orthogonal to an interior surface of the building structure that faces toward the interior of the building structure, the interior installation phase including, arranging a fenestration unit in the rough opening from the interior of the building structure, adjusting a position of the fenestration unit within the rough opening, securing the fenestration unit to the rough opening frame with a plurality of fasteners such that an anchoring clip coupled to a perimeter of the fenestration unit contacts the interior surface of the building structure, and insulating a gap between the rough opening frame and the fenestration unit; and performing an exterior installation phase from an exterior side of the building structure independently from the interior installation phase, the exterior installation phase including, engaging a pop-up fin with the exterior surface of the building structure, the pop-up fin being pre-biased toward engagement with the exterior surface of the building structure, and weather sealing the fenestration unit to an exterior surface of the building structure using the pop-up fin.
2. The method of claim 1, wherein the interior installation phase is carried out by at least one installer and is characterized by an average labor time of 5 minutes or less for the at least one installer.
3. The method of claim 1, wherein at least one of the interior installation phase and the exterior installation phase is carried out by a single installer.
4. The method of claim 1, wherein the exterior installation phase is carried out by at least one installer and is characterized by an average labor time of 3 minutes or less for the at least one installer.
5. The method of claim 1, wherein the exterior installation phase is carried out by an installer on a ladder, and further wherein a percentage of time the installer is on the ladder is 50% or less of a total labor time of the interior and exterior installation phases.
6. The method of claim 1, wherein a total labor time with an installer on an exterior side of the rough opening is 50% or less of a total labor time for the interior and exterior installation phases.
7. The method of claim 1, wherein a total labor time with an installer on an exterior side of the rough opening is 40% or less of a total labor time for the interior and exterior installation phases.
8. The method of claim 1, wherein an average time for the exterior installation phase of the fenestration unit is at least 80% less than an installation of a fenestration unit that includes a nailing fin.
9. The method of claim 1, wherein an average time for the exterior installation phase of the fenestration unit is at least 70% less than an installation of a fenestration unit that includes a nailing fin.
10. The method of claim 1, wherein the exterior installation phase is carried out by an installer on a ladder, and an average labor time with the installer on the ladder is at least 75% less than an exterior installation phase of a fenestration unit that includes a nailing fin.
11. The method of claim 1, wherein weather sealing the fenestration unit to the exterior surface of the building structure includes securing a weather seal system including the pop-up fin to the exterior side of the building structure using a flashing, wherein the weather seal system is configured is such that the fenestration unit meets an ASTM E2112-23 installation sealing standard.
12. The method of claim 1, wherein the interior installation phase is at least 60% of a total labor time for the interior and exterior installation phases.
13. The method of claim 1, wherein adjusting the position of the fenestration unit within the rough opening further includes measuring a level, squareness, and a plumbness of the fenestration unit, and adjusting the position is completed prior to securing the fenestration unit to the rough opening frame with a plurality of fasteners.
14. The method of claim 1, wherein the anchoring clip includes a plurality of anchoring clips secured to the perimeter of the fenestration unit, and wherein securing the fenestration unit to the rough opening frame with a plurality of fasteners further includes securing the plurality of fasteners through the plurality of anchoring clips.
15. The method of claim 1, wherein the fenestration unit includes a frame and a retention system including a spring retainer secured to the frame, and wherein arranging a fenestration unit in the rough opening further includes engaging the retention system with the rough opening such that the retention system exerts a retention force on the rough opening to self-retain the fenestration unit in the rough opening and resists movement out from the rough opening framing against an exterior-to-interior force.
16. The method of claim 1, wherein the fenestration unit includes a frame defining a perimeter and a weather seal system secured to the frame, the weather seal system including the pop-up fin positioned at a top of the frame and configured to transition from a first, folded configuration in which the pop-up fin projects along the top of the frame and a second, projecting configuration in which the pop-up fin assembly projects outward relative to the top of the frame, and a retaining assembly including a clip releasably securing the pop-up fin at the head with the pop-up fin in the first, folded configuration, and wherein the method further includes removing the retaining assembly as a single piece.
17. A method of installing a fenestration unit, the method comprising: performing an interior installation phase from an interior of a building structure having an exterior opposite the interior of the building structure, the building structure including a rough opening having a rough opening frame, the rough opening frame having a center, a perimeter extending around the center, and a support surface facing toward the center and substantially orthogonal to an interior surface of the building structure that faces toward the interior of the building structure, the interior installation phase including, arranging a fenestration unit in the rough opening from the interior of the building structure using an insertion force such that the fenestration unit exerts a retention force on the rough opening frame that is greater than the insertion force to maintain positive engagement of the fenestration unit with the rough opening frame and resist extraction of the fenestration unit from the rough opening after insertion of the fenestration unit in the rough opening such that the fenestration unit remains stationary in the rough opening without use of fasteners, adjusting a position of the fenestration unit within the rough opening, securing the fenestration unit to the rough opening frame with a plurality of fasteners such that an anchoring clip coupled to a perimeter of the fenestration unit contacts the interior surface of the building structure, and insulating a gap between the rough opening frame and the fenestration unit; and performing an exterior installation phase from an exterior side of the building structure independently from the interior installation phase, the exterior installation phase including, weather sealing the fenestration unit to an exterior surface of the building structure.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The accompanying drawings are included to provide a further understanding of the disclosure and are incorporated in and constitute a part of this specification, illustrate embodiments, and together with the description serve to explain the principles of the disclosure.
(2) FIG. 1 is a top-oriented, perspective view of a fenestration unit from an interior side, according to some embodiments.
(3) FIG. 2 is a bottom-oriented, perspective view from the interior side of the fenestration unit of FIG. 1, according to some embodiments.
(4) FIG. 3 is a perspective view from an exterior side of the fenestration unit of FIG. 1, according to some embodiments.
(5) FIG. 4 is a perspective view from an interior side showing the fenestration unit of FIG. 1 in an initial, stowed or pre-installation configuration, according to some embodiments.
(6) FIG. 5 depicts an anchoring clip of the fenestration unit of FIG. 1 from an isometric view, according to some embodiments.
(7) FIGS. 6 and 7 are isometric views of a carrier bracket of the anchoring clip of FIG. 5, according to some embodiments.
(8) FIG. 8 is a backplate of the carrier bracket of FIGS. 6 and 7, according to some embodiments.
(9) FIG. 9 is an isometric view of a receiver of the carrier bracket of FIGS. 6 and 7, according to some embodiments.
(10) FIG. 10 shows a coupling bracket of the anchoring clip of FIG. 5 from an isometric view, according to some embodiments.
(11) FIG. 11 is an isometric view of another anchoring clip design of the fenestration unit of FIG. 1, according to some embodiments.
(12) FIGS. 12, 13, 14, and 15 are isometric view of another anchoring clip design of the fenestration unit of FIG. 1, according to some embodiments.
(13) FIG. 12 is an isometric view of the anchoring clip, according to some embodiments.
(14) FIG. 13 is an isometric view of the anchoring clip of FIG. 12 with a backplate removed, according to some embodiments.
(15) FIG. 14 shows a coupling bracket of the anchoring clip of FIG. 12 from a bottom view, according to some embodiments.
(16) FIG. 15 shows an isometric view of a carrier bracket of the anchoring clip of FIG. 12, according to some embodiments.
(17) FIG. 16 is a bottom view of the fenestration unit of FIG. 1, according to some embodiments.
(18) FIG. 17 is a bottom, perspective view of the fenestration unit of FIG. 1, according to some embodiments.
(19) FIG. 18 is a closeup view of a lower corner of the fenestration unit of FIG. 1, according to some embodiments.
(20) FIGS. 19, 20, and 21 shows a sill spacer of the fenestration unit of FIG. 1, according to some embodiments.
(21) FIG. 19 is an isometric view of a sill spacer of the fenestration unit of FIG. 1, according to some embodiments.
(22) FIG. 20 is an end view of the sill spacer of FIG. 19, according to some embodiments.
(23) FIG. 21 is a bottom view of the sill spacer of FIG. 19, according to some embodiments.
(24) FIG. 22 is an isometric view of another design of a sill spacer of the fenestration unit of FIG. 1, according to some embodiments.
(25) FIG. 23 is an end view of the sill spacer of FIG. 22, according to some embodiments.
(26) FIGS. 24, 25 and 26 are views of another design of a sill spacer of the fenestration unit of FIG. 1, according to some embodiments.
(27) FIG. 24 is an isometric view of a sill spacer of the fenestration unit of FIG. 1, according to some embodiments.
(28) FIG. 25 is an end view of the sill spacer of FIG. 24, according to some embodiments.
(29) FIG. 26 shows the sill spacer of FIG. 24 assembled to different sill designs, according to some embodiments.
(30) FIGS. 27, 28, and 29 are views of another design of a sill spacer of the fenestration unit of FIG. 1, according to some embodiments.
(31) FIG. 27 is an isometric view of another design of a sill spacer of the fenestration unit of FIG. 1, according to some embodiments.
(32) FIG. 28 is an end view of the sill spacer of FIG. 27, according to some embodiments.
(33) FIG. 29 is a bottom view of the sill spacer of FIG. 27, according to some embodiments.
(34) FIGS. 30, 31, and 32 are views of another design of a sill spacer of the fenestration unit of FIG. 1, according to some embodiments.
(35) FIG. 30 is an isometric view of another design of a sill spacer of the fenestration unit of FIG. 1, according to some embodiments.
(36) FIG. 31 an end view of the sill spacer of FIG. 30, according to some embodiments.
(37) FIG. 32 is a bottom view of the sill spacer of FIG. 30, according to some embodiments.
(38) FIGS. 33, 34, and 35 are views of another design of a sill spacer of the fenestration unit of FIG. 1, according to some embodiments.
(39) FIG. 33 is an isometric view of another design of a sill spacer of the fenestration unit of FIG. 1, according to some embodiments.
(40) FIG. 34 an end view of the sill spacer of FIG. 33, according to some embodiments.
(41) FIG. 35 is a bottom view of the sill spacer of FIG. 33, according to some embodiments.
(42) FIGS. 36, 37, 38, and 39 are views of a retainer of the fenestration unit of FIG. 1, according to some embodiments.
(43) FIG. 36 is an isometric view of a retainer of the fenestration unit of FIG. 1, according to some embodiments.
(44) FIG. 37 is a side view of the retainer of FIG. 36, according to some embodiments.
(45) FIG. 38 is a schematic view illustrating engagement of the retainer with a head of rough opening framing as the fenestration unit of FIG. 1 is inserted in a first, exterior direction.
(46) FIG. 39 shows the engagement as the fenestration unit of FIG. 1 is extracted in a second, interior direction, according to some embodiments.
(47) FIGS. 40, 41, 42, and 43 are views of another design of a retainer of the fenestration unit of FIG. 1, according to some embodiments.
(48) FIG. 40 is an isometric view of a retainer of the fenestration unit of FIG. 1, according to some embodiments.
(49) FIG. 41 is a side view of the retainer of FIG. 40, according to some embodiments.
(50) FIG. 42 is a schematic view illustrating engagement of the retainer with a head of rough opening framing as the fenestration unit of FIG. 1 is inserted in a first, exterior direction.
(51) FIG. 43 shows the engagement as the fenestration unit of FIG. 1 is extracted in a second, interior direction, according to some embodiments.
(52) FIG. 44 is an end view of a fin of the fenestration unit of FIG. 1, according to some embodiments.
(53) FIG. 45 is an isometric view of the fin of FIG. 44, according to some embodiments.
(54) FIG. 46 is an isometric view of another fin design similar to that of FIG. 23A, according to some embodiments.
(55) FIG. 47 is a closeup view of a corner of the fenestration unit of FIG. 1, according to some embodiments.
(56) FIG. 48A is an isometric view of a first corner bridge seal of the fenestration unit of FIG. 1, according to some embodiments.
(57) FIG. 48B is an isometric view of a second corner bridge seal of the fenestration unit of FIG. 1, according to some embodiments.
(58) FIG. 48C is a backside view of an adhesive applied to the first corner bridge seal of FIG. 48A, according to some embodiments.
(59) FIG. 49 is an isometric view of a head fin, and first and second corner bridge seals of the fenestration unit of FIG. 1, according to some embodiments.
(60) FIG. 50 is a closeup end view of a first corner of the fenestration unit with a fin assembly of the fenestration unit of FIG. 1 removed, according to some embodiments.
(61) FIG. 51 is a closeup isometric view of the first corner of the fenestration unit of FIG. 1 with the first bridge corner seal removed, according to some embodiments.
(62) FIG. 52A is a closeup, isometric view of the third corner of the fenestration unit of FIG. 1 showing an overlap of a first jamb fin and a sill fin of the fenestration unit, according to some embodiments.
(63) FIG. 52B is a closeup, isometric view of the third corner of the fenestration unit of FIG. 1 showing another design proximate the intersection of the first jamb fin and a sill fin of the fenestration unit, according to some embodiments.
(64) FIG. 53 is an isometric view of the fenestration unit of FIG. 1 in a stowed configuration, according to some embodiments.
(65) FIG. 54 is an isometric view of the fenestration unit of FIG. 1 in a deployed, or installation configuration, according to some embodiments.
(66) FIGS. 55A, 55B, and 55C are isometric views of the second corner bridge seal of the fenestration unit of FIG. 1 transitioning from the folded, stowed configuration to the unfolded, deployed configuration, according to some embodiments.
(67) FIGS. 55D, 55E, 55F, and 55G are isometric views of the second corner bridge seal of the fenestration unit of FIG. 1 transitioning from the unfolded, deployed configuration to the folded, stowed configuration, according to some embodiments.
(68) FIG. 56 is a closeup, isometric view of the fenestration unit of FIG. 1 in a stowed configuration with a plurality of retaining clips removed and showing the first bridge corner seal in a folded configuration, according to some embodiments.
(69) FIGS. 57, 58, and 59 illustrate a retaining clip design of the fenestration of FIG. 53, according to some embodiments.
(70) FIG. 57 is an isometric view of a retaining clip of the fenestration unit of FIG. 53, according to some embodiments.
(71) FIG. 58 is an end view of the retaining clip of FIG. 57, according to some embodiments.
(72) FIG. 59 is sectional view at a head of the fenestration unit of FIG. 30, according to some embodiments.
(73) FIGS. 60, 61, and 62 illustrate another retaining clip design of the fenestration unit of FIG. 53, according to some embodiments.
(74) FIG. 60 is an isometric view of a retaining clip of the fenestration unit of FIG. 53, according to some embodiments.
(75) FIG. 61 is an end view of the retaining clip of FIG. 60, according to some embodiments.
(76) FIG. 62 is sectional view at a head of the fenestration unit of FIG. 53, according to some embodiments.
(77) FIGS. 63, 64, and 65 show a barrier system design of the fenestration unit of FIG. 1, according to some embodiments.
(78) FIG. 63 is a side profile of the barrier system of the fenestration unit including a barrier fin, according to some embodiments.
(79) FIG. 64 is a profile of the barrier system of the fenestration unit including a sealant, according to some embodiments.
(80) FIG. 65 is an isometric view of the barrier system of FIGS. 63A-63B, according to some embodiments.
(81) FIGS. 66, 67, and 68 show a barrier system design of the fenestration unit of FIG. 1, according to some embodiments.
(82) FIG. 66 is a side profile of the barrier system of the fenestration unit including a barrier fin, according to some embodiments.
(83) FIG. 67 is a profile of the barrier system of the fenestration unit including a sealant, according to some embodiments.
(84) FIG. 68 is an isometric view of the barrier system of FIGS. 63A-63B, according to some embodiments.
(85) FIGS. 69, 70, 71, and 72 show an adjustment system design of the fenestration unit of FIG. 1, according to some embodiments.
(86) FIG. 69 is a closeup, side view of the fenestration unit of FIG. 1 showing an adjustment system of the fenestration unit including an edge adjuster, according to some embodiments.
(87) FIG. 70 is an isometric view of the edge adjuster of FIG. 63, according to some embodiments.
(88) FIGS. 71 and 72 are front and side views of the edge adjuster of FIG. 63, according to some embodiments.
(89) FIGS. 73, 74, 75, and 76 show another adjustment system design of the fenestration unit of FIG. 1, according to some embodiments.
(90) FIG. 73 is a closeup, side view of the fenestration unit of FIG. 1 showing an adjustment system of the fenestration unit including an edge adjuster, according to some embodiments.
(91) FIG. 74 is a closeup, side view of the fenestration unit of FIG. 73, with the edge adjuster removed to reveal an adjustment aperture of a frame of the fenestration unit, according to some embodiments.
(92) FIGS. 75 and 76 are isometric views of the edge adjuster of FIG. 67, according to some embodiments.
(93) FIG. 77A is a side-oriented perspective view of a fenestration unit from an interior side, according to some embodiments.
(94) FIG. 77B is a front view of the fenestration unit of FIG. 77A from the interior side, according to some embodiments.
(95) FIG. 77C is a side view of the fenestration unit of FIG. 77A, according to some embodiments.
(96) FIG. 77D is a bottom-oriented perspective view of the fenestration unit of FIG. 77A from the interior side, according to some embodiments.
(97) FIG. 78 is an illustration of a squareness measurement method, according to some embodiments.
(98) FIG. 79 is an illustration of a plumbness measurement method, according to some embodiments.
(99) FIG. 80 is an illustration of a level measurement method, according to some embodiments.
(100) FIG. 81 is an illustration of an interior installation phase of a fenestration unit, according to some embodiments.
(101) FIG. 82 is an illustration of an exterior installation phase of a fenestration unit, according to some embodiments.
(102) FIG. 83 is a chart illustrating the average labor time for installation of the fenestration unit, according to some embodiments.
(103) FIG. 84 is a chart illustrating the average labor time for an Exterior Installation Process for installation of the fenestration unit, according to some embodiments.
DETAILED DESCRIPTION
Definitions and Terminology
(104) This disclosure is not meant to be read in a restrictive manner. For example, the terminology used in the application should be read broadly in the context of the meaning those in the field would attribute such terminology.
(105) With respect to terminology of inexactitude, the terms about and approximately may be used, interchangeably, to refer to a measurement that includes the stated measurement and that also includes any measurements that are reasonably close to the stated measurement. Measurements that are reasonably close to the stated measurement deviate from the stated measurement by a reasonably small amount as understood and readily ascertained by individuals having ordinary skill in the relevant arts. Such deviations may be attributable to measurement error, differences in measurement and/or manufacturing equipment calibration, human error in reading and/or setting measurements, minor adjustments made to optimize performance and/or structural parameters in view of differences in measurements associated with other components, particular implementation scenarios, imprecise adjustment and/or manipulation of objects by a person or machine, and/or the like, for example. In the event it is determined that individuals having ordinary skill in the relevant arts would not readily ascertain values for such reasonably small differences, the terms about and approximately can be understood to mean plus or minus 10% of the stated value.
(106) Persons skilled in the art will readily appreciate that various aspects of the present disclosure can be realized by any number of methods and apparatuses configured to perform the intended functions. It should also be noted that the accompanying drawing figures referred to herein are not necessarily drawn to scale and may be exaggerated to illustrate various aspects of the present disclosure, and in that regard, the drawing figures should not be construed as limiting.
Description of Various Embodiments
(107) Various concepts of this patent specification address installation systems and methods for fenestration units, such as windows and doors. Some features of such systems and methods include one or more of the following: configured to be set into a rough opening (RO) from interior side of a building structure or wall; eliminated or reduced need for jamb and/or sill spacers; pre-applied sill spacers (e.g., factory-applied); pre-applied head stabilizers and/or jamb stabilizers for self-stabilization in the rough opening while leveling, plumbing, squaring, and/or anchoring the fenestration unit; gauged to the interior face of rough opening for more accurate finishing (e.g., drywall and/or trim) offsets; attached with pre-applied (e.g., factory-applied) anchoring clips configured for interior unit installation; no or reduced fasteners utilized on the exterior side of the fenestration unit; pre-attached (e.g., factory-applied) exterior water barrier (e.g., pop-up fin); storable and deployable exterior water barrier (e.g., constrained by removable packaging clips for shipping/installation); facilitates standard flashing tape methods; configured to be installed by a single person/installer; interior and exterior installation tasks can be performed at different times (e.g., with a substantial break in period of time between the two types of tasks).
(108) In various examples, the fenestration units (e.g., fenestration unit 10) include features that promote installation of the fenestration unit from an interior side of a rough opening using a methodology that can be readily achieved by a single installer. In particular, a fenestration unit according to various examples includes a retention system coupled to the frame of the fenestration unit that is operable to exert a retention force on the fenestration unit to maintain positive engagement of the fenestration unit with the rough opening framing and resist extraction of the fenestration unit from the rough opening upon insertion of the fenestration unit in the rough opening from the interior side of the rough opening. The retention system may operate such that the fenestration unit remains stationary in the rough opening without use of fasteners securing the fenestration unit to the rough opening framing. The fenestration unit may include an engagement system coupled to the frame, the engagement system configured to positively engage the interior face of the rough opening framing upon insertion of the fenestration unit in the rough opening from the interior side of the rough opening. In turn, the afore-mentioned retention system may operate to maintain positive engagement of the retention system with the rough opening framing upon insertion of the fenestration unit in the rough opening from the interior side of the rough opening and without use of fasteners securing the fenestration unit to the rough opening framing.
(109) In this manner, a single individual may insert a fenestration unit into a rough opening (RO) from the interior side thereof, without needing a second person to hold the fenestration unit against the rough opening framing, or otherwise assist with maintaining the positioning of the fenestration unit in the rough opening (RO). This retention feature also removes the need for the installer to use one hand to hold the fenestration unit against the rough opening framing, freeing both hands of the installer to carry out the installation process, such as securing the fenestration unit to the rough opening using fasteners, such as nails or screws, and/or leveling, plumbing, and squaring the fenestration unit within the rough opening (RO).
(110) Fenestration Units
(111) FIGS. 1 to 4 show a fenestration unit 10, according to some embodiments, where FIG. 1 is a top-oriented perspective view from an interior side 12 of the fenestration unit 10, FIG. 2 is a bottom-oriented perspective view from the interior side 12 of the fenestration unit 10, and FIG. 3 is a perspective view from an exterior side 14 of the fenestration unit 10. FIGS. 1 to 3 show the fenestration unit 10 in a final, installed configuration, or installation configuration, and FIG. 4 shows the fenestration unit 10 in an initial, stowed or pre-installation configuration (e.g., as initially received by an installer). As referenced above, the term fenestration unit as used herein is to be read broadly to cover windows, doors, and the like.
(112) As shown in FIG. 1, the fenestration unit 10 has a top 20, a bottom 22, a first side 24, and a second side 26. The fenestration unit 10 includes a frame 30 including a head 32, a first jamb 34, a second jamb 36, and a sill 38. The fenestration unit 10 also includes a panel unit or glazing unit 40 supported by the frame 30. The glazing unit 40 may be any of a variety of configurations, but in some embodiments is an insulated glass (IG) unit. As shown, the fenestration unit 10 is configured as a casement window, but any of a variety of configurations (fixed, single hung, double hung, awning or other) are also contemplated.
(113) As shown, the frame 30 may be a wood frame (e.g., aluminum clad wood) design. However, vinyl, fiberglass, or other materials may be implemented for the frame 30. The frame 30 also includes on outer perimeter P and has a front face 42, or interior face 42, as well as a back face 44, or exterior face 44 (FIG. 3).
(114) As shown in FIGS. 1 to 3, the fenestration unit 10 includes one or more installation features for facilitating installation of the fenestration unit 10. For example, as shown, the fenestration unit 10 may include one or more of the following installation features: an anchoring clip system 100 (also described as an engagement system), a retention system including a sill spacer system 200 (FIG. 2) and an installation stabilizer system 300 (FIG. 1), a weather seal system 400 (FIG. 3), and an adjustment system 500 (FIG. 1).
(115) Anchoring Clip System
(116) As shown in FIG. 1, the anchoring clip system 100 (also described as an engagement system) includes a plurality of anchoring clips 102 secured to the outer perimeter P of the frame 30. In particular, the anchoring clips 102 are coupled to the first jamb 34 and the second jamb 36 (e.g., three to each). As shown, the anchoring clip system 100 includes six (6) anchoring clips 102, although greater (e.g., 6, 8, 10, 12, etc.) or fewer (e.g., 4 or 2) anchoring clips 102 are contemplated. Generally, embodiments will include at least four (4) anchoring clips 102, two upper anchoring clips 102 toward the head 32 and two lower anchoring clips 102 toward the sill 38. As the dimensions of the fenestration unit 10 increase, more anchoring clips 102 may be warranted to help ensure proper anchoring of the fenestration unit 10, where that functionality is described in greater detail below.
(117) In use, each of the anchoring clips 102 can be set at an intended depth, or gauged, for installation (e.g., to accommodate jamb extensions and/or drywall returns). The anchoring clips 102 can help gauge the fenestration unit 10 from an interior face of a building rough opening (RO). This gauging capability helps ensure a proper offset for drywall thickness or other wall features and may help eliminate or reduce such problems as jamb extensions of the fenestration unit 10 being proud or recessed from an interior face of the finished wall surface (e.g., inner drywall face). The resulting installation using the anchoring clips 102 may help ensure flush jamb extensions relative to the interior face of the wall (e.g., inner drywall face) which makes the installation of trim (e.g., casing) of the fenestration unit 10 much more efficient for subsequent detailing steps (e.g., finish carpenters). The anchoring clips 102 may be coupled to the frame 30 either forward of the jamb extensions (e.g., in a more exterior direction, situated on the frame base) or may be coupled to the jamb extensions themselves.
(118) In some implementations, the anchoring clips 102 are initially provided to an installer (e.g., shipped or delivered to the installer) in a stowed configuration, for example as shown in FIG. 4. The installer (not shown) removes, flips, or rotates a portion of the anchoring clips 102 around, and reinserts a portion of the anchoring clips 102 to a desired overall depth by pushing to engage a retention feature (e.g., slot) of the anchoring clips 102. In various examples, the portion of the anchoring clips 102 may be both removed by the installer and reinserted without the use of tools. As referenced above, a typical, or average sized fenestration unit 10 will have four (4) to six (6) anchoring clips 102, although fewer or greater anchoring clips 102 are contemplated. As part of the installation process, an installer (not shown) will flip (rotate axially) the anchoring clips 102 around from the position shown in FIG. 4 to that shown in FIGS. 1 to 3 as part of installation prep work. In some designs, the anchoring clips 102 may be adjustable for different installation depths (e.g., to accommodate inch or -inch interior drywall thickness).
(119) Anchoring clips 102 may also have different adjustment settings or features on different portions of the anchoring clips 102 such that the anchoring clips 102 may be flipped to accommodate different (e.g., greater) adjustability. For example, one portion (e.g., one leg) of the anchoring clip 102 may have a first set of adjustment features (e.g., to accommodate inch or -inch interior drywall thickness offsets) and another portion (e.g., another leg) of the anchoring clip 102 may have a second set of adjustment features (e.g., multiple slots for incremental adjustment over a desired distance).
(120) With the foregoing in mind, as shown in FIGS. 1 to 4, the anchoring clips 102 may each be substantially similar to one another and may be described cumulatively in association with a first one of the anchoring clips 102, an example design of which (a first anchoring clip 102a) is depicted from a perspective view in FIG. 5.
(121) As shown in FIG. 5, the first anchoring clip 102a includes a carrier bracket 110 configured to be coupled to the perimeter P (FIG. 1) of the frame 30 and a coupling bracket 112. In some embodiments, the carrier bracket 110 may be coupled to the frame 30 via adhesion to the frame 30 or the carrier bracket 110 may be coupled to the frame 30 via fasteners. However, other attachment methods are contemplated, including adhesives, heat bonding, integral formation, or other methods. The coupling bracket 112 is securable to the carrier bracket 110 such that the coupling bracket 112 can be transitioned between a first stowed configuration and a second installation configuration. The first anchoring clip 102a is optionally made from stamped sheet metal (e.g., galvanized steel) or other appropriate material/manufacturing method. Although the carrier bracket 110 is shown as a separate component from the frame 30 (e.g., pre-attached at the factory or other location remote from the installation site), the carrier bracket 110 or features thereof may be integrally formed (e.g., molded, machined, routed, etc.) into the frame 30 as part of a manufacturing process, for example.
(122) FIGS. 6 and 7 are isolated, isometric views of the carrier bracket 110, according to some embodiments. As shown, the carrier bracket 110 includes a backplate 120 and a receiver 122.
(123) FIG. 8 shows the backplate 120 from an isometric view, according to some embodiments. The backplate 120 is optionally secured to the receiver 122 using rivets, welding, adhesives, co-casting/molding, or other methods. Though shown, in some embodiments, the backplate 120 may be omitted from the carrier bracket 110. FIG. 9 shows the receiver 122 from an isometric view, according to some embodiments.
(124) As shown, the carrier bracket 110 defines a retaining pocket 130 for receiving the coupling bracket 112. The carrier bracket 110, and more specifically the receiver 122, has a retaining lip 132 and a retention member 134.
(125) The retaining lip 132 acts as a guide and a retainer under which the coupling bracket 112 may be slid. The retaining lip 132 and the optional backplate 120 define the retaining pocket 130. Where the backplate 120 or analogous structure is not included, the retaining pocket 130 may be defined by the receiver 122 and the portion of the fenestration unit 10 underlying the first anchoring clip 102a. The retaining lip 132 may define a first side portion 132a and a second side portion 132b toward the edges of the retaining pocket 130 for securing corresponding portions of the coupling bracket 112.
(126) The retention member 134 may be formed by a portion of the retaining lip 132. As shown in FIG. 9, the retaining lip 132 includes a pair of cutouts 140 forming a flex tab 142 of the retention member 134 that is resiliently deflectable. The retention member 134 further includes a release handle 144 that projects from the flex tab 142. As shown in FIG. 7, the retention member 134 further includes one or more catches 150, also described as a tooth 150 or a pawl 150, for engaging with the coupling bracket 112. For example, the release handle 144 may be oriented to project toward the front, or interior side, of the frame 30, the release handle 144 being operable to be lifted away from the frame 30 to actuate, or release, the retention member 134 from the first detent 174 (e.g., as shown in FIG. 10).
(127) In use, the flex tab 142 may be outwardly deflected to release, or translate, the one or more catches 150 in an outward direction, and once released the flex tab 142 will resiliently flex back into its original position. As shown in FIG. 8, the backplate 120 may include receiving slots 152 for receiving the ends of the one or more catches 150. These receive slots 152 may enhance the overall resistance to pullout forces that the retention member 134 may exhibit without being released.
(128) FIG. 10 shows the coupling bracket 112 from an isometric view. As shown, the coupling bracket 112 includes a first leg 114 and a second leg 116 extending from the first leg 114 and an angular offset (e.g., at an approximately orthogonal angle). The first leg 114 is configured to be slidably received by the carrier bracket 110. The second leg 116 is configured to be secured to framing surrounding a rough opening (RO) in a building structure using one or more fasteners (e.g., nails or screws). If desired, the two legs 114, 116 may be reversible in function (both the first and second legs 114, 116 are configured to be slidably received by the carrier bracket 110 and both are configured to be secured to framing surrounding the rough opening (RO) (see, e.g., design shown in FIG. 17). As shown, the first and second legs 114, 116 may have one or more buttresses 160 or other reinforcing features to help reinforce the first and second legs 114, 116 against relative bending.
(129) The second leg 116 of the coupling bracket 112 optionally includes a release aperture 162 through a thickness of the second leg 116. As can be visualized with reference to FIG. 5, the release handle 144 is accessible (e.g., using a screwdriver or other tool) through the release aperture 162 from the interior, or front side of the fenestration unit 10. The release aperture 162 may also extend into the first leg 114, as shown. The release aperture 162 is generally positioned at the intersection, or corner of between the first and second legs 114, 116.
(130) As shown, the first leg 114 has first and second edges 166, 168 that are opposite one another, a length, and a leading end 170 at one end of the length including an insert guide 172 in the form of a rounded projection. The insert guide 172 may assist with aligning and inserting the first leg 114 into the carrier bracket 110 as the leading end 170 is inserted into the carrier bracket 110. In some embodiments, including embodiments where the two legs 114, 116 are reversible in function, both the first leg 114 and the second leg 116 may include the insert guide 172. The first leg 114 also has one or more detents 174 (a pair of first detents 174a as shown) at one or more longitudinal positions along the length of the first leg 114. The one or more detents 174 may take the form of slots through the thickness of the first leg 114 as shown, but other configurations (e.g., partial depth detents) may also be employed. The one or more longitudinal positions of the one or more detents 174 are selected according to a desired offset of the second leg 116 from the front face 42 of the frame 30 when the coupling bracket 112 is in the installation configuration. For reference, a possible location for a pair of second detents 174b is designated generally by broken lines in FIG. 10.
(131) The second leg 116 has one or more fastener apertures 180 operable to receiver one or more fasteners (not shown), such as screws or nails. The second leg 116 also has a length, which may be selected to ensure sufficient overlap with the framing surrounding a rough opening (RO) (not shown) to ensure the fasteners are able to bite into the framing. The fastener apertures 180 may be recessed or countersunk in order to allow screw heads to be mounted flush. In this way, the fasteners will not interfere with drywall or other wall treatment installed over the second leg 116. The coupling bracket 112 may be fastened to the rough opening (RO) and removed from the rough opening (RO) without damaging the components of the coupling bracket 112. The coupling bracket 112 may be removed from the rough opening (RO) using standard tools (e.g., a screwdriver). The one or more fastener apertures 180 may be placed at different lengths along the second leg 116 to account for differences in drywall thickness and lengths of different spaces between the frame 30 and the rough opening (RO).
(132) In FIG. 5, the first anchoring clip 102a is in the installation configuration, with the second leg 116 of the coupling bracket 112 projecting outwardly relative to the carrier bracket 110. As shown, the first leg 114 is sufficiently inserted into the retaining pocket 130 that the retaining lip 132 extends over the first leg 114. As shown, the first side portion 132a (FIG. 9) and the second side portion 132b (FIG. 9) of the retaining lip 132 are positioned toward the edges of the retaining pocket 130 and are secured over the edges of the coupling bracket 112. The one or more catches 150 (FIG. 7), also described as teeth 150, engage into the one or more detents 174 (the first pair of detents 174a) of the first leg 114. The one or more catches 150 also optionally extend into the receiving slots 152 (FIG. 8) of the backplate 120 to help lock the coupling bracket 112 in position. In order to release the catches 150 from the detents 174, a user may press against, or lift, the release handle 144 (FIG. 7) and flex the flex tab 142, thereby lifting the catches 150 from the detents 174.
(133) As shown in FIGS. 1, 2 and 4, the plurality of anchoring clips 102 are secured to the frame 30 at a desired depth from the front face 42 of the frame 30 (e.g., the carrier bracket 110 can be mounted flush or approximately flush to the front face 42 of the frame 30). The plurality of anchoring clips 102 are optionally secured proximate the tops and bottoms of the first and second jambs 34, 36, respectively, with two (2) additional anchoring clips 102 positioned on each of the jambs 34, 36 at an intermediate position, respectively. In some embodiments, the plurality of anchoring clips 102 may be spaced apart at substantially similar intervals along the first and second jambs 34, 36 respectively.
(134) In the installation configuration as shown in FIGS. 1-3, the second legs of each of the coupling brackets, including the second leg 116 of the coupling bracket 112 (FIG. 5), projects away from the center of the frame 30, outwardly from the perimeter P (FIG. 1) of the frame 30. As shown in FIG. 4, when in the stowed configuration, the second legs of each of the anchoring clips 102, including the second leg 116 of the coupling bracket 112 (FIG. 5), projects inwardly away from the perimeter P (FIG. 1) toward the center of the frame 30. In some embodiments, the second legs 122 extend substantially flush to the front face 42, or interior face 42 of the frame 30 when the coupling brackets 112 are in the stowed configuration.
(135) FIG. 11 shows another design for the anchoring clip 102 in the form of anchoring clip 102. Anchoring clip 102 may include features similar to the first anchoring clip 102a. As shown, anchoring clip 102 has a plurality of pairs of detents 174 along the length of the first leg 114, as well as a plurality of pairs of detents 175 along the length of the second leg 116. Thus, the first and second legs 114, 116 can be reversibly positioned in the carrier bracket 110 of the anchoring clip 102. In some examples, the plurality of pairs of detents 174 permit the retention member 134 to be releasably locked at first and second offset distances from the front of the frame 30 as desired. For example, the second offset distance may be approximately 0.125 inches greater than the first offset distance, such that the anchoring clip 102 is configured to accommodate different installation depths, for example to accommodate different thickness wall coverings (e.g., drywall) or fenestration unit features (e.g., jamb extended fenestration units or handles). In some embodiments, the anchoring clip 102 includes built-in grooves along the length of either the first leg or second leg 114, 116 that act as gauges for determining the correct installation depth. There may be any of a variety of detent configurations. For example, the plurality of pairs of detents 175 permit even further adjustability, across a plurality of depths at any desired increments (e.g., 0.0625 inches, 0.125 inches or other). In other embodiments, the number of plurality of pairs of detents 175 may be minimized to reduce error in installation.
(136) In some embodiments, the anchoring clip 102 may include one or more coin lines or indented lines 179 across a width of the anchoring clip 102. The intended line may extend between the plurality of pairs of detents 175. The indented line 179 may be positioned either of the first or second legs 114, 116 and may allow an installer to shorten the length of the anchoring clip 102. For example, after the installer reinserts the coupling bracket 112 into the carrier bracket 110, the coupling bracket 112 may extend too far away from the frame 30, which may affect the installation of features around the fenestration unit 10 such as additional drywall or paint. To shorten the coupling bracket 112, the installer may bend either the first or second leg 114 116 back-and-forth along the indented line 179 such that a portion of first or second leg 114 116 is broken off and removed. Shortening the coupling bracket 112 may further permit the adjustability of the anchoring clip 102. In some examples, the fenestration unit 10 is provided with a kit of differently configured anchoring clips (not shown) having different lengths and/or detent location(s) corresponding to different installation depths. The plurality of differently configured anchoring clips may be color coded, marked with numbering, lettering, or symbols, or otherwise identified to facilitate user selection of an appropriately-sized bracket for a particular installation depth of the fenestration unit 10 in the rough opening (RO).
(137) FIGS. 12 to 15 show yet another design for the anchoring clip 102 in the form of anchoring clip 102. Anchoring clip 102 may include features similar to the first anchoring clip 102a or the anchoring clip 102. Anchoring clip 102 illustrates that the various engagement/adjustment features of the anchoring clip 102 may be interchanged between the carrier bracket and coupling bracket components. For example, as shown with the anchoring clip 102 a plurality of detents 178 positioned on a carrier bracket 110 of the anchoring clip 102 instead of a first leg 114 or second leg 116 of the anchoring clip 102 as shown in other embodiments.
(138) As shown in FIG. 12, the anchoring clip 102 may include a coupling bracket 112 positioned between a backplate 120 and the carrier bracket 110. The backplate 120 and the carrier bracket 110 may define a retaining pocket therebetween to receive the coupling bracket 112. Though shown in some embodiments, the backplate 120 may be omitted. In some embodiments, the frame 30 may instead act as the backplate 120. FIG. 13 shows the anchoring clip 102 with the backplate 120 removed.
(139) As shown in FIG. 15, the carrier bracket 110 may include the plurality of detents 178 or a row of detents 178 along a length of the carrier bracket 110. Additionally, the detents 178 may be formed as depressions (e.g., rather than through holes) and include a serrated, or sawtooth profile for better engagement. The serrated, or sawtooth profile may accommodate rocking of the coupling bracket 112 along the row of detents 178 to allow the coupling bracket 112 to advance to the desired position.
(140) As shown in FIGS. 13 and 14, the carrier bracket 112 may include a retention member 134 on a first leg 114 of the anchoring clip 102. The retention member 134 may include one or more catches 150, also described as a tooth 150 or pawl 150, for engaging with the carrier bracket 110, and in particular the detents 178. The tooth 150 or pawl 150 may be sized to catch within the depressions defined by the detents 178 to hold the coupling bracket 112 in the desired position. In the illustrated embodiment, and as shown in FIG. 14, the retention member 134 includes a guide 144, similar to release handle 144, which may be configured to help guide a tool (e.g., a screwdriver) under the retention member 134 to release the catch 150 from the detents 178 for adjustment purposes. Additionally, or alternatively, the guide 144 may be configured as a handle, similar to handle 144, where the guide 144 may be depressed to accomplish a rocker effect to lift the catch 150 from the detents 178 for adjustment purposes.
(141) Though not shown, similarly to other embodiments, it is also contemplated that a second leg 116 of the anchoring clip 102 includes a second retention system (e.g., similar to retention system 134) such that the first and second legs 114, 116 can be reversibly positioned in the carrier bracket 110 and engage the plurality of detents 178. In some examples, the plurality of detents 178 permit the retention member 134 to be releasably locked at a plurality of offset distances from the front of the frame 30 as desired. This may accommodate, for example, different thickness wall coverings (e.g., drywall) at increments including, but not limited to increments of 0.0625 inches, 0.125 inches, or others. There may be any of a variety of detent configurations to achieve any desired increment.
(142) Sill Spacer System
(143) FIGS. 16 to 18 illustrate a pre-spacing feature of the fenestration unit 10 (e.g., a pre-spaced window) in the form of sill spacer system 200 at the sill 38. FIGS. 16 to 18 show the fenestration unit 10 from bottom, bottom perspective, and enlarged side views, respectively. In some embodiments, the sill spacer system 200 provides a convenient mechanism for positioning and leveling the fenestration unit 10 inside the rough opening (RO). In some embodiments, the sill spacer system 200 facilitates centering of the fenestration unit 10 within the rough opening (RO) by reducing friction between frame 30 of the fenestration unit 10 and the rough opening (RO) as they move against each other. The sill spacer system 200 establishes a gap between the rough opening (RO) and the sill 38 to make it easier for an installer to adjust the fenestration unit 10 positioning (e.g., insert a pry bar or other tool under the sill 38 of the fenestration unit 10 for lifting and leveling). Standard wood shims, or other shims, can be slid under the sill spacer system 200 for leveling the fenestration unit 10 within the rough opening (RO). As described below, the sill spacer system 200 may be adapted to prevent damage to the sill flashing tape or other features on the bottom of the rough opening (RO) framing (e.g., the sill spacer system 200 may have line contact and/or be rounded to avoid damage). And, due to the pre-attached nature of the sill spacer system 200, the number of additional, separate installation shims (e.g., traditional wood shims, polymeric shims, or otherwise) needed may be reduced as well.
(144) The sill spacer system 200 includes one or more sill spacers 202, such as a pair of sill spacers 202, attached to the bottom of the frame 30 at the sill 38. FIGS. 19, 20, and 21 illustrate one of the sill spacers 202, according to some embodiments. FIG. 19 is an isometric view, FIG. 20 is a side, or end view, and FIG. 21 is a bottom view. As shown, the sill spacer 202 includes a lower contact surface 210 that is rounded. If desired, the lower contact surface 210 may have a flattened apex 212. Regardless, as shown, the sill spacer 202 defines a smooth profile when viewed from the end, the sill spacer 202 having a rounded profile.
(145) In some embodiments, one or more of sill spacers 202 may include materials or coatings that have bright colors, fluorescent or fluorescing properties, and/or reflective properties. These features of the one or more sill spacers 202 may provide contrast against the frame 30 to help an installer find the one or more sill spacers 202 quickly during installation of the fenestration unit 10.
(146) The sill spacer 202 also optionally includes an upper attachment surface 216 with one or more projections 218 and/or grooves 220 configured to fit within features of the bottom of the sill 38 to facilitate attachment thereto. In some embodiments, the bottom of the sill 38 includes one or more longitudinal projections and/or grooves (FIGS. 16 and 26) that accommodate and form a complementary fit with the upper attachment surface 216. Additionally, or alternatively, the sill spacer 202 may include one or more apertures to receive a fastener (e.g., a screw) therethrough to couple the sill spacer 202 to the sill 38. The one or more apertures may be modified to accommodate other fastener types and shapes, including by not limited to a staple, to couple the sill spacer 202 to the sill 38. In other embodiments, the sill spacer 202 may be adhered to the sill 38. The sill spacers 202 optionally define a pre-selected gap width from the rough opening (RO). For example, each sill spacer 202 may defines a maximum thickness of about inches, for example. In some embodiments, the sill spacer 202 defines a maximum thickness of at least inches, although a variety of dimensions, including thinner dimensions, are contemplated.
(147) As shown in FIGS. 16 to 18, the one or more sill spacers 202 may be pre-attached to the fenestration unit 10 (e.g., at the manufacturing location) prior to initiating any on-site installation steps. As shown, the sill spacers 202 are positioned entirely between the front face 42 and the back face 44 of the frame 30. In at least this manner, the sill spacer system 200 leaves a continuous gap (e.g., of about inches) between the bottom of the frame at the sill 38 and the rough opening (RO). In this manner, a continuous insulation and/or seal may be better formed at the sill 38 (e.g., using spray foam, or other material as desired). In some embodiments, the pair of sill spacers 202 are spaced apart from one another and are spaced from the first side 24 and the second side 26 of the fenestration unit 10.
(148) As indicated in FIGS. 16 and 17, each of the sill spacers 202 may extend longitudinally between the first and second sides of 24, 26 the fenestration unit 10. As arranged, the sill spacers 202 are offset toward the front, or interior face 42 of the frame 30 relative to the back, or exterior face 44 of the frame 30. As indicated in FIGS. 16 and 18, the glazing unit 40 defines a center of weight W corresponding generally to the plane in which the glazing unit 40 is installed in the frame 30. The sill spacers 202 are offset from the center of weight W toward the interior face 42 along a tilt axis T such that the fenestration unit 10 tends to tip, or fall, on the sill spacers 202 in the exterior direction. In at least this manner, when the fenestration unit 10 is resting on the sill spacers 202, the fenestration unit 10, under its own weight, pushes the anchoring clip system 100 against the framing surrounding the rough opening (RO). This result helps promote a scenario in which an installer (not shown) is not required to press against the fenestration unit 10, or hold it in place, during installation, according to some embodiments. Or in different terms, the fenestration unit 10 is self-balancing in the rough opening (RO) such that the fenestration unit 10 remains in the rough opening without falling in an inward or outward direction.
(149) FIGS. 22 and 23 show another design for the sill spacers 202, in the form of sill spacers 202b, where FIG. 22 is an isometric view and FIG. 23 is an end view. Similar to the design of FIG. 19, the sill spacer 202b of FIGS. 22 and 23 includes a lower contact surface 210 that is rounded. If desired, the lower contact surface 210b may have a flattened apex 212b. Regardless, as shown, the sill spacer 202b defines a smooth profile when viewed from the end, the sill spacer 202b having a rounded profile. The sill spacer 202b of FIGS. 22 and 23 also optionally includes an upper attachment surface 216b with one or more projections 218b and/or grooves 220b configured to abut features of the bottom of the sill 38 to facilitate attachment thereto. Similar to the previously described designs, the sill spacer 202b optionally defines a pre-selected gap width from the rough opening (RO) (e.g., about inches, defining a maximum thickness of at least inches).
(150) FIGS. 24, 25, and 26 show another design for the sill spacers 202, in the form of sill spacers 202c, where FIG. 24 is an isometric view, FIG. 25 is an end view, and FIG. 26 shows the sill spacer 202c of FIG. 24 coupled to the sill 38 of the fenestration unit 10. Similar to the designs of FIGS. 19 and 22, the sill spacer 202c of FIGS. 24 and 25 includes a lower contact surface 210c that is rounded. If desired, the lower contact surface 210c may have a flattened apex 212c. Regardless, as shown, the sill spacer 202c defines a smooth profile when viewed from the end, the sill spacer 202c having a rounded profile. The sill spacer 202c of FIGS. 22 and 23 also optionally includes an upper attachment surface 216c with one or more projections 218c and/or grooves 220c configured to abut features of the bottom of the sill 38 to facilitate attachment thereto. As shown, the upper attachment surface 216c defines a tiered, or staggered upper surface. Similar to the previously described designs, the spacer 202c optionally defines a pre-selected gap width from the rough opening (RO) (e.g., about inches, defining a maximum thickness of at least inches). As shown in FIG. 26, the tiered, or staggered profile of the upper attachment surface 216c helps facilitate the sill spacer 202c engaging sill profiles that are stepped, angled, or ramped for securement thereto.
(151) FIGS. 27-29 show another design for the sill spacers 202, in the form of sill spacers 202d, where FIGS. 27 and 29 are isometric views and FIG. 28 is an end view. Sill spacer 202d may be generally rectangular and includes a perimeter defined by four walls 203d, 204d, 205d, 206d, where at least walls 204d, 206d are configured as a pair of opposing, substantially vertical walls 204d, and 206d that are generally oriented toward the interior and exterior sides of the fenestration unit 10. If desired, the walls 203d and 205d are also optionally substantially vertical as desired. The walls 203d, 204d, 205d, 206d may intersect each other at rounded transition points 207d. Sill spacer 202d includes a lower contact surface 210d that contacts the rough opening (RO). The lower contact surface 210d may have a substantially flat, or relatively planar, smooth profile along a longitudinal axis and a lateral axis. The substantially flat surface helps provide a stable support for the fenestration unit 10. Due to the relatively low profile of the sill spacer 202d, the fenestration unit 10 remains relatively easy to insert into a rough opening (RO) without snagging or otherwise interfering with the rough opening framing, while still functioning as previously described in association with other designs.
(152) The sill spacer 202d also optionally includes an upper attachment surface 216d. Upper attachment surface 216d may include one or more projections 218d and/or grooves 220d configured to engage features of the bottom of the sill 38 to facilitate attachment thereto. The one or more projections 218d do not extend outwardly past the walls 203d, 204d, 205d, 206d such that the top of the sill spacer 202d is relatively planar. The walls 203d, 204d, 205d, 206d and material forming the lower contact surface 210d are generally uniform in thickness. In some embodiments, the sill spacers 202d may include one or more holes 222d to receive a fastener to couple the sill spacer 202d to the sill 38. Similarly to previously described designs, the spacer 202d optionally defines a pre-selected gap width from the rough opening (RO) (e.g., about inches or more, the spacer 202d defining an overall thickness of about inches or more, although greater or smaller thicknesses are contemplated).
(153) FIGS. 30, 31, and 32 show another design for the sill spacers 202, in the form of sill spacers 202e, where FIGS. 30 and 32 are isometric views and FIG. 31 is an end view. Sill spacer 202e may be generally rectangular and includes a perimeter defined by at least two, opposing substantially vertical walls 204e, 206e and, optionally, two inclined walls 203e, 205e. The substantially vertical walls 204e, 205e may intersect inclined walls 203e, 205e at rounded transition points 207e.
(154) As shown in FIG. 32, sill spacer 202e includes a lower contact surface 210e that contacts the rough opening (RO). The sill spacer 202e may define a pocket 224e in the form of a recess formed into the lower contact surface 210e. The lower contact surface 210e may be substantially flat, or relatively planar along a longitudinal axis and a lateral axis. The substantially flat surface helps provide a stable support for the fenestration unit 10. Due to the relatively low profile of the sill spacer 202e, the fenestration unit 10 remains relatively easy to insert into a rough opening (RO) without snagging or otherwise interfering with the rough opening framing, while still functioning as previously described in association with other designs.
(155) The pocket 224e is defined by a pocket surface 228e, an upper portion or walls 230e, 232e, 234e, and 236e of which may be substantially flat, or planar (e.g., being parallel and offset, or discontinuous from, the lower contact surface 210e). The pocket surface 228e includes an upper wall, or base that is substantially flat and planar (e.g., parallel to the lower contact surface 210e) and may further include the four generally vertical walls 230e, 232e, 234e, and 236e. In other embodiments, one of the four generally vertical walls may be removed to, for example, define open end (not shown). The generally vertical walls 230e, 232e, 234e, and 236e may intersect each other at rounded transitions 237e. The pocket 224e may be configured (sized and shaped) to receive a staple or fastener (e.g., to receive a stapler head) to attach the sill spacer 202e to the fenestration unit 10. In some examples, and as shown, the upper wall of the pocket surface 228e includes one or more holes 222e. By design, the pocket 224e does not contact the rough opening or rough opening framing at any point during installation of fenestration unit 10. In other words, only the lower contact surface 210e contacts the rough opening, or more specifically, the rough opening framing, during installation.
(156) As shown, the thickness of the various walls forming the sill spacer 202e may be substantially uniform, or the material forming the sill spacer 202e may be of substantially uniform thickness throughout. This feature, in addition to the rounded transitions, may serve to enhance moldability for formation in one or more molding procedures (e.g., injection molding procedures). For example, it is generally known that sharp corners or edges are often impractical for molded parts, and it is typical to include rounded transitions such as those shown and described.
(157) As shown in FIG. 30, the sill spacer 202e also optionally includes an upper attachment surface 216e with one or more projections 218e and/or grooves 220e configured to abut features of the bottom of the sill 38 to facilitate attachment thereto. The position of the projection 218e may correspond to a position of pocket surface 228e such that the upper attachment surface 216e is relatively uniform and flat overall. Similarly, a position of the one or more grooves 220e may correspond to a position of the lower contact surface 210e such that the overall thickness of the sill spacer 202e is uniform. In different terms, the thickness of the various walls, or material, forming the sill spacer 202e features may be substantially uniform throughout. This feature of uniform wall thickness, in addition to the rounded transitions, may serve to enhance moldability for formation in one or more molding procedures (e.g., injection molding procedures).
(158) Similar to the previously described designs, the spacer 202e optionally defines a pre-selected gap width from the rough opening (RO) (e.g., about inches or more, the spacer 202e defining an overall thickness of about inches or more, although greater or smaller thicknesses are contemplated).
(159) FIGS. 33, 34, and 35 show another design for the sill spacers 202, in the form of sill spacers 202f, where FIGS. 33 and 35 are isometric views and FIG. 34 is an end view. As shown in FIG. 33, the sill spacer 202e includes a perimeter defined by four substantially vertical walls 203f, 204f, 205f, and 206f. The substantially vertical walls 203f, 204f, 205f, 206f may intersect each other at rounded transitions 207f, such as those previously described (e.g., to enhance moldability).
(160) As shown in FIG. 35, the sill spacer 202f includes a lower contact surface 210f that contacts the rough opening (RO). The sill spacer 202f may define a pocket 224f formed as a recessed area relative to the lower contact surface 210f. As shown, the lower contact surface 210f may be substantially flat, or planar. The substantially flat surface helps provide a stable support for the fenestration unit 10. Due to the relatively low, flat profile of the sill spacer 202f, the fenestration unit 10 remains relatively easy to insert into a rough opening (RO) without snagging or otherwise interfering with the rough opening framing, while still functioning as previously described in association with other designs.
(161) The sill spacer 202f may also include an aperture 222f formed through the lower contact surface 210f to receive a fastener. The pocket 224f is defined by a pocket surface 228f, an upper portion or walls 230f, 234f, and 236f of which may be substantially flat, or planar (e.g., being parallel and offset, or discontinuous from, the lower contact surface 210f). The pocket surface 228f may include three generally vertical walls 230f, 234f, and 236f with the pocket 224f having an open end 250f. In other embodiments, the open end 250f is replaced by a fourth generally vertical wall, for example, to define an enclosed pocket (not shown).
(162) The generally vertical walls 230f, 232f, 234f, and 236f may intersect each other at rounded intersections 237f. The pocket 224f may be configured (sized and shaped) to receive a staple or fastener (e.g., to receive a stapler head). In use, the pocket 224f does not contact the rough opening or the rough opening framing at any point during installation of the fenestration unit 10. Only the lower contact surface 210e contacts the rough opening or rough opening framing during installation.
(163) As shown in FIG. 33, the sill spacer 202f also optionally includes an upper attachment surface 216f. Upper attachment surface may define one or more projections 218f and/or one or more grooves 220f, which are defined along substantially vertical wall 206f, configured to abut, or otherwise engage features of the bottom of the sill 38 to facilitate attachment thereto. Projection 218f may extend upwardly from the substantially vertical wall 206f. The position of the projections 218f may generally correspond to a position of the pocket 224f and pocket surface 228f such that an overall thickness of the sill spacer 202f is uniform. Similarly, a position of the one or more grooves 220f may correspond to a position of the remainder 226f of the lower contact surface such that the overall thickness of the sill spacer 202f is uniform across a longitudinal axis. In different terms, the thickness of the various walls, or material, forming the sill spacer 202e features may be substantially uniform throughout. This feature of uniform wall thickness, in addition to the rounded transitions, may serve to enhance moldability for formation in one or more molding procedures (e.g., injection molding procedures).
(164) As shown, the upper attachment surface 216f defines a tiered, or staggered upper surface. Upper attachment surface 216f may include substantially vertical walls 203f and 205f, as well as a central substantially vertical wall 208f. Each of the substantially vertical wall 203f, 205f, and 208f may include one or more steps 240f and/or angled surfaces 242f. Similar to the design shown in FIG. 26, the tiered, or staggered profile of the upper attachment surface 216f helps facilitate engagement of the sill spacer 202f with sill profiles that are stepped, angled, or ramped such that the sill spacer 202f may be secured thereto. This accommodation of a stepped sill profile of the fenestration unit 10 helps ensure that the lower contact surface 210f remains substantially flat, or planar.
(165) Similar to the previously described designs, the sill spacer 202f optionally defines a pre-selected gap width from the rough opening (RO) (e.g., about inches, defining a maximum thickness of at least inches or more, although greater or smaller thicknesses are contemplated).
(166) Installation Stabilizer System
(167) As shown in FIG. 1, the installation stabilizer system 300 includes at least one retainer 302, also described as a stabilizer clip 302. The retainer 302 is optionally applied prior to any installation steps being undertaken, and at a location remote from the installation site (e.g., at a manufacturing facility). As shown, the retainer 302 is located on the head 32 of the fenestration unit 10. The retainer 302 is optionally formed as a stamped and/or cut metal piece that is bent to shape.
(168) FIG. 36 is an isometric, or perspective view and FIG. 37 is a side view of one design for the retainer 302, according to some embodiments. FIGS. 36 and 37 show the retainer 302 in a natural, unbiased state. Generally, the retainer 302 is configured to permit insertion of the frame 30 within the rough opening (RO) in the structure (not shown) in a first insert direction D1 (FIG. 38) and resist extraction of the frame 30 from the opening in a second extraction direction D2 (FIG. 39).
(169) As shown in FIG. 37, the retainer 302 includes a base 310 configured to be secured to the frame 30 (FIG. 1), a plurality of flex arms 312 extending from the base 310 each including an engagement feature 316 at a terminal end of the flex arm 312. In some embodiments, the base 310 may be coupled or secured to the frame 30 via adhesion to the frame 30 or may be coupled to the frame 30 via fasteners. However, other attachment methods are contemplated. As shown in FIG. 36, the plurality of flex arms 312 include first through fourth flex arms, although any number of flex arms (one, two, three, five, etc.) are contemplated. As shown, the plurality of flex arms 312 may be of different lengths to accommodate different spaces, or a range of space sizes, between the frame 30 and the header of the rough opening (RO).
(170) The retainer 302 optionally includes a strap member (e.g., similar to strap member 302a of FIG. 40) that extends rearwardly from the base 310. The strap member optionally includes a plurality of fastener apertures for receiving one or more fasteners (e.g., screws or nails). The strap member may be generally bendable between a stowed configuration in which it extends toward the center of the fenestration unit 10 and an extended configuration in which it extends upwardly away from the center of the fenestration unit 10.
(171) As shown in FIG. 36, the engagement features 316 of the plurality of flex arms 312 each include an engagement edge 316a (FIG. 36) including one or more sharpened edges or teeth for biting into (e.g., two projecting teeth), for frictionally engaging the header H of the framing of the rough opening (RO) (FIG. 38). In different terms, the engagement feature 316 includes one or more teeth configured to bite into the material defining the rough opening (RO) upon movement of the frame in the interior direction (e.g., D2). In some embodiments, the sharpened edges or teeth are cut edges of material (e.g., metallic material) that may be sharp with or without additional mechanical sharpening.
(172) As shown in FIGS. 38 and 39, in various embodiments, during insertion of the frame 30 in the first insert direction D1 one or more of the flex arms 312 (e.g., the first of the flex arm 312a if a large gap is present or all four flex arms 312 if a very small gap is present between the header H and the frame 30) of the retainer 302 bends or is deflected in a first flex direction and upon movement of the frame 30 in the second extraction direction D2 such that the flex arm 312 bends in a second flex direction to resist movement of the frame 30 in the second direction D2 (e.g., toward the interior side).
(173) In some embodiments, the retainer 302 is configured to be secured in a constrained state (compressed downward) such that the retainer 302 is compressed flat against the frame 30. The retainer 302 may be held in the constrained state using a securement member (e.g., tape). The securement member may be removed to release the retainer 302 to a deployed state such that the retainer 302 projects outwardly from the frame 30 (e.g., in a similar manner to that shown in FIG. 1).
(174) FIG. 38 is a schematic representation of the retainer 302 engaged with a header H of the framing of a rough opening (RO). As shown FIG. 38, the fenestration unit 10 is configured such that as the fenestration unit 10 is slid in the exterior direction, or the first insert direction D1, and is being inserted from an interior side of the rough opening RO, the retainer 302, and specifically the flex arm 312 serves as a spring body that deflects to compresses in height as the engagement edge 316a of the engagement feature 316 bites into the header H. The retainer 302 may self-deployed against the header H of the framing of the rough opening (RO) during installation without action or intervention by the installer. As shown in FIG. 38, during compression, the engagement feature 316 slides against the header H. This compression and sliding action permits the retainer 302, and thus the fenestration unit 10, to be inserted in the exterior direction, or the first insert direction D1, with a first, relatively lower resistance to insertion. In various embodiments, the engagement edge 316a does not bite into, or otherwise prevent sliding of the engagement edge 316a as it is slid across the header H. This may be due to the angle of the engagement edge 316a. The insertion force, or force required to move in the first direction D1 may be 1 lb. or less, more than 1 lb, more than 10 lbs, or more than 15 lbs, for example. Generally, the fenestration unit 10 is tipped, or tilted back in the exterior direction and into place for final seating during insertion in the first direction D1.
(175) FIG. 39 shows the retainer 302 deforming, and resisting movement, as the fenestration unit 12 and the retainer 302 are moved in the interior direction, or the second extraction direction D2. As shown, the flex arm(s) 312 rotate back, or kick up (or kick down, not shown) as the engagement edge(s) 316a of the engagement feature 316 bites into the head H and inhibits sliding of the engagement feature(s) 316 against the header H. In some examples, the flex arm(s) 312 bend or flex as a result of the movement. The extraction or tipping force, or force required to move in the second direction D2 after seating may be 1 lb. or less, more than 1 lb, 10 lbs or more, at least 15 lbs, or 15 lbs or more, for example. In some examples, the extraction force is 80 lbs or more, or approximately 88 lbs. Generally, a higher required extraction or tipping force (e.g., as compared to the insertion force) helps ensure the fenestration unit 10 remains in place after being inserted into the rough opening (RO) to permit subsequent levelling and/or securement procedures. The retainer's 302 ability to resist movement in the second extraction direction D2 may help prevent the fenestration 10 from falling out of the rough opening (RO) toward the interior.
(176) In embodiments, any of the insertion force, extraction force, or retention force is determinable using a force gauge placed perpendicular to a vertical plane of the fenestration unit 10 on the exterior side fenestration unit 10 approximately eight inches from the top of the fenestration unit 10 along a vertical centerline of the fenestration unit 10. For the retention force, the force gauge may be pushed in an interior direction until the fenestration unit 10 is pressed out of the rough opening (RO) such that the force gauge obtains a maximum force for retention.
(177) With insertion of the fenestration unit 10 into the rough opening (RO) the retainer 302 compresses and engages (e.g., bites) into the header H of the rough opening (RO) and optionally applies some degree of downward force on the fenestration unit 10. The function of the retainer 302 may be to help stabilize the fenestration unit 10 in the rough opening (RO) to help ensure the fenestration unit 10 does not fall back toward the interior (i.e., resists extraction in the second extraction direction D2). This self-retaining, or stabilizing feature helps allow a single installer (not shown) to complete leveling and centering tasks without having to hold the fenestration unit 10 in the rough opening (RO). Where present, the sill spacer system 200 may also contribute to this self-retaining/stabilizing functionality. As shown, the retainer 302 is compressible, and thus adjusts and adapts to a range of typical gap sizes between the head 32 and header H of the rough opening (RO). Additionally, the retainer 302 is flexible laterally, made from a spring like material, which permits side-to-side adjustment of the fenestration unit 10 within the rough opening (RO) as well as levelling of the fenestration unit 10 without substantially impeding those processes.
(178) In some embodiments, the fenestration unit 10 may be extracted from the rough opening (RO) without damaging the retainer 302. The fenestration unit 10 may be lifted upwards by the sill 38 (e.g., either manually or with a tool) such that the retainer 302 is further compressed toward the header H of the framing of the rough opening (RO). The fenestration unit 10 may then be rotated out from the rough opening (RO) and toward the interior. This movement allows controlled release of the fenestration unit 10 from the rough opening (RO) without the need for specialized tools and without damaging to the retainer 302. The retainer 302 may be used again when re-installing the fenestration unit 10 within the rough opening (RO).
(179) FIG. 40 is an isometric, or perspective view and FIG. 41 is a side view of another design for the retainer 302, in the form of retainer 302, also described as a stabilizer clip 302, according to some other embodiments. FIGS. 40 and 41 show the retainer 302 in a natural, unbiased state. Generally, the retainer 302 is configured to permit insertion of the frame 30 within the rough opening (RO) in the structure (not shown) in a first insert direction D1 and resist extraction of the frame 30 from the opening in a second extraction direction D2.
(180) As shown in FIG. 41, the retainer 302 includes a base 310 secured to the frame 30, a flex arm 312 extending from the base 310, a stop arm 314 extending from the flex arm 312, and an engagement feature 316 extending from the flex arm 312 and/or the stop arm 314. As shown in FIGS. 42 and 43, in various embodiments, the retainer 302 is operable such that during insertion of the frame 30 in the first insert direction D1, the flex arm 312 bends in a first flex direction and upon movement of the frame 30, and in the second extraction direction D2, the flex arm 312 bends in a second flex direction. As shown in FIG. 40, the retainer 302 optionally includes a strap member 302a that extends rearwardly from the base 310.
(181) As shown in FIG. 40, the strap member 302a optionally includes a plurality of fastener apertures for receiving one or more fasteners (e.g., screws or nails). The strap member 302a is generally bendable between a stowed configuration in which it extends toward the center of the fenestration unit 10 and an extended configuration in which it extends upwardly away from the center of the fenestration unit 10.
(182) As shown in FIG. 41, the base 310 includes a bottom segment 310a and a return segment 310b. The flex arm 312 includes a slide segment 312a, an extension segment 312b, a lever segment 312c, and a back segment 312d. The stop arm 314 also terminates in a bent end 314a. And, the engagement feature 316 includes an engagement edge 316a (FIG. 40) including one or more sharpened edges or teeth for biting into, or frictionally engaging the header H of the framing of the rough opening (RO) (FIG. 42). In different terms, the engagement feature 316 includes one or more teeth configured to bite into the material defining the rough opening (RO) upon movement of the frame in the interior direction (e.g., D2).
(183) As shown, the return segment 310b extends back on a portion of the bottom segment 310a. The lever segment 312c extends from the return segment 310b (as shown, at an intermediate location of the base 310). The back segment 312d extends at a downward angle from the lever segment 312c and the slide segment 312a extends back up from, and beyond the back segment 312d to the engagement feature 316. The stop arm 314 extends back (toward the exterior, or back direction) from the engagement feature 316 and/or the extension segment 312b toward the bottom segment 310a. In some embodiments, the retainer 302 is configured to be secured in a constrained state (compressed downward) such that the retainer 302 is compressed flat against the frame 30. The retainer 302 may be held in the constrained state using a securement member (e.g., tape). The securement member may be removed to release the retainer 302 to a deployed state such that the retainer 302 projects outwardly from the frame 30 as shown in FIG. 1.
(184) FIG. 42 is a schematic representation of the retainer 302 engaged with a header H of the framing of a rough opening (RO). As shown FIG. 42, the fenestration unit 10 is configured such that as the fenestration unit 10 is slid in the exterior direction, or the first insert direction D1, and is being inserted from an interior side of the rough opening RO. The retainer 302, and specifically the flex arm 312 and the stop arm 314 serve as a spring body that compresses in height as the engagement edge 316a of the engagement feature 316 bites into the header H. As shown in FIG. 42, during compression, the peak at the extension segment 312b and stop arm intersection moves downward as does the peak at the lever segment 312c and slide segment 312a intersection. The lever segment 312c rotates forward and downward and the slide segment 312a and the stop arm 314 slide outward (e.g., against the base 310). This compression and sliding action permits the retainer 302, and thus the fenestration unit 10, to be inserted in the exterior direction, or the first insert direction D1, with a first, relatively lower resistance to insertion. In various embodiments, the engagement edge 316a does not bite into, or otherwise prevent sliding of the engagement edge 316a as it is slid across the header H. This may be due to the angle of the engagement edge 316a.
(185) FIG. 43 shows the retainer 302 deforming, and resisting movement, as the fenestration unit 10 and the retainer 302 are moved in the interior direction, or the second extraction direction D2. As shown, the lever segment 312c rotates back, or kicks up as the engagement edge 316a of the engagement feature 316 bites into the head H and inhibits sliding of the engagement feature 316 against the header H. In some examples, the stop arm 314 deflects (e.g., bends) as a result of the movement of the lever segment 312c, further increasing resistance to further movement in the interior direction, or the second extraction direction D2. In other words, the stop arm 314 is operable to engage with the base 310 after the flex arm 312 bends in the second flex direction to inhibit further flexing of the flex arm 312.
(186) With insertion of the fenestration unit 10 into the rough opening (RO) the retainer 302 compresses and engages (e.g., bites) into the header H of the rough opening (RO) and applies a downward force on the fenestration unit 10. The function of the retainer 302 may be to help stabilize the fenestration unit 10 in the rough opening (RO) to help ensure the fenestration unit 10 does not fall back toward the interior (i.e., resists extraction in the second extraction direction D2). This self-retaining, or stabilizing feature helps allow a single installer (not shown) to complete leveling and centering tasks without having to hold the fenestration unit 10 in the rough opening (RO). Where present, the sill spacer system 200 (FIGS. 16 to 26) may also contribute to this self-retaining/stabilizing functionality. As shown, the retainer 302 is compressible, and thus adjusts and adapts to a range of typical gap sizes between the head 32 and header H of the rough opening (RO). Additionally, the retainer 302 is flexible laterally, made from a spring like material, which permits side-to-side adjustment of the fenestration unit 10 within the rough opening (RO) as well as levelling of the fenestration unit 10 without substantially impeding those processes.
(187) Although, in various examples, one or more retainers 302, 302 are secured to one or more portions of the fenestration unit 10 (e.g., frame 30), in other examples, similarly designed retainers 302, 302 are optionally secured to framing surrounding the rough opening (RO) and engage the fenestration unit 10 upon positioning of the fenestration unit 10 in the rough opening (RO).
(188) Weather Seal System
(189) As shown in FIG. 1, another aspect of this invention is the weather seal system 400, which may be remotely applied (e.g., at a manufacturing location) and acts as an exterior water barrier. The weather seal system 400 may be biased to a deployed state or may be otherwise described as a pop-up fin. In various examples, the weather seal system 400 is initially provided (e.g., shipped or transported to the installation site) in a stowed, or flattened configuration (FIG. 4) against the frame 30 of the fenestration unit 10. This flattened, or stowed position can be described as a 180 position. The weather seal system 400 may be held in the stowed position with a retaining assembly, as described below. After the fenestration unit 10 is installed and anchored (e.g., using one or more fasteners, such as screws or nails) the original installer (not shown) or another installer may separately proceed to the exterior side of the rough opening (RO) to remove the retaining assembly and transition the weather seal system 400 to the deployed state. In some examples, upon removal of the retaining assembly, the weather seal system 400 automatically pops-up, or projects outwardly from the frame 30 (e.g., at approximately 90 degrees) to rest against the exterior surface of the wall in which the rough opening (RO) is formed. As described below, the weather seal system 400 may include three-dimensional corner seals (e.g., factory applied and welded, adhered, or otherwise attached) to a head pop-up fin to provide protection against water infiltration.
(190) In various examples, no fasteners (e.g., screws or nails) are used on the exterior side of the fenestration unit 10 (e.g., the fenestration unit 10 is secured entirely from the interior side of the rough opening (RO)). Flashing tape or other treatments may be applied around the perimeter of the fenestration unit 10, over the weather seal system 400 to seal the fenestration unit 10 to the exterior surface of the wall in which the rough opening (RO) is formed. In various examples, the exterior surface of the wall may include a weather resistant barrier (e.g., Tyvek home wrap available from DuPont de Nemours, Inc.).
(191) FIG. 1 shows the weather seal system 400 from an interior view. As shown, the weather seal system 400 is secured includes a fin assembly 410 that is outwardly biased to project radially outward from the perimeter of the frame 30 when unconstrained. FIG. 4 shows the fenestration unit 10 with various installation features in a stowed configuration. As shown in FIG. 4, the weather seal system 400 also includes a retaining assembly 412 releasably securing the fin assembly 410 in a constrained state such that the fin assembly 410 is compressed toward the frame 30 in a stowed configuration.
(192) As shown in FIG. 3, the fin assembly 410 includes a plurality of fins 420, including a head fin 420a (also described as a top fin 420a), a first jamb fin 420b, a second jamb fin 420c, and a sill fin 420d. As shown in FIG. 3, the fin assembly 410 also optionally includes a first corner bridge seal 430 and a second corner bridge seal 432. Optionally, a third corner bridge seal may be positioned between the first jamb fin 420b and the sill fin 420d and a fourth corner bridge seal may be positioned between the second jamb fin 420c and the sill fin 420d.
(193) FIG. 44 is an end view and FIG. 45 is an isometric view of one of the plurality of fins 420 (each may have a substantially similar construction, with differences in length to correspond to the portion of the frame 30 to which they are attached). As shown, each of the plurality of fins 420 has a coupling portion 440 and a projection portion 442, with a hinge portion 446 between the coupling portion 440 and the projection portion 442. The coupling portion 440 is coupled to the outer perimeter P (FIG. 1) of the frame 30 and the projection portion 442 is biased by the hinge portion 446 to project radially outward from the outer perimeter P of the frame 30 by the hinge portion 446. In some embodiments, the coupling portion 440 may be coupled to the frame 30 via adhesion to the frame 30. However, other attachment methods are contemplated, including any of those previously described. In some embodiments, the hinge portion 446 is formed of a first material and the projection portion 442 is formed of a second material different than the first material. The first material of the hinge portion 446 may be a first polymeric material and the second material may be a second polymeric material that is different than the first polymeric material. Generally, the first material may be more flexible than the second polymeric material (e.g., the first material being elastic in nature and the second material being generally less elastic, or inelastic). In terms of manufacture, the coupling portion 440, the projection portion 442, and the hinge portion 446 may be co-extruded or co-molded parts.
(194) In some embodiments, the first material is a Nitrile Thermoplastic Elastomer (TPE), such as that sold under the tradename Auroraflex by Aurora Plastics, for example, although a variety of materials are contemplated. In some embodiments, the second material is an inelastic material, such as a glass or mineral filled polypropylene, or a thermoplastic polyolefin, such as that sold under the tradename RAVATUF 400X by Ravago Manufacturing Americas, for example, although a variety of materials are contemplated.
(195) As shown, the coupling portion 440 includes an elongate, relatively planar, thin rectangular base 450 and an attachment feature 452 extending (e.g., perpendicularly) from the base 450. The attachment feature 452 is configured to be inserted into a complementary feature (e.g., an accessory channel, or kerf) of the frame 30 to secure the fin 420 to the frame 30. The attachment feature 452 may be a barbed projection that is flexible and allows the attachment feature 452 to be inserted into the complementary feature of the frame 30 but resist removal therefrom. The attachment feature 452 may be described as a Christmas tree configuration and may be formed of the first and second materials, with the second material forming the base or trunk of the attachment feature 452 and the first material forming the flexible branches of the attachment feature 452.
(196) The projection portion 442 also includes an elongate, relatively planar, thin body 458. As shown, the projection portion 442 may be substantially free of any apertures or openings suitable for receiving a fastener, such as a nail or screw, to attach the projection portion 442 to the framing of the rough opening (RO) or wall of the building in which the fenestration unit 10 is to be installed. In various examples, the projection portion 442 need not include such features, as the plurality of fins 420 do not provide substantial structural support, but instead are designed primarily to provide exterior water barrier functionality.
(197) The hinge portion 446 is located between the coupling portion 440 and the projection portion 442, being coupled to each respectively. The hinge portion 446 is configured to flex between a folded state with the projection portion 442 folded against the coupling portion 440 and an extended state with the projection portion 442 extending away from the coupling portion 440 at an angle between the coupling portion 440 and the projection portion 442, such as that shown in FIGS. 44 and 45 (e.g., 90 degrees, or greater than 90 degrees, such as 100 degrees). The hinge portion 446 has a width that is selected to allow the projection portion 442 and the coupling portion to not only be angularly displaced relative to one another, but also to be laterally displaced to smaller and greater lateral offsets.
(198) For example, by having a small portion of the hinge portion 446 projecting vertically in the 90-degree position, the edges of the coupling portion 440 and projection portion 442 define a relatively small lateral offset (in the interior-exterior direction as installed) from one another. And, by extending a larger portion of the hinge portion 446 width in the lateral direction (in the interior-exterior direction as installed) the edges of the coupling portion 440 and the projection portion 442 are at a greater lateral offset from another. In this manner, the hinge portion 446 provides functionality of the fin 420 to accommodate variations in wall thickness when the fenestration unit 10 is installed in a rough opening (RO). In some embodiments, the hinge portion 446 is at least -inch, -inch, inch, or inch wide to facilitate sufficient depth adaptability to the fin 420 to accommodate and adapt to different wall depths of the building structure into which the fenestration unit 10 is installed.
(199) In some embodiments, the fin assembly 420 may include a tip 618 (e.g., as shown in FIGS. 63-65) positioned on the exterior side of the fin assembly 420 that extends continuously or discontinuously along a length of the frame 30. The tip 618 may extend outwardly, and optionally at an angle, relative to the exterior side of the frame 30 and abuts the exterior side of frame 30. The tip 618 may be configured to prevent water/moisture movement along the length of the frame 30 such that water is prevented or substantially impeded from transferring across the an attachment point of the fin assembly 420 and the frame 30.
(200) FIG. 46 shows another variation in design applicable to one, some, or all of the fins 420, as shown as fin 420. As shown, the base 440 is somewhat narrower in the design depicted in FIG. 46 as compared to the design in FIG. 45. Moreover, the projection portion 442 includes a plurality of dimples 442a formed into the outer face of the projection portion 442 (i.e., the face that projects away from the building surface to which the projection portion 442 is ultimately abutted). These dimples 442a have a thickness, and project from the back side of the projection portion 442 to help create gaps or spacing, also described as standoff, between the particular fin 420 and the surface to which the fin 420 is ultimately abutted. This design in FIG. 46 is typically applied for the fin 420 corresponding to the sill 38 of the fenestration unit 10, which assists with ensuring that external air, or more specifically external air pressure, is allowed to pass under the sill 38 to the air/water barrier between the sill 38 and the rough opening (RO). The standoff, however, does not interfere with the ability of the fin 420 to shed water, helping ensure a water-tight installation. As shown, the dimples 442a are in a staggered arrangement along the length of the fin 420. Each of the dimples 442a are shown to have a round, dome-shaped profile but any of a variety of shapes are contemplated (e.g., criss-cross, square, diamond, or other patterns and shapes and combinations thereof). The dimples 442a may be cold formed, molded, or otherwise incorporated into the fin 420.
(201) Additionally, as shown in FIG. 46, the fin 420 optionally includes an edge seal 450a in the form of a more flexible, or soft (e.g., elastomeric) material configured to help ensure water does not penetrate between the fin 420 and the frame 30 of the fenestration unit 10. The edge seal 450a generally extends along the length of the base 450.
(202) FIG. 47 shows a closeup view of a first corner of the frame 30 of FIG. 1 defined at an intersection of the head 32 and the first jamb 34 of the frame 30 (the frame 30 also defines a second corner at the intersection of the head 32 and the second jamb 36 of the frame 30). As shown, the first corner bridge seal 430 is located at the first corner and provides a transition between the head fin 420a and the first jamb fin 420b (the second corner bridge seal 432 is similarly located at the second corner and similarly provides a transition between the head fin 420a and the second jamb fin 420c).
(203) FIG. 48A is an isometric view of the first corner bridge seal 430 and FIG. 48B is an isometric view of the second corner bridge seal 432, the second corner bridge seal 432 being substantially similar to the first corner bridge seal 430, in various embodiments. The second corner bridge seal 432 may mirror the first corner bridge seal 430. As shown, the first corner bridge seal 430 includes a gutter portion 460 in the form of an L-shaped flange formed by two flat webs of material and a hood portion 462 in the form of a flat web of material extending in an orthogonal plane from the gutter portion 460. The hood portion 462 may have an arcuate, or curved shape. The hood portion 462 of the first corner bridge seal 430 may define a first end 461a positioned along the first jamb fin 420b and a second end 461b positioned along the head fin 420a.
(204) The first corner bridge seal 430 may be formed of a substantially flexible (e.g., elastomeric material) so that it can be folded similarly to the fins 420. For example, both the hood portion 462 and/or the gutter portion 460 may be substantially flexible (e.g., elastomeric) and able to be resiliently deformed. The hood portion 462 may include one or more seams to facilitate folding and unfolding the first corner bridge seal 430 between the stowed and deployed configurations. For example, a seam 465 may be positioned in an approximate center of the hood portion 462 to facilitate folding and unfolding of first corner bridge seal 430. The seam(s) may be pre-formed (e.g., via a molding or other forming process) or formed as part of a folding process (e.g., mechanically formed due to the folding procedure itself, which may be manual or automated).
(205) The first corner bridge seal 430 may define a first half 468 of the hood portion 462, which may be extend approximately between the first end 461a of the hood portion 462 and the seam 465. The first corner bridge seal 430 may also define a second half 469 of the hood portion 462, which may extend approximately between the second end 461b and the seam 465. Similarly, the second corner bridge seal 432 may define a first half 468 of the hood portion 462, which may extend between the first end 461a and the seam 465 and a second half 469, which may extend between the second end 461b and the seam 465.
(206) Although gutter portion 460 is shown as having an approximately 90-degree angle, other angles are contemplated. The gutter portion 460 may couple with one or more portions of frame 30, such as a corner of the frame 30, and in some embodiments, the first and second corner bridge seals 430, 432 may be modified to interact with frames of different shapes, including but not limited to triangular frames, trapezoidal frames, rounded frames, and the like, as desired. In such embodiments, the gutter portion 460 may have a shape complimentary to the corners, such as a triangular shape, a trapezoidal shape, or a rounded shape. In other embodiments, the corners of frame 30 may be at angles greater than or smaller than 90 degrees to accommodate different corners, and gutter portion 460 may be modified to complement the corner angle. As such, the gutter portion 460 may be between approximately 45 degrees and approximately 60 degrees, between approximately 60 degrees and approximately 75 degrees, between approximately 75 degrees and approximately 90 degrees, between approximately 90 degrees and approximately 105 degrees, between approximately 105 degrees and approximately 120 degrees, between approximately 120 degrees and approximately 135 degrees.
(207) As shown in FIGS. 55A to 56, the hood portion 462 may be substantially flexible and folded into a stowed, folded configuration or a non-deployed configuration. Generally, the first corner bridge seal 430 is flexible, while being sufficiently tough and resilient to avoid tearing or failure while being flexed as part of a fin deployment process. In some embodiments, the first corner bridge seal 430 is formed of an elastomer, including but not limited to a thermoplastic elastomer. The thermoplastic elastomer may include, but is not limited to, Versaflex CL40 Thermoplastic Elastomer (TPE) available from GLS Corp. Generally, Versaflex CL40 Thermoplastic Elastomer (TPE) has high toughness and flexibility which may allow the first corner bridge seal 430 to exhibit desired flexibility while resisting failure (e.g., tearing).
(208) In some embodiments, the first corner bridge seal 430 may be manufactured via injection molding, or other methods such as an additive manufacturing process. The first corner bridge seal 430 may define a net, or web (e.g., as shown in at least FIG. 48A) that can be folded and unfolded between the stowed and deployed configurations. By manufacturing the first corner bridge seal 430 to be flexible and/or foldable, there is a reduced need for additional processing or conditioning for folding, unfolding, and deployment (e.g., stretching, or other manipulation of a shape of the first corner bridge seal 430 to facilitate deployment of the fin assembly 410). The elasticity and attachment of the bridge corner seal 430 to the fin assembly 410 in an installation configuration with the fins projecting radially outward, with subsequent folding of the bridge corner seal 430 to the stowed configuration, helps ensure the bridge corner seal 430 does not tear or detach in use when transitioning from the stowed configuration to deployed, or installation configuration. In contrast, fin systems that have a corner element that requires further manipulation or stretching upon deployment (e.g., that require deformation in order to fold a fin system outward) may lead to tearing, hole formation, or other defects in the corner element.
(209) In some embodiments, as shown in FIG. 48C, one or both of the first corner bridge seal 430 and the second corner bridge seal 432 include an adhesive 467. The adhesive 467 may be pre-applied prior to shipping. The adhesive 467 may facilitate adhesion of the first corner bridge 430 to one or more of the fins 420 and/or the frame 30 (e.g., at the corner of the frame 30). In some embodiments, the first corner bridge seal 430 may be a separate component from the fin assembly 420 and may be coupled to a portion of the fin assembly 420 via the adhesive 467. As shown, the adhesive 467 may be positioned onto a portion of hood portion 462, and along one or both of the first end 461a and the second end 461b, to facilitate attachment to the first jamb fin 420b and the head fin 420a. In addition, or alternatively, the adhesive 647 may also be positioned on the gutter portion 460 to facilitate attachment to a portion of the frame 30 (e.g., a corner). The adhesive 467 may include, but is not limited to, a pressure-sensitive tape or coating that may be employed temporarily and removed after transitioning to the deployed configuration. In other embodiments, the adhesive 467 may be a permanently applied tape or coating that remains adhered to the first corner bridge seal 430 after deployment. The adhesive 467 may include, but is not limited to, Sealing and Holding Tape 8069 available from 3M Company. The adhesive 467 may have a liner attached thereto that is removed prior to or during installation of first corner bridge seal 430 to the fin assembly 420. In some embodiments, the liner may be oversized relative to the adhesive 467 to facilitate quick removal.
(210) FIG. 49 shows the first and second corner bridge seals 430, 432 assembled to the head fin 420a. In some embodiments, one or both of the first and second corner bridge seals 430, 432 are bonded to the head fin 420a, and optionally the first and second jamb fins 420b, 420c. One or both of the first and second corner bridge seals 430, 432 may be bonded to the projection portion 442 of the head fin 420a and may be positioned on opposing ends of the projection portion 442 (e.g., along a longitudinal axis). In use, unfolding of the fins, or deployment of the fins, may be carried out with the first and corner bridge seals 430, 432 deploying at essentially the same time, according to some embodiments.
(211) As shown, the gutter portion 460 of the first corner bridge seal 430 is coupled to the coupling portion 440 and the hinge portion 446 of the head fin 420a. In some examples, the hood portion 462 is also secured to the projection portion 442 of the head fin 420a. The second corner bridge seal 432 is optionally similarly secured to the head fin 420a at an opposite end of the head fin 420a from the first corner bridge seal 430. In at least this manner, water flowing onto the head fin 420a will be directed over the first and second corner bridge seals 430, 432 along the first and second jamb fins 420b, 420c, respectively. Along those lines the first corner bridge seal 430 is optionally secured to the first jamb fin 420b. For example, the hood portion 462 is optionally secured to the projection portion of the first jamb fin 420b. Optionally, the gutter portion 460 may be secured to the coupling portion of the first jamb fin 420b. The second corner bridge seal 432 may be similarly secured to the second jamb fin 420c.
(212) FIG. 50 shows a closeup view of the first corner of the frame 30 of FIG. 1 showing a complementary edge feature 470 (e.g., accessory channel or kerf) extending around the outer perimeter P of the frame 30 formed into the outer edges of the frame 30. As previously referenced, the coupling portions of the plurality of fins 420 are coupled to (inserted into) the complementary edge feature 470 in order to secure the plurality of fins 420 about the outer perimeter P of the frame 30.
(213) FIG. 51 is a closeup view of the first corner showing the head fin 420a and the first jamb fin 420b secured in the complementary edge feature 470 (FIG. 50) with the first corner bridge seal 430 not shown. And, FIG. 52A is a closeup view of a third corner of the frame 30 defined at an intersection of the sill 38 and first jamb 30 of the frame 30 (e.g., as shown in FIG. 1). Similarly, a fourth corner of the frame 30 is defined at an intersection of the sill 38 and the second jamb 30 of the frame 30. As shown, in some designs, the first jamb fin 420b and the sill fin 420d are overlapped, but not secured together nor is there a corner bridge seal secured thereto. The second jamb fin 420c and the sill fin 420d may be similarly arranged and configured with respect to one another at the fourth corner referenced above. However, FIG. 52B shows another embodiment in which the first jamb fin 420b and the sill fin 420d are secured together using a corner bridge seal 430a that is similar to the first corner bridge seal 430. The second jamb fin 420c is optionally similarly secured to the sill fin 420d using another corner bridge seal as desired.
(214) In sum, as shown in FIG. 3, the fin assembly 410 includes the head fin 420a secured or coupled to the head 32 of the frame 30, a first jamb fin 420b coupled, or secured to the first jamb 34 of the frame, a second jamb fin 420c coupled to the second jamb 36 of the frame, and a sill fin 420d coupled to the sill 38 of the frame 30. And, as shown in FIG. 3, the first corner bridge seal 430 overlaps the first side fin 420b and the top fin 420a and the second corner bridge seal 432 overlaps with the second side fin 420c and the top fin 420a to define a continuous water barrier extending about the outer perimeter P of the frame 30 along the first jamb 34, the head 32, and the second jamb 36. In turn, the first jamb fin 420b and the second jamb fin 420c are overlapped with the sill fin 420d.
(215) FIG. 53 shows the fenestration unit 10 in the stowed configuration with the plurality of fins 420 (FIG. 3) folded in an exterior direction with retaining assembly 412 retaining the plurality of fins in the stowed configuration. According to some embodiments, the retaining assembly 412 includes a plurality of retaining clips 480, such as a head clip 480a, a first jamb clip 480b, a second jamb clip 480c, and a sill clip 480d. FIG. 54 shows the fenestration unit 10 after the retaining assembly 412 has been removed, allowing the plurality of fins 420 to unfold and transition to the active, or installation configuration. Although the retaining clips 480 are optionally employed, in other embodiments, such as shown in FIG. 48C, adhesives (e.g., tape or coatings) may additionally or alternatively be employed to temporarily secure the plurality of fins 420 in the folded configuration. For example, a pressure sensitive adhesive set may be applied. In such examples, the adhesive may be removed from the plurality of fins 420 without damaging the plurality of fins 420. As another alternative, cardboard, paperboard, or other material shaped in a C or F shape may be implemented to replace one or more of the retaining clips 480.
(216) FIGS. 55A-55C illustrates the second corner bridge seal 432 being deployed from the folded, stowed configuration (e.g., FIG. 55A), to the unfolded, deployed configuration (e.g., FIG. 55C). Although the second corner bridge seal 432 is shown, the first corner bridge seal 430, or any other corner bridge seal, may be deployed in a similar manner. The second corner bridge seal 432 may include the adhesive 467 applied thereto, as described above, and may be coupled to the fin assembly 420 via the adhesive either prior to or during deployment of the fin assembly 420. As shown in FIG. 55A, the second corner bridge seal 432 may be retained in the folded, stowed configuration by at least one of the retaining clips 480 (e.g., the head clip 480a and/or the second jamb clip 480c). One or more of the retaining clips 480 may be attached to the frame 10 such that at least a portion of the second corner bridge seal 432, such as substantially all of the corner bridge seal, is covered and protected by the one or more retaining clips 480.
(217) Although the retaining clips 480 may be implemented, in other embodiments the second corner bridge seal 432 (or any other bridge seal) may additionally or alternatively be retained in the folded, stowed configuration by an adhesive (e.g., a pressure sensitive and/or releasable adhesive). As shown in FIGS. 55B-55C, in some embodiments, when the retaining clips 480 are removed, the second corner bridge seal 432 may remain in the folded, stowed configuration until the plurality of fins 420 are manual unfolded, or deployed, such that the plurality of fins 420 project substantially outwardly relative to the perimeter P of frame 30.
(218) As the plurality of fins 420 are unfolded, the second corner bridge seal 432 may also unfold, or deploy, such that the second corner bridge seal 432 also projects substantially outwardly relative to the perimeter P of frame 30. The first and second portions 468, 469 may deploy at substantially the same time. In other embodiments, the plurality of fins 420 and the second corner bridge seal 432 may automatically deploy to the unfolded, deployed configuration upon removal of the retaining clips 480. In some embodiments, the second corner bridge seal 432 includes an adhesive applied to the hood portion 462. When the second corner bridge seal 432 is in the deployed configuration, a release liner may be removed from the adhesive and the hood portion 462 may be adhered to the exterior of the building surrounding the rough opening (RO). In such embodiments, the arcuate or curved portion of the hood portion 462 may be substantially free of adhesive, or may include adhesive as desired.
(219) FIGS. 55D-55G shows the second corner bridge seal 432 transitioning from the unfolded, deployed configuration (e.g., as shown in FIG. 55C), to the folded, stowed configuration (e.g., as shown in FIG. 55G). Although the second corner bridge seal 432 is shown, the first corner bridge seal 430, or any other corner bridge seal, may be stowed in a similar manner. As shown in FIG. 55D, one of the plurality of fins 420 (e.g., second jamb fin 420c) may be folded to the stowed configuration and in folding the fin 420, the first portion 468 of the hood portion 462 may also fold such that the first portion 468 is substantially flat against frame 30 or is no longer projecting relative to the frame 30. The first portion 468 may be folded onto the gutter portion 460 of the second corner bridge seal 432. After the first portion 468 of the hood portion 462 is folded against the frame 30, the retaining clip 480 (e.g., second jamb clip 480c) may be attached to the frame 30 to retain the first portion 468 in the folded configuration.
(220) Then, as shown in FIG. 55E, the hood portion 462 may be manually folded along seam 465, such that the hood portion 462 is folded inwardly relative to the frame 30. Folding seam 465 may cause the hood portion 462 to fold onto itself. In such embodiments, an arcuate portion of second portion 469 of the hood portion 462 may fold onto an arcuate portion of the first portion 468 such that the seam 465 lays substantially flat along frame 30. In this configuration, the second portion 469 may at least partially overlap the first portion 468.
(221) Then, as shown in FIG. 55F, the other of the plurality of fins 420 (e.g., the head fin 420a) may be folded to the stowed configuration and in folding the fin, the second portion 469 of the hood portion 462 may also fold such that the second portion 469 is substantially flat against frame 30. When the second portion 469 of the hood portion 462 is folded against the frame 30, the retaining clip 480 (e.g., head clip 480a) may be attached to the frame 30 to retain the second portion 469 in the folded configuration. The first portion 468 of the hood portion 462 and the second portion 469 of the hood portion 462 may at least partially overlap each other in the stowed configuration. In other embodiments, a reverse configuration is contemplated in which the second portion 469 of the hood portion 462 may be folded first. In such embodiments, the first portion 468 may at least partially overlap the second portion 469 in the folded, stowed configuration.
(222) FIG. 56 is a closeup view of the first corner with the head fin 420a and the first jamb fin 420b, as well as the first corner bridge seal 430 folded over into the stowed configuration. As shown, the first corner bridge seal 430 may be folded onto itself so that the first corner bridge seal 430 does not protrude or project substantially from the outer perimeter P of the frame 30. By folding onto itself, the first corner bridge seal 430 may protected prior to deployment of the fins 420 and/or during shipping of the fenestration unit 10. Additionally, at least a portion of the folded first corner bridge seal 430 may be protected under one of the retaining clips 480 (e.g., head clip 480a) in the folded or stowed configuration.
(223) FIG. 57 is a partial view of a length of one of the retaining clips 480, according to a first design, where each of the retaining clips 480 (e.g., the head clip 480a, the first jamb clip 480b, the second jamb clip 480c, and the sill clip 480d) can be of a substantially similar design (apart from having a length suitable for retaining each of the respective plurality of fins 420 in the stowed configuration). FIG. 58 is a transverse sectional view of the retaining clip 480 shown in FIG. 57. As shown in FIG. 58, the retaining clip 480 includes a first channel insert 482, a first retaining lip 486, and a second retaining lip 488. As shown, the first channel insert 482 is substantially parallel to the first retaining lip 486 and interconnected therewith (e.g., defining a C shape in transverse cross-section). The retaining clips 480 may extend for a length approximating the portion of the frame 30 to which it is installed (e.g., the head 32, the first jamb 34, the second jamb 36, and/or the sill 38). In such embodiments, the retaining clips 480 may extend along a substantial portion of a length of the portion of the frame 30 to which it is installed (e.g., a retaining clip 480 installed on the head 32 may extend over all, or substantially all, of a length of the head 32). In this embodiment, when the retaining clips 480 are removed from their respective frame member (e.g., the head 32, the first jamb 34, the second jamb 36, and the sill 38), the retaining clips 480 are each removed as a single piece (e.g., the retaining clip 480 extending along the head 32 is removed as a whole, maintaining the length). Alternatively, the length of each retaining clip 480 may be broken down into one or more smaller, individual clips rather than a single, long clip.
(224) The retaining clips 480 are resiliently deformable such that they can be attached to the frame 30 in a friction fit, for example. In some embodiments, the retaining clips 480 are formed of a polymeric material, such as polyvinyl chloride (PVC), for example. The channel insert 482 may include barbs, prongs, or projections to help assist with mechanical engagement with a complementary face feature (e.g., accessory channel or kerf) formed in the frame 30. The retaining lips 486 may include a rounded curved, or hooked end to help provide a positive bias against portions of the frame 30. The second retaining lip 488 may extend or project substantially orthogonally relative to the channel insert 482 and the first retaining lip 486. The retaining lip 486 extends substantially parallel to the channel insert 482, the first retaining lip 486 and the channel insert 482 defining a receiving channel 489 therebetween. The second retaining lip 488 optionally acts as an insertion stop extending substantially perpendicular to the first retaining lip 486 and the first channel insert 482, which can optionally be configured to abut the back face (or exterior face) of the frame 30 when the retaining clip 480 is assembled to the frame 30.
(225) For example, FIG. 59 is a sectional view at the head 32 of the frame 30 showing one of the retaining clips 480 according to the design of FIG. 57, the head retaining clip 480a, releasably engaged with a complementary face feature 490 (e.g., accessory channel or kerf) formed in the back face 44, or exterior face 44 of the frame 30 toward the outer perimeter P, and specifically in the head 32. For reference, the complementary face feature 490 is optionally formed in each of the head 32, first jamb 34, second jamb 36, and sill 38 of the frame 30. As shown, the first channel insert 482 is releasably engaged in the complementary face feature 490 with the second channel insert 484 arranged along the exterior face 44 and engaged therewith. In turn the first retaining lip 486 extends over the head fin 420a, and specifically over the projection portion 442 to hold the projection portion 442 folded against the coupling portion 440. The second retaining lip 488 extends along the back face 44. Generally, the first retaining lip 486 extends along the side of the frame 30 with the fin 420 of the fin assembly 412 received between the retaining lip 486 and the side, or outer perimeter P of the frame 30.
(226) Each of the retaining clips 480 may be similarly secured about the frame 30 to retain the plurality of fins 420 in the stowed state. In different terms, the channel inserts of the retaining clips 484, 484 are releasably secured into the complementary features 490 (e.g., accessory channels) of the frame 30 with the retaining lips 486, 488 received over the fin assembly 410 to releasably secure the fins 420 in the constrained state, or stowed configuration.
(227) Each of the retaining clips 480 may be reusable such that the retaining clips may be removed and re-installed about the frame 30 without damaging the retaining clips 480. The retaining clips 480 may also be installed and removed without damaging the plurality of fins 420 or the corner bridge seals 430, 432. The retaining clips 480 may be removed and re-installed manually and without the use of specialized tools.
(228) FIG. 60 is a partial view of a length of one of the retaining clips 480 according to another design, shown as retaining clips 480, according to some embodiments, where each of the retaining clips 480 (e.g., the head clip 480a, the first jamb clip 480b, the second jamb clip 480c, and the sill clip 480d) can be substantially similar to each other (apart from having a length suitable for retaining each of the respective plurality of fins 420 in the stowed configuration). FIG. 61 is a transverse sectional view of the retaining clip 480 shown in FIG. 60. As shown in FIG. 61, the retaining clip 480 includes a first channel insert 482, a second channel insert 484, a first retaining lip 486, and a second retaining lip 488. As shown, the first and second channel inserts 482, 484 are substantially orthogonal and the first and second retaining lips 486, 488 are similarly orthogonally offset. The retaining clips 480 may extend for a length approximating the portion of the frame 30 to which it is installed (head 32, first jamb 34, second jamb 36, and sill 38). Alternatively, the length of each retaining clip 480 may be broken down into one or more smaller, individual clips rather than a single, long clip.
(229) The retaining clips 480 are resiliently deformable such that they can be attached to the frame 30 in a friction fit, for example. In some embodiments, the retaining clips 480 are formed of a polymeric material, such as polyvinyl chloride (PVC), for example. The channel inserts 482, 484 may include barbs, prongs, or projections to help assist with mechanical engagement with a complementary face feature (e.g., accessory channel or kerf) formed in the frame 30. The retaining lips 486, 488 may include rounded curved, or hooked ends to help provide a positive bias against portions of the frame 30. The first retaining lip 486 extends substantially parallel to the first channel insert 482, the first retaining lip 486 and the first channel insert 482 defining a receiving channel 489 therebetween. The second retaining lip 488 optionally acts as an insertion stop extending substantially perpendicular to the first retaining lip 486 and the first channel insert 482, which can optionally be configured to abut the back face of the frame 30 when the retaining clip 480 is assembled to the frame 30.
(230) For example, FIG. 62 is a sectional view at the head 32 of the frame 30 showing one of the retaining clips 480, the head retaining clip 480a, releasably engaged with a complementary face feature 490 (e.g., accessory channel or kerf) formed in the back face 44, or exterior face 44 of the frame 30 toward the outer perimeter P, and specifically in the head 32. For reference, the complementary face feature 490 is optionally formed in each of the head 32, first jamb 34, second jamb 36, and sill 38 of the frame 30. As shown, the first channel insert 482 is releasably engaged in the complementary face feature 490 with the second channel insert 484 arranged along the exterior face 44 and engaged therewith. In turn, the first retaining lip 486 extends over the head fin 420a, and specifically over the projection portion 442 to hold the projection portion 442 folded against the coupling portion 440. The second retaining lip 488 extends along the back face 44. Generally, the first retaining lip 486 extends along the side of the frame 30 with the fin 420 of the fin assembly 412 received between the retaining lip 486 and the side, or outer perimeter P of the frame 30.
(231) Each of the retaining clips 480 may be similarly secured about the frame 30 to retain the plurality of fins 420 in the stowed state. In different terms, the channel inserts of the retaining clips 482, 484 are releasably secured into the complementary features 490 (e.g., accessory channels) of the frame 30 with the retaining lips 486, 488 received over the fin assembly 410 to releasably secure the fins 420 in the constrained state, or stowed configuration.
(232) Barrier System
(233) In some embodiments, the fenestration unit 10 further includes a barrier system 600 to control the flow of a sealant 610 (e.g., low expansion spray foam) around the perimeter P of the fenestration unit 10. In particular, the sealant 610 may be expandable to fill a gap 602 between the frame 30 and the rough opening RO for weather sealing. The gap 602 may be between approximately 0.000 to 1.250, approximately 0.000 to 0.125, between approximately 0.125 to 0.250, between approximately 0.250 to 0.375, between 0.375 to 0.500, between 0.500 to 0.625, between 0.625 to 0.750, between 0.750 to 0.875, between 0.875 to 1.000, or between 1.000 to 1.250. The barrier system 600 may control the flow of the sealant 610 within the gap 602 such that the sealant is preferentially portioned in only a portion of the gap. The barrier system 600 may extend about a portion of the perimeter P of the frame 30 or may extend along the entirely of the perimeter P of the frame 30. The sealant 610 may create an interior air and/or water seal which may be continuous and substantially, or entirely, uninterrupted. An interior air and/or water seal typically is necessary for proper water management.
(234) FIGS. 63-65 illustrate a first embodiment of the barrier system 600 in which the barrier system 600 includes a barrier fin 604 that is integrated with the first jamb fin 420b of the plurality of fins 420. In some embodiments, the barrier fin 604 is coextruded, co-pultruded, co-molded, or otherwise formed with the first jamb fin 420b such that the components are integral. As such, the first jamb fin 420b and the barrier fin 604 may comprise the same material. Although the first jamb fin 420b is shown, the barrier fin 604 may also be integrated with one or more of the head fin 420a, the second jamb fin 420c, and the sill fin 420d. The barrier fin 604 may extend continuously or discontinuously along one or more of the plurality of fins 420.
(235) FIGS. 63 and 64 illustrate a side profile of the frame 30 and rough opening RO. FIG. 65 illustrates an isometric view of the barrier system 600. The first jamb fin 420b may project outwardly from an exterior side of the frame 30, and downwardly relative to the perimeter P of the frame 30 to define a first jamb fin projection distance d1. The barrier system 600, and in particular the barrier fin 604, may project outwardly relative to the perimeter P of the frame and toward the rough opening RO framing to define a barrier fin projection distance d2. The barrier fin projection distance d2 may be less than the first jamb fin projection distance d1, such that the barrier fin 604 is shorter than the first jamb fin 420b. The first jamb fin 420b and the barrier fin 604 may be substantially parallel to each other such that the first jamb fin projection distance d1 and the barrier fin projection distance d2 are substantially parallel. In other embodiments, the barrier fin 604 may be non-parallel to the first jamb fin 420b, such that the barrier fin 604 is angled or curved either toward or away from the first jamb fin 420b. This configuration may accommodate variation in the rough opening RO size or variation in gap 602 size, and may allow for ease in inserting the fenestration unit 10 within the rough opening RO. The first jamb fin 420b and the barrier fin 604 may be offset and separated from each other over an intermediate portion of the fin assembly, wherein the intermediate portion of the fin assembly defined the exterior side gap 608. The barrier system 600 and barrier fin 604 may be positioned closer to an interior side of the fenestration unit 10 than the first jamb fin 420b. As shown in FIGS. 63 and 64 (as well as FIGS. 66 and 67), the barrier fin 604 divides the gap 602 into an interior side gap 606 (e.g., closer to the interior side of the fenestration unit 10) and an exterior side gap 608 (e.g., closer to the exterior side of the fenestration unit 10). The exterior side gap 608 is defined between the barrier fin 604 and the first jamb fin 420b. Although not shown, a portion of the anchoring clips 102 may be positioned within the interior side gap 606. A first side 607a of the barrier fin 604 may be in contact with the interior side gap 606 and a second side 607b may be in contact with the exterior side gap 608.
(236) The sealant 610 is applied to the interior side gap 606 and the barrier fin 604 acts to keep the sealant 610 contained within interior side gap 606, or in other words, contained on the first side 607a of the barrier fin 604, such that the exterior side gap 608 is devoid of the sealant 610. For example, as the sealant 610 expands the expansive flow is impeded by the barrier fin 604. By keeping the exterior side gap 608 devoid of the sealant 610, the exterior side gap 608 may act as a water management cavity to reduce or prevent water entry into the exterior side gap 608. Additionally, having the exterior side gap 608 devoid of sealant 610 allows the water management cavity to better respond the pressure modulations on the exterior side of the fenestration unit 10. In some embodiments, the exterior side gap 608 and/or the second side 607b of barrier fin 604 may include a hydrophobic or superhydrophobic coating to reduce or prevent water entry into the exterior side gap 608.
(237) The barrier fin 604 includes an end 612 that extends away from the frame 30 of the fenestration unit and into the gap 602. The barrier fin 604 may extend substantially perpendicular from the frame 30 before or after the application of sealant 610. In other embodiments, the barrier fin 604 may be flexible such that the barrier fin 604 bends or extends at a bent angle relative to the frame 30 upon the application of sealant 610. In still other embodiments, the barrier fin 604 may be substantially rigid and extend at an angle relative to the frame 30 (and interior or exterior angle). The end 612 of the barrier fin 604 may extend into only a portion of the gap 602, for example about halfway into the gap 602 or about three-quarters into the gap 602. As such, the end 612 may not extend to, or otherwise contact the rough opening RO framing when the fenestration unit 10 is installed within the rough opening RO. In such an embodiment, the barrier fin 604 remains able to contain the sealant 610 within the interior side gap 606 upon application and expansion of the sealant 610. Although various examples include a no-contact barrier fin, in other embodiments, the end 612 of the barrier fin 604 extends through the entirely of the height h of the gap 602 to contact the frame of the rough opening RO when the fenestration unit 10 is installed.
(238) The barrier system 600 may include a tip 618 positioned on the exterior side of the first jamb fin 420b that extends continuously or discontinuously along a length of the first jamb 24. The tip 618 may extend outwardly, and optionally at an angle, relative to the exterior side of the frame 30 and abuts the exterior side of frame 30. The tip 618 may be configured to prevent water/moisture movement along the length of the first jamb 24 such that water is prevented or substantially impeded from transferring across the exterior side gap 608 through an attachment point of the first jamb fin 420b and the frame 30. In some embodiments, as discussed above, the tip 618 may be present on the fin assembly 420 without the barrier fin 604.
(239) The barrier system 600 may be retained by one or more of the retaining clips 480 described with respect to the fin assembly 410. Similar to the fin assembly 610, the barrier system 600 may be transitioned between a compressed configuration in which the one or more retaining clips 480 compress the barrier system 600 against the perimeter P of the frame 30 and a deployed configuration wherein the barrier fin 604 extends into the gap 602. The barrier system 600 may be sufficiently flexible to fold between the compressed and deployed configurations.
(240) The barrier fin 604 may also act as a guide to assist an Installer with applying sealant 610 to the interior side gap 602 during installation of the fenestration unit 10. For example, the barrier fin 604 may provide tactile feedback or a physical resistance when contacted by an application tool (e.g., a foam nozzle) such that the Installer can find a position of the barrier fin 604 and preferentially apply sealant 610 within the interior side gap 602. The barrier fin 604 optionally includes one or more protrusions 614, or slip bumps, positioned on at least one of the first side 607a and the second side 607b to help reduce friction between the barrier system 600 at the rough opening framing during installation and placement of the fenestration unit 10 within the rough opening RO.
(241) FIG. 66-68 illustrate another embodiment of the barrier system 600 in which the barrier system 600 includes a barrier fin 624. As shown FIGS. 66-67, the barrier fin 624 may be integral with the sill fin 420d of the plurality of fins 420 to form an assembly 626. The assembly 626 may be coupled to a cladding 50 of the fenestration unit 10 via an attachment feature 632. The attachment barb 632 may be described as a Christmas tree configuration and include one or more flexible fins 634 configured to abut corresponding features of the cladding 50. The tip 618 may extend outwardly, and optionally at an angle, relative to the exterior side of the frame 30 and abut the exterior side of frame 30. The tip 618 may be configured to prevent water entry along the length of the sill 22 such that water does not enter the exterior side gap 608 through the attachment feature 632. In some embodiments, as discussed above, the tip 618 may be present on the fin assembly 420 without the barrier fin 624.
(242) The cladding 50 may be coupled to the sill 38 on the exterior side of the fenestration unit 10 and may extend outwardly (exteriorly) relative to the exterior side of the fenestration unit 10. As shown in FIGS. 66-67, the assembly 626 may at least partially extend into the gap 602 such that the barrier fin 624 is positioned within the gap 602. The barrier fin 624 may extend, continuously or discontinuously, about the perimeter P of the frame 30.
(243) The barrier fin 624 may include similar features as described above with respect to barrier fin 604. The barrier fin 624 may include an end 628 that extends at least partially into the gap 602 to divide the gap 602 into the interior side gap 606 and the exterior side gap 608. A first side 628a of the barrier fin 624 may face the interior side gap 606 and a second side 627b of the barrier fin 624 may face the exterior side gap 608. The barrier fin 624 may extend about halfway into gap 602, about three-quarters into gap 602, or along an entire height h of the gap 602 such the end 628 contacts the framing of the rough opening RO. Similar to barrier fin 604, barrier fin 624 is configured to contain the sealant 610 within the interior side gap 606, or in other words, contain the sealant 610 on the first side 627a of the barrier fin 624. As such, the exterior side gap 608 is devoid of sealant 610 and may act as a water management cavity.
(244) Similar to barrier fin 604, the barrier fin 624 may optionally include a plurality of protrusions 630, or slip bumps, positioned on at least one of the first side 627a and the second side 627b to help reduce friction between the barrier system 600 at the rough opening framing during installation and placement of the fenestration unit 10 within the rough opening RO.
(245) Adjustment System
(246) FIG. 69 shows a close-up view of the first jamb 34 (FIG. 1), and a portion of the adjustment system 500 secured to the first jamb 34, and in particular an edge adjuster 502a of a plurality of edge adjusters according to a first design. The adjustment system 500 may serve to help straighten the jambs 34, 35 in order to help generate a more uniform exterior reveal between the sash and frame 30. In various examples, by performing this function, the adjustment system 500 helps improve the weather sealing ability of the fenestration unit 10 by creating more sash to frame 30 weather-strip contact, for example.
(247) The plurality of edge adjusters may be substantially similar to the first edge adjuster 502a (FIG. 69) secured to the first jamb 34. For example, a second edge adjuster 502b may be secured to the second jamb 36 of the frame 30 (e.g., at the location indicated on FIG. 2 for edge adjuster 502b). Any number of edge adjusters 502 at any number of positions on the frame 30 are contemplated. FIG. 70 shows the close-up, isometric view of the first edge adjuster 502a removed from the frame 30 to show additional details thereof. FIGS. 71 and 72 are front and side views of the edge adjuster 502a of FIG. 69.
(248) As shown, the first edge adjuster 502a includes a guide portion 504, a first ramp portion 506, and a second ramp portion 508. The first edge adjuster 502a defines a longitudinal axis extending between the first and second ramp portions 506, 508. The guide portion 504 is positioned between the first and second ramp portions 506, 508 and includes a sliding surface 504a, a first guide edge 504b, and a second guide edge 504c. The sliding surface 504a is recessed (e.g., relative to the first and second ramp portions 506, 508) to define the first and second guide edges 504b, 504c. The first and second guide edges 504b, 504c are optionally spaced a distance corresponding to a standard wooden, composite, or polymeric shim width (e.g., 1.5 inches). As shown, the guide portion 504 optionally includes a fastener aperture 505 (e.g., for a screw or bolt). The fastener aperture 505 may be used to affix the frame 30 to the rough opening (RO) using a fastener and/or to secure the first edge adjuster 502a to the frame 30 (e.g., either jamb 34, 36). Additionally, or alternatively, the one or more edge adjusters 502 may be coupled or secured to the frame 30 via adhesion to the frame 30.
(249) The first and second ramp portions 506, 508 each taper in thickness, going from a first, greater thickness to a second, smaller thickness in a direction away from the guide portion 504. In use, the first edge adjuster 502a is assembled to the first jamb 34 with the longitudinal axis extending along the first jamb 34. Once the fenestration unit 10 is received in the rough opening (RO), a shim (not shown) is slide in either an upward or downward direction over the first or second ramp portions 506, 508, respectively, until the shim passes into the guide portion 504. In some examples, a user (not shown) feels a tactile response to the shim sliding into place into the guide portion 504. At that point, the shim can be driven into the gap between the first edge adjuster 502a and a first jamb of the rough opening (RO). This shimming action can help to reinforce the first jamb 34 of the fenestration unit 10. Any number of edge adjusters (e.g., of similar design to the first edge adjuster 502a) may be coupled to the perimeter P of the frame 30 (e.g., at a remote location from the installation site), such as on the first and second jambs 34, 36.
(250) FIG. 73 shows another close-up view of the first jamb 34, and a portion of the adjustment system 500 secured to the first jamb 34, and in particular a plurality of edge adjusters 502, according to another design shown as edge adjuster 502. The plurality of edge adjusters 502 include a first a first edge adjuster 502a (FIG. 73) secured to the first jamb 34 and a second edge adjuster 502b (similar to 502b of FIG. 2) secured to the second jamb 36 of the frame 30. The plurality of edge adjusters 502 are optionally substantially similar. FIG. 74 shows the close-up view of FIG. 73 with the first edge adjuster 502a removed to show a first adjustment aperture 510a of a plurality of adjustment apertures included in the frame 30. As shown, the first adjustment aperture 510a is formed in the first jamb 34. Though not shown, the second jamb 36 includes a similar adjustment aperture (not shown) in which the second edge adjuster 502b can be secured. Any number of edge adjusters 502 may be included with corresponding adjustment apertures 510.
(251) FIG. 75 is a first isometric view of one of the edge adjusters 502 and FIG. 76 is a second isometric view of the edge adjuster 502. As shown, the edge adjuster 502 includes a contact head 511 having a plurality of engagement features 512 and an adjustment body 520 extending from the contact head 511 and configured to be received in the adjustment aperture 510 in the frame 30 (e.g., in the first adjustment aperture 510). The adjustment body 520 is rotatably actuatable to adjust a depth of the adjustment body 520 within an adjustment aperture 510. The contact head defines a projection distance from the frame 30 based upon the depth of the adjustment body 520 within the adjustment aperture 510.
(252) In some embodiments, the adjustment body 520 of the edge adjuster 502 may have male threading and the adjustment aperture 510 may have complementary female threading. In this manner, the adjustment body 520 can be rotatably adjusted (e.g., screwed in or out) in order to adjust the distance at which the contact head 511 projects from the frame 30. For example, the plurality of engagement features 512 of the contact head 511 may include a plurality of radial projections 530 with a plurality of recesses 532 between the plurality of projections. In some examples, the recesses may be sized to engage with an end (e.g., tip) of a standard flathead screwdriver (e.g., having a -inch head and a shaft length of at least 4 inches). The contact head 511 may have a terminal end, or free end, defining a leading profile, the leading profile being dome-shaped.
(253) As shown, the contact head 511 may include a circumferential groove 534 (FIG. 76). An elongate filament (e.g., strand or braid) may be wrapped around the contact head 511 and spooled in the circumferential groove 534. In order to extend the contact head 511, the elongate filament (not shown) may be pulled to rotate the contact head 511 and unscrew the adjustment body 520 to extend the contact head 511.
(254) In various examples, the first edge adjuster 502a is located closer to the back, or exterior face 44 of the fenestration unit 10 than the front 42 of the fenestration unit 10. In this manner, an installer (not shown) may be able to insert a screwdriver or other tool in a gap between the fenestration unit 10 and the framing of the rough opening (RO), engage the tool with the edge adjuster 502, 502, rotate the edge adjuster 502 with the tool, and engage the edge adjuster 502 (and particularly the contact head 511) with the framing of the rough opening (RO). In other examples, an installer may pull an elongate filament (not shown) wrapped around the contact head 511 and spooled in the circumferential groove 534 to adjust the depth of the first edge adjuster 502, or the amount the contact head 511 extends from the frame 30.
(255) Installation Method
(256) Installation of the fenestration unit 10 can proceed in view of the various concepts described in the foregoing sections. In particular, installation of the fenestration unit 10 in the rough opening (RO) may proceed from the interior side of the rough opening (RO) and may be executed by a single installer on the interior side of the rough opening.
(257) As part of the installation process, the rough opening (RO) in the building structure should be prepared for fenestration unit 10 installation. Generally, the rough opening (RO) is sized to be between inches and inches larger than the fenestration unit 10 in both width and height, although other setups may also be suitable. Some methods also include forming the rough opening (RO), such as by cutting out the rough opening (e.g., plywood cladding covering rough opening framing). The sill portion of the framing of the rough opening (RO) (lower framing) may be flashed (e.g., using appropriate flashing tape).
(258) The fenestration unit 10 is then partially deployed from the stowed to the active configuration. In particular, the anchoring clips 102 (or anchoring clips 102) are transitioned to the installation configuration by removing the coupling brackets 112 from the carrier brackets 110, rotating them 180 degrees so they no longer extend inward toward the center of the fenestration unit 10, and then re-inserting the coupling brackets 112 into the carrier brackets 110 such that the coupling brackets project radially outward from outer perimeter P of the frame 30. When the coupling brackets 112 are sufficiently inserted into the carrier brackets 110 the catches 150 engage the detents 174. In various examples, this engagement results in an audible click or noise providing a clear, audible cue to the installer that the coupling brackets 112 have been properly secured and are at the desired depth of insertion. This audible cue can be augmented by adjusting the spring bias and material selection for the anchoring clips 102. The click or vibration may also present as tactile feedback, keying to a user that the coupling brackets 112 have been properly installed. Various details on insertion depth and assembly of the coupling brackets 112 are provided in the foregoing sections.
(259) Advantageously, in various implementations, no tools are needed for the foregoing steps. In other words, the removal, reversal, re-insertion, and coupling/assembly of the anchoring clips 102 can be accomplished by hand. If it is desired to remove the coupling brackets 112 from the carrier brackets 110 after the catches 150 have engaged the detents 174, a user may lift the catches 150 from the detents 174 (e.g., using by hand and/or by using a tool such as a screwdriver as previously described) and the coupling brackets 112 may then be withdrawn.
(260) The fenestration unit 10 is inserted or pushed unit into the rough opening (RO) from the interior side of the rough opening (RO), for example by a single installer. The fenestration unit 10 may be passed from the exterior, through the rough opening (RO) and then repositioned or pushed or pulled in an exterior direction to seat the fenestration unit but this is generally less preferred. The ability and functionality to be installed from an interior side of the unit can be an important feature of the fenestration unit 10, as traditional fenestration installations require at least one installer on the exterior side of the rough opening (RO) and/or at least one installer on the interior side of the rough opening (RO).
(261) In some embodiments, the fenestration unit 10 is inserted into the rough opening (RO) by first inserting a bottom of the fenestration unit 10 into the rough opening (RO) and then tilting the fenestration unit 10 back toward an exterior side of the rough opening (RO) such that the retention system exerts the retention force on the fenestration unit 10 to maintain positive engagement of the fenestration unit 10 with the framing of the rough opening (RO). The installation stabilizer system 300 permits insertion of the fenestration unit 10 within the rough opening (RO) in a first, interior-to-exterior direction at a first insertion force and resist extraction of the fenestration unit from the opening in a second, exterior-to-interior direction at a second extraction force, the second extraction force being substantially greater than the first insertion force. The method includes inserting the fenestration unit 10 within the rough opening (RO) in the first direction at a force that meets or exceeds the insertion force. The retainer 302 of the installation stabilizer system 300 may engage the header H of the framing of the rough opening (RO) such that a noise is produced providing a clear, audible cue to the installer that the retainer 302 is properly engaged. In some embodiments, both the retainer 302 and the anchoring clips 102 together provide an audible cue to the installer that the fenestration unit 10 is engaged within the framing of the rough opening (RO) and properly seated within the rough opening (RO).
(262) The fenestration unit 10 is pushed into the rough opening (RO) until the anchoring clips 102 engage the edges of the rough opening (RO), and specifically the jamb portions of the rough opening framing. The retention system exerts a retention force on the fenestration unit 10 to maintain positive engagement of the fenestration unit 10 with framing of the rough opening (RO) upon insertion of the fenestration unit 10 in the rough opening (RO). The retention system exerts this retention force without use of fasteners securing the fenestration unit 10 to the rough opening framing. The anchoring clips 102 act as an engagement system that is positively engaged with the interior face of the rough opening framing from the interior side of the rough opening (RO) and the retention system operates to maintain positive engagement of the engagement system with the rough opening framing (RO) upon insertion therein.
(263) For example, the sill spacer system 200 provides the offset tilt bias toward the exterior side of the rough opening (RO), as previously described, as the fenestration unit 10 is resting on the sill portion of the rough opening framing and the installation stabilizer system 300 engages the header H of the rough opening framing, as previously described. When the stabilizer system 300 automatically engages the head H, there is some resistance to inserting the fenestration unit 10 within the rough opening (RO), but this resistance is easily overcome by a single installer and the resistance to the fenestration unit 10 being withdrawn from the rough opening (RO) is substantially greater, preventing inadvertent extraction, or preventing the fenestration unit 10 from falling out of the rough opening (RO).
(264) If desired, the strap member 302a of the retainer 302 (or similar features of retainer 302) may be reoriented (e.g., bent) to project upwardly away from the fenestration unit 10 and against the head H of the rough opening framing. The strap member 302a may then be fastened (e.g., screwed or nailed) to the rough opening framing to further ensure the fenestration unit 10 is securely held in place.
(265) The fenestration unit 10 is then centered in the rough opening (RO). In some embodiments, the fenestration unit 10 begins spaced from the sill portion of the rough opening framing a desired distance due to the thickness of the sill spacers 202. In some embodiments, this distance is approximately inches. The fenestration unit 10 may be centered side-to-side by inserting a screwdriver having a standard head (e.g., -inch-thick head) and rotating the screw driver to ensure a minimum desired gap is achieved at the first and second jambs 34, 36. To begin the shimming/levelling processes, a level is used to check the horizontal level of the fenestration unit 10 and a single shim is slid underneath the low side sill spacer 202 to begin levelling the fenestration unit 10. Additional shims are applied as needed to achieve a desired level and sill spacing with periodic measuring of horizontal level as at the sill 38 as needed.
(266) Once a desired levelling and spacing is achieved at the sill portion of the fenestration unit 10, fasteners (e.g., screws or nails) are driven through the first anchoring clip 102a and second anchoring clip 102b, corresponding to the two bottom-most clips on the fenestration unit 10, and into the rough opening framing.
(267) The fenestration unit 10 can then continue to be plumbed, squared, and fully coupled to the framing of the rough opening (RO). For example, a user may plumb one of the first jamb 34 and the second jamb 36 to vertical level. This operation of adjusting vertical level at the first jab 34 and/o the second jamb 36 may be carried out using a tool (e.g., a crowbar or prybar) to adjust the plumb of the jambs 34, 36. Additionally, or alternatively, an installer may use an air bag designed for such a purpose that can be inflated to adjust the gap between the jambs 34, 36 and the rough opening framing, and thus vertical level thereof, or other suitable methods may be implemented as desired. Once plumbed to be vertically level, the remaining anchoring clips 102 are fastened to the rough opening framing until all anchoring clips 102 are attached to the rough opening framing using one or more fasteners such that the fenestration unit 10 is structurally secured to the rough opening (RO).
(268) In some embodiments, the installer adjusts the adjustment system 500 to engage the framing (jamb portions) of the rough opening (RO). The deploying or adjusting of the adjustment system 500 may be carried out to help ensure that any torsional forces on the frame 30 (e.g., during high winds, such as those encountered in a hurricane) do not twist or deform the frame 30 to the point of failure during such an event. In various examples, the adjustment of the adjustment system 500 (e.g., shimming or otherwise engaging the rough opening (RO)) using the edge adjusters 502, 502 (such as those shown in FIG. 69 or 73) proceeds from the exterior side of the fenestration unit 10. Access and adjustment from an exterior side may be facilitated as the edge adjusters 502, 502 may be located and biased toward the exterior side of the fenestration unit 10. Although exterior installation of the shims and/or access to the contact head 511, depending on design, may be facilitated by an exterior approach, the installer may access from either side of the fenestration unit 10 (interior and/or exterior) according to various embodiments.
(269) The installer may apply an air sealant (e.g., spray foam or other air seal material) around the outer perimeter P of the fenestration unit 10 in the gap between the rough opening (RO) framing and the fenestration unit 10 to create an interior air seal. This interior air seal may be continuous and substantially, or entirely, uninterrupted. An interior air seal typically is necessary for proper water management. As previously referenced, the positioning of the sill spacer system 200 helps provide sufficient gap for the air sealant to be deposited in the gap, and also provides a continuous gap around the perimeter of the fenestration unit 10 to ensure a continuous seal can be formed. This sealing operation is typically carried out from an interior side of the rough opening (RO). Notably, the sealant may be applied before, or after the exterior water barrier steps described below in association with the weather seal system 400.
(270) In contrast to other methods and systems, at this point the fenestration unit 10 is entirely squared, plumbed, and securely fastened in the rough opening (RO) all from the interior side of the rough opening (RO). This can be accomplished by a single installer, rather than requiring two installers. At that time, or a later time as desired, the same installer, or another installer, may proceed to the exterior side of the rough opening (RO) to finish exterior water barrier installation for the fenestration unit 10 in the rough opening (RO). This is to be contrasted with traditional, nailing fin installations which require a second installer to be present on the exterior side of the rough opening (RO) during installation of the fenestration unit 10.
(271) Forming an exterior water barrier for the installation unit 10 includes removing the retaining clips 480 such that the plurality of fins 420 transition from the stowed state to a radial outwardly projecting installation, or deployed configuration. In various operations, in order to ensure proper deployment of the plurality of fins 420 (or fins 420), the sill retaining clip 480d is removed first, followed by the first and second jamb retaining clips 480b, 480c, and finally the head retaining clip 480a. This ordering can help ensure the proper overlapping of the plurality of fins and the first and second corner bridge seals 430, 432, with the sill fin 420d being outwardly overlapping with the first and second jamb fins 420b, 420c.
(272) As discussed above, removing the retaining clips 480 may also allow the corner bridge seals, such as first corner bridge seal 430 and/or second corner bridge seal 432, to be deployed to the unfolded, deployed configuration. The first corner bridge seal 430 may be transitioned from the folded, stowed configured (e.g., as shown in FIG. 55A) to the unfolded, deployed configuration (e.g., as shown in FIG. 55C). The first corner bridge seal 430 may project substantially outwardly relative to the frame 30 when transitioned from the folded, stowed to the unfolded, deployed configurations. As described above with respect to FIG. 49, one or more of the corner bridge seals 430, 432 may act as a single member or unit with the fins 420 (e.g., head fin 420a), such that when the fins 420 are deployed, the corner bridge seals 430, 432 are also deployed. Once deployed, additional processing or conditioning for folding, unfolding, and deployment (e.g., stretching, or other manipulation of a shape of the first corner bridge seal 430 and/or second corner bridge seal 432 to facilitate deployment of the fin assembly 410) may not be necessary. Similarly, the barrier system 600 may be deployed with the fin assembly 410 upon removal of the retaining clips 480.
(273) Generally, no fasteners are used with the plurality of fins 420, which can be contrasted to traditional nailing fins. Though such fasteners (e.g., screws or nails) are not present in various examples, it is contemplated that such fasteners could be implemented in other embodiments (e.g., the embodiment of FIG. 46). Regardless, installation proceeds by using flashing tape or another suitable flashing material to flash over the first and second jamb fins 420b, 420c, then the head fin 420a. Generally, weather resistant barrier (e.g., Tyvek home wrap available from DuPont de Nemours, Inc.) will be present on the exterior wall of a building and will be cut with two 45-degree cuts at the rough opening head corners and folded vertically against itself. Once the first and second jamb fins 420b, 420c and the head fin 420a have been flashed, the weather resistant barrier can be folded back down over the head fin 420a and flashing (e.g., flashing tape) can be applied across the 45-degree cuts at the corners. Flashing (e.g., flashing tape) is not applied to the sill fin 420d in various examples. This absence of sealing at the sill 38 of the frame 30 can help ensure that the sill fin 420d acts as a water barrier, but not an air seal at the sill 38. This water-but-non-air barrier configuration promotes equalization of air pressure at a location under the sill 38 and exterior to the rough opening sealant to exterior air pressure. This equalization to exterior air pressure can help prevent water from being forced through the water seal at the sill 38 during a storm or other high external ambient air pressure event.
(274) Various advantages may be achieved according to the foregoing example systems and methods. The various examples may be one or more of: more efficient (e.g., cycle time reduced by 50% or more); easier to learn; easier to remember; easier to train; may be less physically demanding (e.g., fenestration unit 10 is not set from the exterior side which could be on uneven ground or require a ladder); fenestration unit 10 is unable to fall out toward exterior during installation; can be installed by a single person from the interior of the building structure; interior and exterior installation tasks do not need to be done simultaneously; improved fenestration unit 10 install quality and fenestration unit 10 performance following installation; delivers an installation method that is unique to the industry and offers many benefits for the installer; faster cycle times; improved performance (water and air infiltration); adapts to wall depth variation; simplifies casing installation for finish carpenters; separates interior and exterior work so they can be done independently.
Installation Performance Example
(275) A study was done to compare installation of fenestration unit 700 (also referred to herein as FIG. 77 Unit) to other comparative fenestration units to compare installation time, quality (e.g., plumbness, squareness, and level), and relative safety (e.g., time spent on a ladder during installation). The FIG. 77 Unit is illustrated in FIGS. 77A-77D and includes an anchoring clip system 702 (also described as an engagement system), a retention system including a sill spacer system 704, an installation stabilizer system 706, and a weather seal system 708. The anchoring clip system 702 may be substantially as described in association with FIGS. 5-10. The sill spacer system 704 may be substantially as described in association with FIGS. 30-32. The installation stabilizer system 706 may be substantially as described in association with FIGS. 36-39. The weather seal system 708 may be substantially as described in association with FIGS. 48A-49 and 55A-55G, and may include the retaining clips 480 as described in association with FIGS. 56-59. Each trial was filmed, timed, and evaluated, as described below.
(276) The FIG. 77 unit was compared to an Andersen 400 Casement fenestration unit (herein 400 Unit), a Jeld-Wen W-2500 Series Casement fenestration unit (herein W-2500 Unit), a Marvin Elevate Casement fenestration unit (herein Elevate Unit), a Sierra Pacific Standard H3 Casement fenestration unit (herein H3 Unit), a Windsor Pinnacle Series Casement fenestration unit (herein Pinnacle Unit), and a Pella Lifestyle Casement fenestration unit (herein Lifestyle Unit). The above-mentioned fenestration units will be referred to collectively herein as the comparative fenestration units. The comparative fenestration units were substantially the same size. Further details for each fenestration unit of the comparative fenestration units can be found in Table 1. The installation instructions for the comparative fenestration units and the FIG. 77 Unit are filed herewith.
(277) In the study, each fenestration unit of the comparative fenestration units was installed by two professional Installers I. The FIG. 77 Unit was installed by one professional Installer I. The comparative fenestration units and the FIG. 77 Unit were installed over two installation phases. The same Installers I were used for each trial of the two testing phases. In the first testing phase of the two testing phases, the first three trials of all fenestration units, with the exception of the Pinnacle Unit, were conducted over two consecutive days. The same fenestration unit was installed three times in a row before moving onto the next fenestration unit. In the second testing phase of the two testing phases, the remaining ten trials of all fenestration units, were conducted over four consecutive days. The same fenestration unit was installed ten times in a row before moving onto the next fenestration unit. For the Pinnacle Unit, all thirteen installation trials were conducted in the second testing phase. For all trials in the two testing phases, each fenestration unit was installed on a second-story test rough opening, where one of the Installers I could stand on a ladder L on the exterior side of the rough opening (RO) during installation, as part of the standard installation procedure provided for each comparative fenestration unit.
(278) For each trial, the installation instructions for each comparative fenestration unit and the FIG. 77 Unit were provided to the Installers I, and the Installers I were asked to follow the installation instructions as listed. The Installers I were able to review the installation instructions prior to the installation trials without time constraint. The time spent reviewing the installation instructions was not included in the recorded installation time. The installation instructions remained available during each installation trial of the respective fenestration unit and were able to be referenced at any time. The comparative fenestration units were unwrapped and all shipping and packaging materials were removed prior to installation (this time was not included in the recorded installation time). However, removal of the retaining clips 480 was included in the installation time of the FIG. 77 Unit. As discussed above in association with retaining clips 480, the retaining clips 480 were removed from their respective frame members as a single piece.
(279) To allow fastening of the comparative fenestration unit and the FIG. 77 Unit to the same rough opening, and to avoid re-using any screw holes in subsequent installation trials, custom wood frame inserts were prepared at the respective comparative unit's recommended rough opening size. The custom wood frame inserts were installed prior to each trial and removed at the conclusion of each trial. The time to install and remove the custom wood frame inserts was not included in the recorded installation trial times.
(280) The test environment, all installation materials, and all tools required by the comparative test unit's installation instructions were provided to the Installers I by the test coordinator. During each trial, installation steps for foaming or caulking were mimicked using a foam gun, but those foaming and chalking steps were not actually performed for ease of clean up and fenestration unit removal from the rough opening after each trial. For similar reasons, masking tape was used for simulated flashing instead of actual flashing tape. All needed tools, such as caulk guns and foam guns, were provided for the Installers I to mimic these installation steps. If any of the caulking or foaming steps were omitted for a particular trial, the installation time was modified to add the caulking and foaming time back in. The time spent on these installation steps was verified using video recording time stamps. It is noted that the omission, and later remedial steps of caulking and foaming only happened once, which was during Lifestyle Unit installation trial 1.
(281) Each installation was timed and observed by the test coordinator, and no assistance by the test coordinator was provided during the trials. All of the installation trials were filmed from both the interior side of the test rough opening and the exterior side of the test rough opening. The film equipment included time stamps and the labor times reported in Tables 2a, 3a, 4a, and 5a were all taken directly from the time stamps. The time is reported in minutes: seconds. Table 2a includes the data for the total labor time for each trial, which is the sum of the time spent on the interior installation phase (Table 3a) and time spent on the exterior installation phase (Table 4a). FIG. 83 shows the average total labor time of Table 2a as a bar chart. Table 2b includes comparisons of the total average labor time compared to the FIG. 77 Unit, taken from the data in Table 2a. Table 3a includes the total labor time spent installing the fenestration units from the interior side (Interior Installation Phase), which is a subset of the total labor time of Table 2a. Table 3b includes comparisons of the Interior Installation Phase time compared to the FIG. 77 Unit, taken from the data in Table 3a. Table 4a includes the total labor time spent installing the fenestration units from the exterior side (Exterior Installation Phase), which is a subset of the total installation time of Table 2a. FIG. 84 shows the average total labor time of the Exterior Installation Phase of Table 4a as a bar chart. Table 4b includes comparisons of the Exterior Installation Phase time compared to the FIG. 77 Unit, taken from the data in Table 4a. Table 5a includes the total time spent on the ladder L when installing the fenestration units from the exterior side (Exterior Installation Phase), which is a subset of the total installation time of Table 4a. Table 5b includes comparisons of the ladder time during the Exterior Installation Phase time compared to and the FIG. 77 Unit, taken from the data in Table 5a. Table 6 includes the percentage of total labor time with at least one Installer I was performing installation steps on the exterior side of the rough opening, based on the data in Table 4a. Table 7 includes the percentage of total labor time with at least one Installer I on a ladder L, based on the data in Table 5a.
(282) After each trial, measurements were taken to determine if the comparative fenestration units and FIG. 77 Unit were square, plumb, and level, which is an indicator of relative quality of the installation.
(283) FIG. 78 illustrates the squareness measurement method. After each trial installation, squareness was measured using a tape measure. To determine if the fenestration unit 10 was square, a first diagonal distance D1 was measured between an upper left corner L1 of the fenestration unit and a lower right corner R1 of the fenestration unit 10 and a second diagonal distance D2 was measured between an upper right corner R2 of the fenestration unit 10 and a lower left corner L2 of the fenestration unit 10. The second diagonal distance D2 was then subtracted from the first diagonal distance D1 to calculate a difference. If the determined difference is zero, then the fenestration unit 10 is identified as being square and, in this study, the data has been recorded as square. If the difference is clearly non-zero, then the fenestration unit 10 is not square and, in this study, the data is recorded as not square. The data for squareness is recorded in Table 6.
(284) FIG. 79 illustrates various aspects of the plumbness measurement method. Plumbness was measured using a digital caliper. To determine if the fenestration unit 10 is plumb, a distance measurement d is taken between an interior wall the rough opening RO and an exterior wall of a frame 30 of the fenestration unit 10. The distance measurement was taken on vertical sides of the frame, which includes two side frame members. Two measurements were taken for each side member, and the two measurements were taken near a top corner (e.g., near L1 and R2) and a bottom corner of the frame (e.g., near L2 and R1). Out of the four distance measurements, a maximum value and a minimum value were determined. The minimum value was then subtracted from the maximum value to calculate a difference. Generally, the closer the difference is to zero, the more plumb the fenestration unit is considered. In this study, plumbness was recorded in inches, and analyzed as a relative measurement. In other words, if a difference value of a first fenestration unit was determined to be closer to zero than a determined difference value of a second fenestration unit, the first fenestration unit was considered more plumb than the second fenestration unit. The data for plumbness was recorded in inches in Table 7, and was reported as an average measurement between the three trials of the first testing phase and an average between the ten trials of the second testing phase. For the Pinnacle Unit, all thirteen trials of the second testing phase were reported together.
(285) FIG. 80 illustrates aspects of the level measurement method. Level was measured using a digital level. To determine if the fenestration unit is level, an angle measurement a is taken relative to a vertical axis V of the rough opening (RO). The angle measurement a may be a positive value or a negative value, depending on if the fenestration unit is angled, or tilted, toward the interior side or the exterior side of the rough opening. In this study, a positive angle measurement a indicated a tilt toward the interior side of the rough opening RO and a negative angle measurement a indicated a tilt toward the exterior side of the rough opening RO. The angle measurement a is taken on each of the two vertical sides of the frame 30. In this study, the two side frame members 24, 26 were evaluated individually and were measured twice. The closer the angle measurement is to zero, the closer the fenestration unit is to level. In this study, level was measured in degrees and analyzed as a relative measurement. In other words, if an angle measurement of a first fenestration unit was closer to zero when compared to an angle measurement of a second fenestration unit, the first fenestration unit was considered more level than the second fenestration unit. The level data was recorded in degrees and is recorded in Table 8 as an average of all measurements on the left side of the respective fenestration unit and an average of all measurements on the right side of the respective fenestration unit.
(286) TABLE-US-00002 TABLE 1 Fenestration Unit Size, Rough Opening Size, and Number of Installers Actual Rough Number of Unit Name Actual Unit Size Opening Size Installers 400 Unit 28 59 28 60 2 W-2500 Unit 29 59 30 60 2 Elevate Unit 28 59 29 59 2 H3 Unit 29.5 59.5 30 60 2 Pinnacle Unit 30 60 30.75 60.75 2 Lifestyle Unit 29 59 29 59 2 FIG. 77 Unit 29 59 29 59 1
(287) TABLE-US-00003 TABLE 2a Total Labor Time for each Trial (in min:sec) Time 400 W-2500 Elevate H3 Pinnacle Lifestyle FIG. 77 (Min:Sec) Unit Unit Unit Unit Unit Unit Unit Trial 1 41:58 32:47 42:04 22:25 21:12 36:14 16:29 Trial 2 29:12 22:38 30:21 17:43 16:38 23:41 7:47 Trial 3 21:16 18:59 30:04 20:21 15:08 29:34 5:18 Trial 4 32:53 29:24 37:55 32:33 19:18 41:14 9:00 Trial 5 24:08 20:30 25:27 23:08 12:57 26:24 6:48 Trial 6 20:01 24:01 17:36 19:56 11:12 19:02 5:36 Trial 7 20:00 17:32 18:58 18:21 10:29 14:03 5:21 Trial 8 16:06 16:57 23:09 16:49 12:10 13:58 4:27 Trial 9 17:39 16:06 20:20 17:01 11:36 13:46 4:44 Trial 10 16:16 13:06 17:02 17:16 12:55 11:15 4:25 Trial 11 17:14 12:51 16:25 18:19 13:24 11:38 4:20 Trial 12 16:02 12:21 17:30 18:12 10:27 10:58 4:20 Trial 13 15:24 10:55 15:08 16:59 10:13 09:24 3:38 Average 22:10 19:05 24:00 19:56 13:40 20:05 6:19
(288) TABLE-US-00004 TABLE 2b Total Labor Time Compared to FIG. 77 Unit On average, how Difference in many times less On average, how average labor labor for the much less labor to from FIG. 77 FIG. 77 install the FIG. 77 Unit Name Unit (min:sec) Unit (unitless) Unit (%) 400 Unit 15:50 3.5 72% W-2500 Unit 12:46 3.0 67% Elevate Unit 17:40 3.8 74% H3 Unit 13:36 3.2 68% Pinnacle Unit 7:20 2.2 54% Lifestyle Unit 13:46 3.2 69%
(289) TABLE-US-00005 TABLE 3a Labor Time on Interior Installation Phase Time in 400 W-2500 Elevate H3 Pinnacle Lifestyle FIG. 77 (Min:Sec) Unit Unit Unit Unit Unit Unit Unit Trial 1 18:03 17:27 22:50 11:59 9:26 17:05 10:27 Trial 2 15:40 11:17 15:56 9:05 7:48 12:10 5:18 Trial 3 10:19 9:09 15:24 10:17 6:06 14:54 3:12 Trial 4 14:44 15:25 17:10 16:09 8:06 20:17 6:48 Trial 5 10:41 9:01 11:46 10:40 4:58 13:31 4:37 Trial 6 8:32 10:17 7:09 8:38 4:31 9:05 3:44 Trial 7 9:06 6:46 6:52 8:35 4:15 6:52 3:21 Trial 8 6:07 6:55 9:50 7:51 5:29 6:29 2:41 Trial 9 8:22 6:08 9:12 6:55 4:29 6:33 2:48 Trial 10 7:15 5:00 7:18 7:45 4:45 5:17 2:43 Trial 11 8:08 5:19 6:30 7:05 5:39 5:47 2:38 Trial 12 7:17 4:58 7:29 8:22 3:50 5:23 2:24 Trial 13 5:44 3:34 6:26 7:18 4:01 4:47 2:05 Average 10:00 08:34 11:04 09:17 05:39 09:52 4:04
(290) TABLE-US-00006 TABLE 3b Average Interior Installation Phase Labor Time Compared to FIG. 77 Unit Difference between average On average, how much Interior Installation Phase of the total labor Labor and Average FIG. 77 time is performed Unit Interior Installation on the Interior Unit Name Phase Labor (min:sec) Installation Phase (%) 400 Unit 5:56 45% W-2500 Unit 4:30 45% Elevate Unit 7:00 46% H3 Unit 5:13 47% Pinnacle Unit 1:35 41% Lifestyle Unit 5:48 49% FIG. 77 Unit 64%
(291) TABLE-US-00007 TABLE 4a Time Spent on Exterior Installation Phase Time in 400 W-2500 Elevate H3 Pinnacle Lifestyle FIG. 77 (Min:Sec) Unit Unit Unit Unit Unit Unit Unit Trial 1 23:55 15:20 19:14 10:26 11:46 19:09 6:02 Trial 2 13:32 11:21 14:25 8:38 8:50 11:31 2:29 Trial 3 10:57 9:50 14:40 10:04 9:02 14:40 2:06 Trial 4 18:09 13:59 20:45 16:24 11:12 20:57 2:12 Trial 5 13:27 11:29 13:41 12:28 7:59 12:53 2:11 Trial 6 11:29 13:44 10:27 11:18 6:41 9:57 1:52 Trial 7 10:54 10:46 12:06 9:46 6:14 7:11 2:00 Trial 8 9:59 10:02 13:19 8:58 6:41 7:29 1:46 Trial 9 9:17 9:58 11:08 10:06 7:07 7:13 1:56 Trial 10 9:01 8:06 9:44 9:31 8:10 5:58 1:42 Trial 11 9:06 7:32 9:55 11:14 7:45 5:51 1:42 Trial 12 8:45 7:23 10:01 9:50 6:37 5:35 1:56 Trial 13 9:40 7:21 8:42 9:41 6:12 4:37 1:33 Average 12:10 10:32 12:56 10:39 8:01 10:14 2:16
(292) TABLE-US-00008 TABLE 4b Average Exterior Installation Phase Labor Time Compared to FIG. 77 Unit Difference On average, between On average, On average, how much average how much how many times more time is Exterior of the total more labor time spent on Installation labor time is is spent on the Exterior Phase labor performed on Exterior Phase Installation and FIG. 77 the Exterior compared to the Phase than Unit Installation FIG. 77 Unit FIG. 77 Unit Unit Name (min:sec) Phase (%) (unitless) (%) 400 Unit 9:54 55% 5.4 81% W-2500 Unit 8:16 55% 4.6 78% Elevate Unit 10:40 54% 5.7 82% H3 Unit 8:23 53% 4.7 79% Pinnacle Unit 5:45 59% 3.5 72% Lifestyle Unit 7:58 51% 4.5 78% FIG. 77 Unit 36%
(293) TABLE-US-00009 TABLE 5a Time Spent on a Ladder in the Exterior Installation Phase Time in 400 W-2500 Elevate H3 Pinnacle Lifestyle FIG. 77 (Min:Sec) Unit Unit Unit Unit Unit Unit Unit Trial 1 19:50 14:58 19:14 8:54 11:46 18:33 4:08 Trial 2 13:19 10:55 14:25 8:38 8:50 11:31 2:29 Trial 3 10:46 9:48 14:40 10:04 9:02 14:40 2:06 Trial 4 18:09 13:44 20:45 16:24 11:12 20:57 2:12 Trial 5 13:27 11:29 13:41 12:28 7:59 12:53 2:11 Trial 6 11:29 13:30 10:27 11:18 6:41 9:57 1:52 Trial 7 10:54 10:46 12:06 9:46 6:14 7:11 2:00 Trial 8 9:59 10:02 13:19 8:58 6:41 7:29 1:46 Trial 9 9:17 9:58 11:08 10:06 7:07 7:13 1:56 Trial 10 9:01 8:06 9:44 9:31 8:10 5:58 1:42 Trial 11 9:06 7:32 9:55 11:14 7:45 5:51 1:42 Trial 12 8:45 7:23 10:01 9:50 6:37 5:35 1:56 Trial 13 9:40 7:21 8:42 9:41 6:12 4:37 1:33 Average 11:49 10:26 12:56 10:32 8:01 10:11 2:07
(294) TABLE-US-00010 TABLE 5b Average Ladder Time Compared to FIG. 77 Unit How much more time is spent on Average total ladder than FIG. 77 labor time spent Unit Exterior Unit Name on Ladder (%) Installation Phase (%) 400 Unit 53% 82% W-2500 Unit 55% 80% Elevate Unit 54% 84% H3 Unit 53% 80% Pinnacle Unit 59% 74% Lifestyle Unit 51% 79% FIG. 77 Unit 34%
(295) TABLE-US-00011 TABLE 6 Squareness Results, where S indicated Square and NS indicated not square 400 W-2500 Elevate H3 Pinnacle Lifestyle FIG. 77 Unit Unit Unit Unit Unit Unit Unit Trial 1 S S S S NS NS NS Trial 2 S S S S NS S S Trial 3 S S NS S NS S S Trial 4 S NS S NS NS S S Trial 5 S S S S NS S S Trial 6 S NS S S S S S Trial 7 S S S S S S S Trial 8 S NS S S S S S Trial 9 S S S NS S S S Trial 10 S NS S S S S S Trial 11 S NS S NS S S S Trial 12 S S S NS S S S Trial 13 S NS S S S S S
(296) TABLE-US-00012 TABLE 7 Plumbness Results, where Testing Phase 1 is an average from Trials 1-3, and Testing Phase 2 is an average from Trials 4-13 W- Pin- Life- FIG. 400 2500 Elevate H3 nacle style 77 Unit Unit Unit Unit Unit Unit Unit Testing 0.033 0.015 0.040' 0.038 0.057 0.010 Phase 1 Testing 0.062 0.025 0.163 0.023 0.045 0.136 0.030 Phase 2 Average 0.048 0.020 0.101 0.030 0.045 0.096 0.020
(297) TABLE-US-00013 TABLE 8 Level Results 400 W-2500 Elevate H3 Pinnacle Lifestyle FIG. 77 Unit Unit Unit Unit Unit Unit Unit Left Side 0.05 0.04 0.12 0.03 0.01 0.09 0.25 Right Side 0.15 0.10 0.17 0.03 0.17 0.019 0.03 Average 0.05 0.07 0.15 0.03 0.09 0.05 0.14
(298) Each comparative fenestration unit of the comparative fenestration units, with the exception of the FIG. 77 Unit, was installed in a standard installation, according to the installation instructions for that particular product. Although there was some variation in the installation process steps according to the provided instructions for each unit, in general, the standard installation included installation into the rough opening RO of a building structure from an exterior side. The standard installation generally included installation steps of arranging the fenestration unit in the rough opening from the exterior side, adjusting a position of the fenestration unit (e.g., using measurements for level, square, and/or plumb as described herein), securing the fenestration unit to the rough opening on the exterior side, and insulating a gap between the rough opening and the fenestration unit on one or both of the interior and exterior sides. In some embodiments, securing the fenestration unit to the rough opening on the exterior side was performed by installing a plurality of fasteners though a nailing flange of the fenestration unit, where the nailing flange contacted the exterior side of the building structure. The step of insulating a gap between the rough opening and the fenestration unit on one or both of the interior and exterior sides included weather sealing the fenestration unit on the exterior side of the building structure. Weather sealing included filling a gap between the rough opening frame and the fenestration unit by applying foam, caulk or the like within the gap. The weather sealing was performed such that the fenestration unit would meet the manufacturer's installation instructions, and in various instances such that the fenestration unit substantially meets an ASTM E2112-23 installation standard.
(299) In the standard installation, at least one Installer I supported the weight of the fenestration unit on the exterior side of rough opening to facilitate the installation process and a second Installer I was on the interior side of the rough opening. In some examples, the weight of the fenestration unit was approximately 50 pounds.
(300) In contrast, as described throughout the application, the FIG. 77 Unit was installed in an interior installation process in which the majority of the installation steps were performed from the interior side of the rough opening. In the interior installation process, such as that described herein, the FIG. 77 Unit included the anchoring clip system 702 and installation stabilizer system 706 that retained the fenestration unit 10 within the rough opening such that the Installer(s) I did not need to independently support the weight of the fenestration unit 10 while preforming installation steps. In this regard, installation steps in which the Installer I is supporting the weight of the fenestration unit while standing on the ladder L were eliminated. The interior installation process was performed entirely by a single Installer I, and the single Installer I may move between the interior and exterior sides to perform all installation steps. For reference the single Installer I could have been two installers, one performing the interior functional steps and a second performing the separate exterior functional steps. Thus, more than one Installer I may install the FIG. 77 Unit, but for purposes of understanding, a single Installer I labor unit is only required for the full installation. This single installer I capability is partly due to the ability of the Installer I to have both hands free for installation steps subsequent to fenestration unit insertion in the rough opening.
(301) The interior installation process included an interior installation phase performed on an interior side of the rough opening/building structure, which is illustrated in FIG. 81, and an exterior installation phase performed on an exterior side of the rough opening/building structure, which is illustrated in FIG. 82. The interior installation phase included arranging the fenestration unit in the rough opening from the interior side of the rough opening, adjusting a position of the fenestration unit (e.g., leveling, squaring, and/or plumbing the fenestration unit), securing the fenestration unit to the rough opening frame with a plurality of fasteners, and insulating a gap between the rough opening frame and the fenestration unit. The exterior installation phase included weather sealing the fenestration unit to an exterior surface of the building structure and, in the case of the comparative units, securing a nailing flange to the exterior side of the rough opening framing. Weather sealing included filling a gap between the rough opening frame and the fenestration unit by applying caulk and foam within the gap. The weather sealing was generally performed in a manner to meet the manufacturer's installation instructions.
(302) As shown in Tables 2a and 2b, the total labor time of the installation process of the fenestration unit of FIG. 1 was approximately 6 minutes and 19 seconds on average, which is less labor time than each of the standard installations for the comparative fenestration units. As shown in Tables 2a and 2b, on average, the labor of the FIG. 1 fenestration unit was approximately 15 minutes and 50 seconds, approximately 3.5 times, and approximately 72% less than the 400 Unit; approximately 12 minutes and 46 seconds, approximately 3.0 times, and approximately 67% less than the W-2500 Unit; approximately 17 minutes and 40 seconds, approximately 3.8 times, and approximately 74% less than the Elevate Unit; approximately 13 minutes and 36 seconds, approximately 3.2 times, and approximately 68% faster than the H3 Unit; approximately 7 minutes and 20 seconds, approximately 2.2 times, and approximately 54% less than the Pinnacle Unit; and approximately 13 minutes and 46 seconds, approximately 3.2 times, and approximately 69% less than the Lifestyle Unit.
(303) As shown in Tables 3a and 3b, the Interior Installation Phase of the installation process was approximately 4 minutes and 4 seconds on average, which was approximately 64% of the average total labor time. The average labor time of the Interior Installation Phase of FIG. 1 is less than each of the standard installations for the comparative fenestration units. As shown in Tables 3a and 3b, on average, the labor of the FIG. 1 fenestration unit was approximately 5 minutes and 56 seconds, and approximately 45% less than the 400 Unit; approximately 4 minutes and 30 seconds and approximately 45% less than the W-2500 Unit; approximately 7 minutes and 00 seconds and approximately 46% less than the Elevate Unit; approximately 5 minutes and 13 seconds and approximately 47% less than the H3 Unit; approximately 1 minute and 35 seconds and approximately 41% less than the Pinnacle Unit; and approximately 5 minutes and 48 seconds and approximately 49% less than the Lifestyle Unit.
(304) As shown in Tables 4a and 4b, the labor time of exterior installation phase time of the interior installation process (e.g., time spent installing on the exterior side of the rough opening) was approximately 2 minutes and 16 seconds on average, which was approximately 36% of the average total labor time. On average, the total labor time was less than the average labor of each of the standard installations for the comparative fenestration units. As shown in Tables 4a and 4b, the Exterior Installation Phase labor of the FIG. 1 fenestration unit was approximately 9 minutes and 54 seconds, approximately 5.4 times, and approximately 81% less than the 400 Unit; approximately 8 minutes and 16 seconds, approximately 4.6 times, and approximately 78% less than the W-2500 Unit; approximately 10 minutes and 40 seconds, approximately 5.7 times, and approximately 82% less than the Elevate Unit; approximately 8 minutes and 23 seconds, approximately 4.7 times, and approximately 79% less than the H3 Unit; approximately 5 minutes and 45 seconds, approximately 3.5 times, and approximately 72% less than the Pinnacle Unit; and approximately 7 minutes and 51 seconds, approximately 4.5 times, and approximately 78% less than the Lifestyle Unit. Additionally, the percentage of total labor time on the Exterior Installation Phase was higher for each of the standard installations for the comparative fenestration units, which signals a higher percentage of time the installers I spend outside and exposed to the elements. On average, the Exterior Installation Phase was approximately 55% of the total labor time of the 400 Unit; approximately 55% of the total labor time of the W-2500 Unit; approximately 54% of the total labor time of the Elevate Unit; approximately 53% of the total labor time of the H3 Unit; approximately 59% of the total labor time of the Pinnacle Unit; and approximately 51% of the total labor time of the Lifestyle Unit. In comparison, the Exterior Installation Phase was approximately 36% of the total labor time of the FIG. 77 Unit.
(305) As shown in Tables 5a and 5b, time spent on the ladder L during the interior installation process of the FIG. 1 fenestration unit was approximately 2 minutes and 7 seconds on average, which was less than each of the standard installations for the comparative fenestration units. As shown in Tables 5a and 5b, the time spent on the ladder L during the exterior installation phase of the fenestration unit of FIG. 1 was approximately 82% less than the 400 Unit; approximately 80% less than the W-2500 Unit; approximately 84% less than the Elevate Unit; approximately 80% less than the H3 Unit; approximately 74% less than the Pinnacle Unit; and approximately 79% less than the Lifestyle Unit. Not only is ladder time significantly reduced in the interior installation process of the FIG. 77 Unit as compared to the standard installation, but installation steps in which the Installer I was both standing on the ladder L and supporting the weight of the fenestration unit were eliminated. Additionally, the percentage of total labor time that Installer I was on a ladder L was higher for each of the standard installations for the comparative fenestration units. On average, time spent on the ladder L was approximately 53% of the total labor time of the 400 Unit; approximately 55% of the total labor time of the W-2500 Unit; approximately 54% of the total labor time of the Elevate Unit; approximately 53% of the total labor time of the H3 Unit; approximately 59% of the total labor time of the Pinnacle Unit; and approximately 51% of the total labor time of the Lifestyle Unit. In comparison, the Exterior Installation Phase was approximately 34% of the total labor time of the FIG. 77 Unit.
(306) The relative quality of each installation trial is discussed with respect to the squareness results of Table 6, the plumbness results of Table 7, and the level results of Table 8. The interior installation process of the FIG. 77 Unit did not compromise the relative quality of the installation as compared to the standard installation. On average, the average plumbness of the FIG. 77 Unit was better or at least approximately equal to each of the comparative fenestration units. As described herein, features of the FIG. 77 Unit, including the anchoring clip system 702 and installation stabilizer system 706, can improve plumbness by holding the FIG. 77 Unit within the rough opening framing during the installation process. For example, on average, the average plumbness of the FIG. 77 Unit was within approximately 0.03 inches of the 400 Unit; approximately equal to the W-2500 Unit; within approximately 0.09 inches of the Elevate Unit; within approximately 0.01 inches of the H3 Unit; within approximately 0.03 inches of the Pinnacle Unit; and within approximately 0.08 inches of the Lifestyle Unit. Similarly, the average level of the FIG. 77 Unit was within approximately 0.1 degrees of the 400 Unit; within approximately 0.1 degrees of the W-2500 Unit; within approximately 0.3 degrees of the Elevate Unit, within approximately 0.1 degrees of the H3 Unit; within approximately 0.2 degrees of the Pinnacle Unit; and within approximately 0.2 degrees of the Lifestyle Unit.
(307) The invention of this application has been described above both generically and with regard to specific embodiments. It will be apparent to those skilled in the art that various modifications and variations can be made in the embodiments without departing from the scope of the disclosure. Thus, it is intended that the embodiments cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
