U.S. patent application number 10/900747 was filed with the patent office on 2005-01-20 for window flashing assembly.
Invention is credited to Ackerman, Dale S. JR., Ackerman, Katarzyna M..
Application Number | 20050011140 10/900747 |
Document ID | / |
Family ID | 34067629 |
Filed Date | 2005-01-20 |
United States Patent
Application |
20050011140 |
Kind Code |
A1 |
Ackerman, Dale S. JR. ; et
al. |
January 20, 2005 |
Window flashing assembly
Abstract
A window or door flashing assembly includes a weather resistive
barrier that covers a portion of a wall around a rough opening. The
barrier may be comprised of adhesive saturated open cell foam or
scrim laminated between layers of impervious film A tapered sealing
gasket that engages the inner surface of the door or window nailing
flange or molding seals exterior air and moisture from the interior
of the building. The barrier may extend into the rough opening and
integrate with a sill pan.
Inventors: |
Ackerman, Dale S. JR.;
(US) ; Ackerman, Katarzyna M.; (US) |
Correspondence
Address: |
Dale S. Ackerman Jr.
2319 Federal Avenue East
Seattle
WA
98102
US
|
Family ID: |
34067629 |
Appl. No.: |
10/900747 |
Filed: |
July 28, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10900747 |
Jul 28, 2004 |
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10114756 |
Apr 2, 2002 |
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10114756 |
Apr 2, 2002 |
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09567866 |
May 9, 2000 |
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6305130 |
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Current U.S.
Class: |
52/58 |
Current CPC
Class: |
E06B 2001/628 20130101;
E06B 1/62 20130101 |
Class at
Publication: |
052/058 |
International
Class: |
E04D 001/36; E04D
003/38; E04D 013/14 |
Claims
The embodiments of the invention in which an exclusive property or
privilege is claimed as defined as follows:
1. The window arid door flashing assemblies under flange seal is
constructed from compressible closed cell foam formed in varying
widths approximate to the width of manufactured window and door
nailing flanges; and said under flange seal being tapered in depth
across its width.
2. The under flange seal of claim 1 tapered surface is scalloped
facilitating use of denser foam while maintaining optimal
compression.
3. The tapered under flange seal of claim 1 is comprised of a
series of slanted fins providing several individual barriers
inhibiting moisture and air penetration.
4. The tapered under flange seal of claim 3 whose fins each have
serrated teeth on the outer portion of the fin providing additional
individual barriers inhibiting moisture penetration.
5. The under flange seal of claim 1 is adhered or bonded to a
flashing membrane; and the under flange seal is positioned on the
flashing membrane such that when said flashing membrane is shingled
around the rough opening the under flange seal is compressed
between the windows nailing flange and the buildings sheathing;
6. The flashing membrane of claim 5 is adhered or bonded to the
flashing membrane in such manner that an inner flashing flap may
remain inward from the under flange seal with such inner flap being
folded into the window or door rough opening.
7. The flashing membrane and under flange seal of claim 5 includes
an outer flange sealing flap with adhesive and release liner that
is integrally formed or bonded to the flashing membrane in such
position that when the release liner is removed and the sealing
flap is folded to the flashing membrane the outer sealing flap
adhesive extends over the window nailing flange covering and
adhering to nailing slots and fasteners.
8. A flashing membrane consisting of a layered composite made from
a film that is laminated to cellular foam or scrim material
saturated with a bituminous, butyl, synthetic rubber or acrylic
based adhesive; and that is laminated with a forming roller over
the adhesive with an additional layer of impervious film such that
as the composite is straightened vapor flow creases are formed in
the additional film layer.
9. The flashing membrane of claim 8 with an adhered or bonded
closed cell foam with exposed adhesive and release liner affixed
along the length of one edge of the flashing membrane.
10. The flashing membrane of claim 8 where the tapered under flange
seal of claim 1 is bonded or adhered to the length of the flashing
membrane.
11. An extruded sill pan base extending the approximate width of
the rough opening framing with lateral sill drain channels formed
at regular intervals across the width of the base with such lateral
sill drain channels formed at incremental depths moving from the
inner to outer side of the sill rough opening; and said extruded
sill pan base having periodic exterior sloped drain channels; and a
sill pan window flange support integrally formed with the extruded
sill pan base at an approximate 90 degree angle to the sill pan
base that is greater in width than the typical window flange.
12. The sill pan base of claim 11 having a lateral nail slot drain
channel extending the length of the sill pan base that is
positioned such that the window flange nail slots overlay the drain
channel.
13. The sill pan base of claim 11 having corner interlock grooves
along the length of the lower inner side of the sill pan base and
the lower inner side of the sill pan window flange support.
14. A molded sill pan corner oppositely formed for the right side
and left side of the window rough opening formed from thin gauge
plastic having an L shaped wall panel integrally formed at the
inner sides of the L shape with a sill panel and jamb panel that
oppose the wall panel at approximately 90 degrees with the sill and
jamb panel being similarly joined; and said sill panel having
integrally formed sill base interlock teeth shaped such that when
pressure is applied said teeth snap into the sill pan base lateral
drain channels of claim 11 forming a water tight seal of the drain
channel, said interlock teeth allowing adjustment of sill window
frame support at the comers of the window from approximately 1" to
3" in length; and said sill panel having an integrally formed
exterior sloped jamb gap drain channel that adjoins the interlock
teeth and the jamb panel.
15. The molded sill pan corner of claim 14 having a sill panel
support leg that is an extension of the jamb panel past the
intersection of that panel and the sill panel such that the corner
is supported on the window or door sill rough framing.
16. The molded sill pan corner of claim 14 having a wall panel
drain channel extending downward from the sill panel jamb gap drain
channel to the lower edge of the L shaped wall panel.
17. The molded sill pan corner of claim 14 having sill pan
interlock tabs that snap over the molded interlock channel of the
sill pan base of claim 11.
18. An L shaped rear sill sealing leg where the longer leg of the L
when adhered to the lateral sill drain channels of claim 11 spans
several channels sufficient in width to allow adjustment of the
rear seal to adapt to various window frame depths while the shorter
L leg provides sufficient height to form a seal to the window
frame, such adhesion functions being provided by tube caulk or a
pre-applied adhesive with application release liner.
19. The rear sill sealing leg of claim 18 further formed by joining
or molding two segments together at 90 degrees to form a jamb
sealing leg that mates to the lower jamb corner of the flashing
membrane positioned in the window rough opening framing, the sill
panel of claim 14 and the rear sill sealing leg of claim 18 thereby
forming a seal at each corner of the sill pan assembly.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of prior
U.S. patent application Ser. No. 10/114,756, filed Apr. 2, 2002,
which is a continuation-in-part of U.S. patent application Ser. No.
09/567,866, filed May 9, 2000 now U.S. Pat. No. 6,305,130, the
benefit of the filing dates being claimed under 35 U.S.C. .sctn.
120.
FIELD OF THE INVENTION
[0002] The present invention relates to building materials in
general, and in particular, to seals, flashing, sill pans and
flashing membrane for doors and windows.
BACKGROUND OF THE INVENTION
[0003] One of the most common failure points where water enters a
building's envelope is around windows and doors. Water penetration
is one of the most significant factors leading to premature failure
of structures. Many windows and doors, whether they are aluminum or
vinyl, are secured in the building's rough opening by a continuous
nailing flange. As an example, the window is placed in the rough
opening from the outside and secured using nail or screw fasteners
that are driven through the window's nailing flange.
[0004] Installation methods vary significantly and range from as
little as building paper lapping over or under the window flange to
flashing materials being shingled in the rough opening prior to
window installation, installation of sill pans, application of
caulking installed from a tube caulk gun under the window flange,
and various flashing or adhesive tapes applied over the window
flange. Installation is often performed from ladders or scaffolding
at various levels above the ground. Flashing materials are often
misaligned or applied in an inconsistent manner that leaves
wrinkles or voids in the material leading to leaks, i.e., direct
water pathways to the underlying building materials. Adhesion to
the numerous substrates is a major problem.
[0005] Current flashings are assembled from numerous separate
components that when installed cover each other, making inspection
of the completed flashing assembly extremely difficult. Further,
since there is often a time lapse between installations of the
various components, they are often damaged by wind, rain, or other
mechanical disturbances.
[0006] Current materials used in flashing do not satisfy the
various needs of sealing windows and doors nor a flashing barrier
around the rough opening. Adhesive tapes provide a self sealing
function for nail and staple penetrations. Unfortunately, they do
not adhere to many substrates used in construction, are relatively
expensive and many are incompatible with components they are
adhered to. There application is extremely sensitive to moisture
and cold with primers often being used with questionable success.
Further, because they are often adhered directly to the buildings
sheathing vapor diffusion is limited. This can result in decay of
the underlying sheathing.
[0007] In other instances, materials used as the flashing barriers
are of thin gauge materials made from polyethylene or
polypropylene. Products like these provide little water penetration
protection for nails and staples.
[0008] In products that are in current use adhesive caulking is
typically applied between the window nailing flange and the
building sheathing. Unfortunately caulk is rarely applied
consistently or correctly and even when it is the continual
expansion and contraction of components causes adhesive failure and
opportunity for ultimate water penetration to the buildings
structure. Further caulk adhesion failure is contributed to by low
temperature and moisture at the time of installation.
[0009] Adhesive barriers applied over the nailing flange are often
incompatible with the windows flange. They also often have
insufficient thickness that when compressed around and over
fasteners they do not create a proper seal.
[0010] Many windows eventually leak in areas of the window assembly
or provide inadequate opportunity to seal the window at the outer
wall face of the assembly. Other windows do not have a continuous
window flange. In these instances a sill pan assembly must
complement the flashing installation. Current sill pans are often
custom fabricated from metal, are fabricated from self adhering
flashing material while a few are manufactured from plastic
materials. These methods variously; do not adequately provide
sufficient support for the window assembly, do not provide adequate
interface to other flashing materials, are difficult to seal to the
window, are not adaptable to various window widths, do not provide
a channel that allows water to be separated from the window frame
or do not slope to the exterior of the building to assist moisture
drainage.
[0011] The object of window and door flashing assemblies and sill
pans is to adequately interface to surrounding weather resistive
barriers, seal staple and other fastener penetrations, seal the
window assembly to the flashing membrane, provide drainage at the
sill when window leaks occur, adapt to various window depths that
range from full sill width to as little as 11/2", protect window
and structure materials from degradation and comply with the
multitude of window and door manufacture and industry
standards.
[0012] Given these problems, there is a need for an improved method
of ensuring a weather-tight barrier for window installations.
SUMMARY OF THE INVENTION
[0013] The present invention is a flashing assembly for sealing
around doors or windows. The present system combines integrated
components that minimize material failure or installation error
that will allow exterior water or air to penetrate the interior
building structure. The object of the assembly is to provide an
adaptable system that provides for vapor flow under the flashing,
provides sealing redundancy and maximizes sealing performance. This
current invention minimizes the number of components required in
field installation.
[0014] The flashing assembly preferably includes a flashing
membrane made from a adhesive saturated open cell foam laminated
between solid film sheets with vapor flow creases that are
positioned behind a nailing flange of a window or door. The foam
adhesive flashing membrane is adhered to the building sheathing by
staples or similar fasteners. The foam adhesive flashing membrane
provides a water seal around nail and staple penetrations without
use of exposed asphalt or butyl adhesives tapes that are often
incompatible with other components and whose performance is
inhibited by extreme temperatures and moisture. The sealing
characteristic of the foam adhesive flashing membrane is enhanced
by the adhesive being squeezed into the open cell structure during
manufacture. The integration of the foam and adhesive also helps
physically stabilize the adhesive at higher temperatures. While
high density foam has strong sealing characteristics without an
adhesive, its use in this application is uneconomic. The
fabrication of the foam adhesive flashing membrane causes the wall
side of the membrane to develop creases as it is straightened
against the wall providing the opportunity for vapor to escape from
behind membrane. The wall side film may be impressed with a pattern
prior to fabrication to the foam further enhancing the films
ability to be held off the wall.
[0015] The under flange seal is bonded to the flashing membrane or
directly to the window flange, in its preferred embodiment having
slanted parallel fins with serrated teeth, is compressed between
the window or door nailing flange and the sheathing of the building
thereby eliminating the use of caulk. The taper allows the sealing
gasket to be uniformly compressed by the nailing flange while
minimizing flange distortion and elevation from the wall. The
serrated teeth of the sealing gasket enhance its ability to keep
moisture and air from passing by the gasket.. The uniform size of
the under flange seal provides consistent high performance by
utilizing compression to create a seal, adapting to window flange
movement and variations of the substrate. Field installation of
caulk is inconsistent, generally too small in volume, does not
adhere to many flashing materials and often does not cure prior to
expansion that results in seal failure.
[0016] Integration of the over flange seal to the flashing membrane
eliminates the requirement of sealing the two components in the
field in adverse weather conditions. A factory seal is more
reliable and only requires the seal to then be adhered to the
window flange itself I the field. Use of closed cell foam adhesive
assures compatibility and high bonding performance to the flange
and full encapsulation of flange fasteners.
[0017] Integration of a sill pan to the flashing system that allow
moisture to drain through channels to the exterior of the building
structure, adapts to all window depths and manufactures support
requirements, interlocks the sill base and molded corners while
integrating to other flashing components provides additional
moisture penetration protection with the simple easily installed
components of the current invention. No other current system
addresses all the required design considerations to comply with
manufacture and industry standards.
[0018] Combining flashing membrane and closed cell foam adhesive
with a release liner provides a flashing component that provides
compatibility, broad temperature range and sealing performance not
available from other current self adhering flashing systems. These
systems are often insufficient in thickness to encapsulate flange
fasteners, do not adhere in both hot and cold conditions and are
blended for either a hot or cool environment while many weather
patterns will expose the flashing system to both over the life of
the installation.
[0019] The present inventions flashing components adapt the various
versions currently accepted by industry standards at levels of
performance and ease of installation unavailable by any other
combination of products available.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The foregoing aspects and many of the attendant advantages
of this invention will become more readily appreciated as the same
become better understood by reference to the following detailed
description, when taken in conjunction with the accompanying
drawings, wherein:
[0021] FIG. 1 illustrates an extruded tapered profile seal that
seals between a window flange and the wall sheathing.
[0022] FIG. 2 illustrates an extruded tapered profile seal with
scalloped fins.
[0023] FIG. 3 illustrates an extruded tapered profile seal with
fins.
[0024] FIG. 4 illustrates how a window flange flexes under
stress.
[0025] FIG. 5 illustrates the fabrication path for foam adhesive
flashing membrane.
[0026] FIG. 6 illustrates a profile of foam adhesive flashing
membrane.
[0027] FIG. 7 illustrates flashing membrane with adhesive
strip.
[0028] FIG. 8 illustrates an isometric view of FIG. 7.
[0029] FIG. 9 illustrates a profile of flashing membrane with an
extruded tapered profile seal with fins, an inner flashing flap and
an outer flashing flap.
[0030] FIG. 10 illustrates an isometric view of FIG. 9.
[0031] FIG. 11 illustrates a profile of flashing membrane with an
extruded tapered profile seal, an outer flashing flap, and outer
flange flap.
[0032] FIG. 12 illustrates an isometric view of FIG 11.
[0033] FIG. 13 illustrates flashing membrane, an outer flashing
flap and adhesive tape positioned over a window nailing flange.
[0034] FIG. 14 illustrates an extruded tapered profile seal adhered
to the inner surface of a window flange.
[0035] FIG. 15 illustrates a flashing membrane with inner flap,
outer flap with an adhered extruded tapered profile seal positioned
within the window rough opening and over the exterior wall
sheathing. Adhesive tape is positioned over the window flange.
[0036] FIG. 16 illustrates FIG. 15 with the adhesive tape over the
window flange replaced by an outer flange sealing flap that is
integrally formed or bonded to the flashing membrane.
[0037] FIG. 17 illustrates an extruded sill pan base with parallel
drain channels, exterior sloped drain channels formed to full width
of sill and a variable window width rear sealing leg.
[0038] FIG. 18 illustrates the exterior sloped drain channels of
FIG. 17 formed at partial width of sill for most vinyl and aluminum
windows.
[0039] FIG. 19 illustrates an isometric view of sill pan molded
corner with interlock teeth and sloped jamb gap.
[0040] FIG. 20 illustrates the reverse view of FIG. 19.
[0041] FIG. 21 illustrates the combined isometric view of the sill
pan base and molded corner.
[0042] FIG. 22 illustrates an exploded view of the flashing
assembly with sill pan.
DETAILED DESCRIPTION OF THE INVENTION
[0043] The present invention is a window flashing assembly that
provides an improved barrier to moisture.
[0044] FIG. 1 demonstrates a cross section of the under flange seal
6 from closed cell foam 1 that is formed at a width approximate to
the width of a window nailing flange and is tapered 36 from one
side to the other. As is demonstrated in FIG. 4 it is essential
that the seal tapers to correspond with the compression strength of
the nailing flange to avoid excessive flange deflection. In
addition to stressing the flange, contrary to industry and
manufacture standards, the flange elevation away from wall
sheathing makes installation of trim around the window difficult.
Current flashing systems rely on caulk to seal the window to the
flashing membrane. Sealing caulks currently in use have a cure time
varying from a few days to a few weeks. Testing shows that when
these caulks are placed between materials having a low perm rating
such as many flashing membranes and a window flange cure periods
lengthen considerably. During the period that caulk is curing it is
exposed to weather conditions that often cause areas of the seal to
fail. Expansion, wind and rain are contributing factors. Caulk is
rarely applied in the proper location and at the proper volume to
affect a consistent seal. Caulk also often does not adhere to many
of the flashing membranes in use or the other substrates utilized
in many current systems. The present inventions under flange seal
that is easily placed in the proper position, is consistent in
volume and has consistent sealing performance regardless of
environmental conditions is a significant improvement over existing
methods. In some instances the under flange seal can be applied to
areas of the window flange prior to shipment further reducing the
opportunity for field errors. Ellingson in U.S. Pat. No. 4,720,936
defined various seal configurations related to door and window
components that are regularly opened and closed like a door against
the door frame. Ellingson does not address or suggest solutions for
the unique issues of permanently sealing a window or door flange
against exterior wall sheathing and flashing membranes.
[0045] FIG. 2 demonstrates the tapered 36 closed cell foam 1 under
flange seal 6 with scalloped seal fins 29 and alternatively with
added seal fin teeth 30. The scalloped shape and teeth provide
independent surfaces to mate with the surface to be sealed with the
sealing teeth providing additional higher tension points that
inhibit passage of moisture or air. This variation may be formed
from sheet foam thereby reducing manufacturing cost and introducing
the option to use materials like polypropylene that may be heat
bonded directly to the flashing membrane rather than being bonded
by adhesives.
[0046] FIG. 3 demonstrates the tapered 36 closed cell foam 1 under
flange seal 6 with angled seal fins 31 and alternatively with added
seal fin teeth 30. The angled seal fins maximize potential seal
depth while minimizing required compression.
[0047] FIG. 4 demonstrates a window assembly 39, the window flange
inner surface 41 with an under flange seal 6 positioned for
adhesion to the window flange 40. The window flange is manufactured
as shown at 40b while 40a demonstrates typical deflection of the
flange. The point furthest from the window 39 frame deflects the
greatest amount. The design of the under flange seal therefore must
correspond in density and shape to provide the maximum sealing
potential while minimizing deflection. Testing demonstrates that an
under flange seal that is not tapered as in the current invention
results in the flange being significantly deformed and elevation of
the flange off the wall sheathing resulting in difficulty in
installation of window trim
[0048] FIG. 5 demonstrates fabrication of foam adhesive flashing
membrane 9. A high strength film laminated to a low density foam 10
is fed through adhesive saturation rollers 28 where a sealing
adhesive like butyl, bituminous, or synthetic 32 is compressed into
the foam leaving sufficient surface residue that an outer film 23
will adhere to the assembly as it is fed over the vapor flow crease
forming roller 11 as it is fabricated together with a compression
roller 3. The completed assembly will block moisture, stabilize the
adhesive by suspension in the foam or scrim, provides excellent
seal around penetrations through the fabricated flashing membrane
8. Since this assembly is formed over a curved surface one side
will crease when laid flat. Since this membrane does not adhere
directly to wall sheathing or the window assembly, will seal the
200 typical nail and staple penetrations around a window or door
and has creases that facilitate vapor movement it is a simple,
economic and superior alternative to materials currently on the
market. Pacific in U.S. Pat. No. 6,035,582 defines a foam film
laminate material for flashing application constructed from closed
cell foam without adhesive and no vapor seal crease. The present
invention is superior as testing shows that foam required in the
Pacific application must be high in density resulting in an
uneconomic system for window assemblies. Further the fabrication
defined by Pacific does not indicate formation of vapor seal
creases.
[0049] FIG. 6 is a cross section of flashing membrane 8 fabricated
to form a foam adhesive flashing membrane 9 comprised of an inner
polyolefin film 12, open cell foam 22 and an outer film 23 that is
formed with vapor flow creases 38.
[0050] FIG. 7 is a cross section view of flashing membrane 8 with
an outer flashing flap 25 and a closed cell foam with adhesive and
release liner 2. FIG. 8 is an isometric view of FIG. 7. Many
current flashing materials that adhere over the window flange do
not adequately encapsulate fasteners; do not perform in wide
temperature ranges and discolor window assemblies. The current
inventions use of a closed cell foam adhesive with poly release
liner exceeds current product, like Fortifiber EZ Seal, performance
in all of these areas.
[0051] FIG. 9 is a cross section view of flashing membrane 8 with
an outer flashing flap 25, an inner flashing flap 13 and an under
flange seal 6. FIG. 10 is an isometric view of FIG. 9. Combination
of the flashing membrane with under flange seal combines the
advantages of the previously described advantages in avoiding use
of caulk while improving installation efficiency.
[0052] FIG. 11 is a cross section view of flashing membrane 8 of
foam adhesive flashing membrane 9 with an outer flashing flap 25,
an integrally formed or bonded outer flange sealing flap with
adhesive and release liner 24, and an under flange seal 6 such seal
formed of closed cell foam 1 having a tapered profile 36 angled
sealing fins 31 with seal fin teeth 30. FIG. 12 is an isometric
view of FIG. 10. This variation of the flashing assembly combines
the advantages described in FIG. 9 with the addition of the
integrally formed or bonded outer flange sealing flap with adhesive
and release liner. Since the sealing flap is bonded in a controlled
manufacturing environment performance of the over flange seal is
improved significantly. The flap must only adhere to the window
flange itself to be effective unlike all other systems that are
exposed to weather environment and installation error at the time
they are bonded to the weather membrane.
[0053] FIGS. 13, 14, 15 and 16 demonstrate a wall section with
window sill 42, exterior wall sheathing 5, window assembly 39
having an integrally formed flange 40 having an inner surface
41.
[0054] FIG. 13 demonstrates placement of flashing membrane 8 with
and outer flashing flap and a closed cell foam with adhesive and
release liner 2 in relation to the window and wall.
[0055] FIG. 14 demonstrates placement of an under flange seal 6 in
relation to the window and wall. In this application the seal will
be compressed by the window flange inner surface 41 against the
exterior wall sheathing 5 or flashing membrane (not shown).
[0056] FIG. 15 demonstrates placement of flashing membrane 8 with
inner flashing flap 13, an outer flashing flap 25, and an under
flange seal 6 in relation to the window and wall. Foam adhesive
flashing tape with release liner 46 is positioned to seal over the
top of the window flange 40 while overlapped onto the outer
flashing flap 25.
[0057] FIG. 16 demonstrates placement flashing membrane 8 with
inner flashing flap 13, an outer flashing flap 25, an integrally
formed or bonded outer flange sealing flap with adhesive and
release liner 24, and an under flange seal 6.
[0058] FIG. 17 is an isometric view of the full sill width extruded
sill pan base 7 with lateral sill drain channels 45 having stepped
depth 4 matching the exterior sloped drain channels 43 that are
repeated along the length of the sill pan base, nail slot drain
channel 21 is positioned to align with typical window nail slots,
window flange support 35 assures stable fastening of the window
flange across the sill, a molded corner interlock 44 provides
alignment of the molded sill pan corner. A rear sill sealing leg 27
is adjusted to the window frame width and caulked into position or
has an adhesive with release liner 33 to bond with the sill pan
base 7. Sill pans are currently installed in an insignificant
number of windows in the United States, however industry standards
are being developed that will recommend their use for all windows.
The current invention provides several layers of redundant
protection against air and moisture intrusion into a building
structure. The over flange seal, under flange seal, inner flap and
seal of the inner side of the window frame to the inner flap all
combine to limit sealing failure at the window and flashing
membrane interface. Utilization of a sill pan protects against
leaks within the window assembly itself and provides a relief valve
for all other potential failures by allowing penetrated moisture to
escape to the exterior. In Williams U.S. Pat. No. 6,401,401
numerous components are fabricated in the field, without use of a
separate window shim manufacture support requirements that vary
from 1" to 3" from the corner being suspended are not met,
development of sloped drainage while providing level shim or window
frame support is difficult, integration with interior trim and
varying window widths require adaptation of the design by the
installer. In Wark U.S. Pat. No. 6,385,925 the assembly must be
specifically adapted to accommodate varying window frame depths,
the window frame support is fragile expensive and intermittent
rather than continuous as required by some major window and door
manufactures. The volume of air infiltration at the sill is also
significant due to the large area of opening between the sill pan
and the window flange. The current inventions sill pan base is
rugged, a simple extrusion of PVC or similar materials, can be cut
to manufactures defined length for continuous support, allows
moisture to drop to the bottom of the lateral sill drain channels
minimizing exposure to wood window components, provides
intermittent drainage relief to the exterior that is controlled in
volume, covers the entire sill width making interior trim identical
to current practice where sill pans are not installed and readily
adapts to window frame widths ranging from full wall to the
narrowest of frames.
[0059] FIG. 18 demonstrates the extruded sill pan base 7 with
lateral sill drain channels 45, and an exterior sloped drain
channel 43 formed to a width slightly greater than common vinyl and
aluminum windows. The horizontal width of the rear sill sealing leg
27 is of sufficient width to cover the inner end of the exterior
sloped drain channel 43 when installed for the described style of
window.
[0060] FIG. 19 is an isometric view of the molded sill pan corner
34 having an exterior wall panel 20 having a sill pan interlock
tabs 17, jamb panel 16 and sill panel 18 having a jamb gap sloped
drain channel 14 and sill base interlock teeth 15. A significant
portion of moisture entering the sill pan area falls into the pan
at the rough opening jamb gap and drains to the exterior by the
wall panel jamb gap drain channel 47. It is essential that this
area be sloped to the exterior while allowing for suspension of the
window frame at each corner to allow for expansion movement while
meeting the requirements described at FIG. 17 for the sill pan
base. In Wark the window frame supports are intermittently glued to
the sill pan base during the manufacture process making end support
imprecise, the molded corner is glued in the field in a manner that
can lead to failure in addition to the previously described
deficiencies. Williams does not directly address the sloped
drainage and support issues. Other fabricated sill pans are formed
from metal and flexible flashing tapes requiring significant field
skill and labor for successful installation. The current invention
sill pan molded corner is sloped at the rough opening gap that is
drained by drainage channel, interlocks with the sill pan base
where a butyl or other flexible adhesive insures successful seal
while the window compresses the joint further ensuring the seal.
The molded corner lateral interlock teeth can be positioned at
varying positions providing the required variance in window frame
support for most windows. The sill pan interlock tabs 17 on the
molded sill pan corner further assures proper alignment of the
parts. The sill pan corner is supported at the sill jamb corner to
assure proper alignment of the assembly. The installation of the
rear jamb sealing leg accommodates variation in the length the
installer cuts the rear sill sealing leg.
[0061] FIG. 20 is an isometric reverse view of the molded sill pan
corner 34 shown in FIG. 19 that additionally demonstrates the sill
panel support leg 19.
[0062] FIG. 21 demonstrates the integration of the sill pan base 7
shown in FIGS. 17 and 18 and the sill pan molded corner 34 shown in
FIGS. 19 and 20 with the addition of the rear jamb sealing leg 26
formed from material of the rear sill sealing leg 27 or sealing leg
with adhesive and release liner 33.
[0063] FIG. 22 is an isometric exploded view of the window flashing
assembly. The current window flashing assembly adapts to a wide
variety of installation requirements. The under flange seal 6 can
be installed directly to the inner surface of the window flange 41.
The extruded sill pan base 7 and molded comers 34 can be utilized
for further protection. Variations in flashing membrane 8 including
utilization of the inventions foam adhesive flashing membrane 9 can
be installed with or without an inner flashing flap 13. The flange
may be sealed over the top with either an assembly providing an
outer flange sealing flap with adhesive & release liner 24, a
closed cell foam adhesive tape with release liner 46 or a flashing
membrane with adhered closed cell foam adhesive with release liner
2. Murphy U.S. Pat. No. 6,725,610 requires field fabrication of a
large number of components that contribute to installation error,
utilizes flashing membranes that do not address sealing nail and
staple penetrations that often exceed 200 per window, relies on
caulk, as other systems do, to seal the window to the flashing
membrane and does not provide for moisture release at the sill.
Further, the components in Murphy do not adapt to design
variations.
[0064] As can be seen from the above, the present invention
provides a simple, convenient and cost effective mechanism for
improving the flashing of windows.
[0065] While the present invention has been described with respect
to its preferred embodiments, those skilled in the art will
recognize that various changes may be made without departing from
the scope of the present invention. It is therefore intended that
the scope of the invention be determined solely from the following
claims and the equivalents thereto.
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