U.S. patent application number 10/730414 was filed with the patent office on 2005-03-17 for door and window sill pan with drain.
Invention is credited to Teodorovich, Mishko.
Application Number | 20050055912 10/730414 |
Document ID | / |
Family ID | 34279792 |
Filed Date | 2005-03-17 |
United States Patent
Application |
20050055912 |
Kind Code |
A1 |
Teodorovich, Mishko |
March 17, 2005 |
Door and window sill pan with drain
Abstract
A window sill pan or door sill pan flashing. The sill pan has an
inclined base, window or door supports which can be extruded as
part of the base unit, and corner elements which can be snapped or
otherwise attached to the base. Sill pan offsets provided in the
rear sill pan wall and in the front flange create a flow path for
water to drain from the sill. The base may be solid or hollow with
window or door supports extending vertically through the base. The
sill pan may be manufactured by extrusion, and corner pieces may be
injection molded. The base may be fabricated from fiberglass,
metal, or plastic. A window support means is provided in a
horizontal orientation so that the base can be extruded.
Inventors: |
Teodorovich, Mishko;
(Austin, TX) |
Correspondence
Address: |
Rick B. Yeager
10805 Mellow Lane
Austin
TX
78759
US
|
Family ID: |
34279792 |
Appl. No.: |
10/730414 |
Filed: |
December 8, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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60497078 |
Aug 22, 2003 |
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60507915 |
Oct 1, 2003 |
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Current U.S.
Class: |
52/261 |
Current CPC
Class: |
E06B 1/702 20130101;
E06B 1/705 20130101 |
Class at
Publication: |
052/261 |
International
Class: |
E04B 001/00 |
Claims
What is claimed is:
1. A sill pan for a window or door comprising a base having a
length and a width, the base comprising a first end, a second end a
sloped upper portion, a rear wall, a front flange, a rear support,
and a front support such that the rear support and the front
support on the base are lengthwise in order to permit the base to
be manufactured by extrusion without requiring subsequent addition
of support elements; a first end piece, attachable to the base in
the proximity of the first end of the base, the first end piece
comprising a side upward lip, and a downwardly extending front lip;
and a second end piece, attachable to the base in the proximity of
the second end of the base, the second end piece comprising a side
upward lip, and a downwardly extending front lip.
2. The sill pan of claim 1 further comprising a raised side lip;
and a front lip.
3. The sill pan of claim 1 further comprising a first portion of
the base, the first portion having a first length; a second portion
of the base; the second portion having a second length; and at
least one connector, such that the connector joins the first
portion to the second portion of the base.
4. The sill pan of claim 1 wherein the base is constructed of a
plastic.
5. The sill pan of claim 1 wherein the base is constructed of a
metal.
6. The sill pan of claim 1 wherein the first end piece snaps onto
the first end of the base.
7. The sill pan of claim 6 wherein the first end piece includes a
least one projecting portion; and the first end of the base
includes a slot which accepts the projecting portion.
8. The sill pan of claim 1 wherein the first end piece is glued
onto the first end of the base.
9. A fiberglass sill pan for a window or door comprising a base
having a length and a width, the base comprising a first end, a
second end a slanted upper portion, a rear wall, a front flange, a
rear support, and a front support such that the rear support and
the front support on the base are lengthwise; a first end piece
comprising a side upward lip, and a downwardly extending front lip;
and a second end piece comprising a side upward lip, and a
downwardly extending front lip.
10. A method of manufacturing a sill pan comprising extruding a
first base unit, the base unit comprising a first end a second end
a slanted upper portion, a rear wall, a front flange, a rear
support, and a front support such that the rear support and the
front support on the first base unit are lengthwise in order to
permit the first base unit to be manufactured by extrusion; cutting
the first base unit to a desired length; affixing a first end
element to the first end of the base unit; and affixing a second
end element to the second end of the base unit.
11. A method of manufacturing a sill pan comprising extruding a
first base unit, the base unit comprising a first end a second end
a slanted upper portion, a rear wall, a front flange, a rear
support, and a front support such that the rear support and the
front support on the first base unit are lengthwise in order to
permit the first base unit to be manufactured by extrusion;
extruding a second base unit, the base unit comprising a first end
a second end a slanted upper portion, a rear wall, a front flange,
a rear support, and a front support such that the rear support and
the front support on the second base unit are lengthwise in order
to permit the first base unit to be manufactured by extrusion;
joining the first base unit to the second base unit to form a base
of a desired length; affixing a first end element to the first end
of the base first base unit; and affixing a second end element to
the second end of the second base unit.
12. A sill pan for a window or door comprising a central base
having a first end, a second end, a rear, a front, and a plurality
of support ridges and a plurality of drain channels between the
support ridges, such that the drain channels are sloped towards the
front of the base, and such that a window or door may be supported
upon the ridges; a rear wall extending perpendicularly upward from
the rear of the base portion, such that the rear wall has a
plurality of spacers which provide an offset spacing between the
rear wall and the window or door; a front face extending
perpendicularly downward from the front of the base portion, such
that the support ridges extend beyond the front face and extend
downwardly along the front face in order to create an offset
spacing from the front face; a first end integral to the first end
of the central base, and a second end integral to the second end of
the central base, each end comprising a side face extending
perpendicularly upward from the base; and a front face extending
perpendicularly upward and downward from the side face.
13. The sill pan of claim 12 wherein the side face further
comprises a plurality of spacers.
14. An adjustable width sill pan for a port such as a window or
door, the sill pan comprising a first base section comprising a
first end comprising a first corner element which includes a side
face extending perpendicularly upward from the first base section,
the first end having a first thickness profile, a second end having
a second thickness profile which is shorter than the first
thickness profile, a rear wall, a port support means; and a second
base section comprising a second end comprising a second corner
element which includes a side face extending perpendicularly upward
from the second base section, the second end having the first
thickness profile, a first end having the first thickness profile
with a lower recess in the shape of the second thickness profile, a
rear wall, a port support means, such that the first end of the
second section may be slid over the second end of the first section
in order to adjust the length of the assembled sill.
15. The adjustable width sill pan of claim 14 wherein the first
base section comprises a bottom part integral to the first corner
element, the bottom part comprising a rear wall, an inwardly facing
lip along the top of the wall, a front face, a plurality of support
ridges, such that the support ridges overhang the front face, such
that the support ridges define the second thickness profile, a
plurality of sloped channels between the support ridges, a top part
insertable onto a portion of the bottom part, the top part
comprising a rear wall, a rear support, a front support, a front
face; and the second base section comprises a bottom part integral
to the first corner element, the bottom part comprising a rear
wall, an inwardly facing lip along the top of the wall, a front
face, and a top part insertable and overlapping the bottom part,
the top part comprising a rear wall, a rear support, a front
support, a front face.
16. The sill pan of claim 14 wherein the first end of the second
section partially covers the second end of the first section; and a
cover element is placed over substantially all of the exposed
second end of the first section.
17. The sill pan of claim 14 further comprising at least one middle
section comprising a rear wall, and a port support means, such that
the middle section is positioned between the first section and the
second section in order to increase the length of the assembled
sill pan.
18. A sill pan for a window or door comprising an extrudable base
having a length and a width, the base comprising a first end, a
second end, a sloped upper portion, a rear wall, a rear support,
and a front support, such that the rear support and the front
support are oriented lengthwise on the base; a first end piece,
attachable to the base in the proximity of the first end of the
base, the first end piece comprising a horizontal tab which may be
inserted between the rear support and the front support, the
horizontal tab having a top surface aligned with the top surfaces
of the rear support and the front support, a recess for receiving
and overlapping the first end of the rear wall, a recess for
receiving the first end of the rear support, and a recess for
receiving the first end of the front support; and a second end
piece, attachable to the base in the proximity of the second end of
the base, the first end piece comprising a horizontal tab which may
be inserted between the rear support and the front support, the
horizontal tab having a top surface aligned with the top surfaces
of the rear support and the front support, a recess for receiving
and overlapping the second end of the rear wall, a recess for
receiving the second end of the rear support, a recess for
receiving the second end of the front support.
19. The sill pan of claim 18 wherein the horizontal tab of the
first end piece is tapered.
20. The sill pan of claim 18 further comprising a front flange
projecting downwardly from the front edge of the extrudable base; a
recess in the first end piece for receiving a first end of the
front flange; and a recess in the second end piece for receiving a
second end of the front flange.
Description
RELATED APPLICATIONS
[0001] This application is related to and claims priority from U.S.
Provisional patent application No. 60/497,078 filed Aug. 22, 2003,
and U.S. Provisional patent application No. 60/507,915 filed Oct.
1, 2003.
FIELD OF INVENTION
[0002] This invention relates to a sill, sill pan flashing, sill
pan, or sill pan flashing for a door or window, where the sill pan
drains accumulated moisture.
BACKGROUND
[0003] It is desirable to provide a relatively low cost window and
door sill pan with pan flashing for directional drainage of water
and moisture which can be used for construction in all price ranges
of housing, and for any door or window width. In one embodiment of
the current invention, a base unit is provided which can be
manufactured by extrusion and either cut to a desired length to fit
the door or window width opening, or used with other similar
elements and connectors to establish a desired final length. End
pieces and optional center joining elements are provided for field
assembly.
[0004] The prior art includes U.S. Pat. No. 5,921,038 to Burroughs
which describes a window sill pan with an inclined plate and ribs
perpendicular to the front edge. The patent includes a front cover,
but does not disclose end members.
[0005] U.S. Pat. No. 6,385,925 B1 to Wark teaches an inclined plate
with ribs perpendicular to the front edge. The Wark patent does not
include a cover, but does have end members. Wark also describes the
possible use of other window support means such as truncated cones.
Wark describes the supports as being on the apparently solid
inclined base.
[0006] It is desirable to provide a sill pan that can be used for
doors or windows of any length. It is desirable to provide an
economical sill pan device that can be used in most construction.
One way to provide a relatively low cost device is to extrude the
base. It is desirable in such applications to provide window or
door supports which can be extruded in relatively long lengths
suitable to be cut in the field in order to accommodate different
size windows and doors. It is desirable to extrude a unit which
includes door or window supports in order to avoid attaching
separate support elements to a base unit.
[0007] It is desirable to manufacture window and door sill pan
elements in an efficient and economical extrusion process, to
supply the elements in relatively long lengths, and to cut the
elements to a desired length at a construction site. This
manufacturing and installation method may provide sill pans units
that are more readily available to builders and which are more
economical that purchasing prefabricated sizes from a supplier who
is required to stock a large number of possible widths. This
manufacturing and installation method eliminates the need for
special ordering of sill pans for field dimensions.
[0008] Also, if an injection molding tool were required for each
size, then relatively high volumes of each size would be required
to pay for the tool. It is difficult to order and store many
different sizes of sill pans for the variety of window and door
dimensions which are used in construction. By designing the sill
pan for manufacture by extrusion, a single extrusion tool and a
single injection molding tool for end pieces can provide sill pans
of a variety of lengths. In some embodiments, sections of base may
be connected to establish a desired length. In other embodiments,
the base may be cut to a desired length.
SUMMARY
[0009] The current invention is for a window sill pan or door sill
pan flashing. In some embodiments of the current invention, the
device can be made in a low cost manufacturing operation by
extrusion. In one embodiment, SureSill.TM. is made by combining
extrusion and injection molding processes. The sill pan typically
includes an inclined base, window or door supports which can be
extruded as part of the base unit, and corner elements which can be
snapped or otherwise attached to the base.
[0010] In some embodiments, the base may be solid. In other
embodiments, the base may be hollow with window or door supports
extending vertically through the base. In the case of fiberglass
construction, the base may include a slanted upper face, but no
lower face.
[0011] In one embodiment, the sill pan has offsets provided in both
a rear sill pan wall and in a front flange. These offsets create a
flow path for water to drain from the sill.
[0012] In one embodiment, the sill pan includes corner side flanges
that are preferably provided without openings, and the sill pan is
secured in a window or door opening by stapling across a corner of
the side flange, by bending a nail over the flange, or by nailing
through the flange.
[0013] In some embodiments, the window support means is provided in
a horizontal orientation so that the base can be extruded. In other
embodiments, the base may be fabricated from fiberglass, metal, or
molded plastic, and may not have a horizontal orientation.
[0014] In other metal or plastic embodiments, the sill pan is
provided as a center piece that can be cut to a desired length, and
as end elements that can be snapped or glued to the center
piece.
[0015] In one embodiment, an extruded base unit is cut to a desired
length, and an installation tolerance is provided in corner units
which slide onto the base unit.
[0016] In another embodiment, a base unit is provided in two or
more sections which slidably overlap in a manner that compensates
for rough framing tolerances.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] These and other objects and advantages of the present
invention are set forth below and further made clear by reference
to the drawings, wherein:
[0018] FIG. 1 is a top view of an embodiment of the invention
[0019] FIG. 2 is a side cross section view of the embodiment of
FIG. 1.
[0020] FIG. 3 is a front view of the embodiment of FIG. 1.
[0021] FIG. 4 is an exploded view of an embodiment with a base
element and corner elements.
[0022] FIG. 5 is an enlarged detail perspective view of the right
end element of the embodiment of FIG. 4.
[0023] FIG. 6 is a metal embodiment of the invention with a lateral
additional central ridge.
[0024] FIG. 7A is a top view of a fiberglass embodiment of the
invention.
[0025] FIG. 7B is a cross section view of the fiberglass embodiment
of FIG. 7A.
[0026] FIG. 7C is a front view of a fiberglass embodiment of FIG.
7A.
[0027] FIG. 8 is an exploded view of an alternate embodiment with a
base element and end elements.
[0028] FIG. 9 is an enlarged detail view of a right end element for
the embodiment of FIG. 8.
[0029] FIG. 10 is a perspective view of a lock in channel base
plate for the embodiment of FIG. 8.
[0030] FIG. 11 is a cross sectional view of the base element for
the embodiment of FIG. 8.
[0031] FIG. 12A is a perspective view of a fiberglass sill pan
embodiment.
[0032] FIG. 12B is a perspective view of a fiberglass sill pan
embodiment.
[0033] FIG. 13A is a top perspective view of an extruded sill pan
section.
[0034] FIG. 13B is a perspective view of the extruded sill pan
section of FIG. 13A with material removed in order to create a
drain path.
[0035] FIG. 14A is a top perspective views of another embodiment of
an extruded sill pan section.
[0036] FIG. 14B is a top perspective view of the extruded sill pan
section of FIG. 14A with a drain slot.
[0037] FIG. 15A is an exploded top perspective view of a sill pan
base and corner units.
[0038] FIG. 15B is a top perspective view of the assembled base and
corner units of the sill pan of the embodiment of FIG. 15A.
[0039] FIG. 15C is a top perspective view of an alternate
embodiment of a right end element.
[0040] FIG. 16 is a detailed cross section view of the base of the
embodiment of FIG. 15A.
[0041] FIG. 17A is a front perspective view of the right corner
unit of the embodiment of FIG. 15A.
[0042] FIG. 17B is a rear perspective view of the right corner unit
of the embodiment of FIG. 15A.
[0043] FIG. 17C is a bottom perspective view of the right corner
unit of the embodiment of FIG. 15A.
[0044] FIG. 18A is a top perspective view of an assembled two-part
sliding joint sill pan.
[0045] FIG. 18B is an exploded top perspective view of the two-part
sliding joint sill pan of FIG. 18A.
[0046] FIG. 18C is a bottom perspective view of the two-part
sliding joint sill pan of FIG. 18A.
[0047] FIG. 18D is a top perspective view of the second section of
the two-part sliding joint sill pan of FIG. 18A
[0048] FIG. 18E is a bottom perspective view of the second section
of the two-part sliding joint sill pan of FIG. 18A
[0049] FIG. 18F is a top perspective view of the first section of
the two-part sliding joint sill pan of FIG. 18A
[0050] FIG. 18G is a bottom perspective view of the first section
of the two-part sliding joint sill pan of FIG. 18A
[0051] FIG. 19A is a top perspective view of an assembled two-part
sliding joint sill pan where the sections have been cut to a
desired length.
[0052] FIG. 19B is an exploded top perspective view of the two-part
sliding joint sill pan of FIG. 19A.
[0053] FIG. 19C is a bottom perspective view of the two-part
sliding joint sill pan of FIG. 19A.
[0054] FIG. 20A is a top perspective view of an assembled two-part
sliding joint sill pan with a cap section.
[0055] FIG. 20B is an exploded top perspective view of the two-part
sliding joint sill pan of FIG. 20A
[0056] FIG. 20C is a bottom perspective view of the two-part
sliding joint sill pan of FIG. 20A
[0057] FIG. 21A is a top perspective view of an assembled two-part
sliding joint sill pan with a middle extension.
[0058] FIG. 21B is an exploded top perspective view of the sill pan
of FIG. 21A.
[0059] FIG. 21C is a bottom perspective view of the sill pan of
FIG. 21A.
[0060] FIG. 22A is a top perspective view of an alternate
embodiment of the sill pan.
[0061] FIG. 22B is a bottom perspective view of the sill pan of
FIG. 22A.
[0062] FIG. 23A is a top perspective view of an assembled
adjustable sill pan.
[0063] FIG. 23B is an exploded top perspective view of the sill pan
of FIG. 23A.
[0064] FIG. 23C is a bottom perspective view of the sill pan of
FIG. 23A.
[0065] FIG. 23D is a top perspective view of a left corner element
for the sill pan of FIG. 23A.
[0066] FIG. 23E is a bottom perspective view of the left corner
element of FIG. 23D.
[0067] FIG. 23F is a top perspective view of a right corner element
for the sill pan of FIG. 23A.
[0068] FIG. 23G is a bottom perspective view of the right corner
element of FIG. 23F.
[0069] FIG. 23H is a top perspective view of a bottom element for
the sill pan of FIG. 23A.
[0070] FIG. 23I is a bottom perspective view of the bottom element
of FIG. 23H.
[0071] FIG. 23J is a bottom perspective view of a cap element for
the sill pan of FIG. 23A.
[0072] FIG. 23K is a bottom perspective view of the cap element of
FIG. 23J.
DETAILED DESCRIPTION OF EMBODIMENT--PLASTIC STILL PAN WITH EXTRUDED
BASE CUT TO DESIRED LENGTH
[0073] Referring now to FIG. 1 which is a top view of a single sill
pan, the sill pan includes a base 30 with a downwardly sloping top
surface. The sill pan has a front support ridge 31 and a rear
support ridge 32 for supporting a window or door. In this
embodiment the sill pan includes an extruded middle piece 16, or
lock-in channel plate, and end pieces 15, or, lock-in corners,
which may be molded or provided by other manufacturing processes.
Pieces are typically joined with cement such as PVC glue or with a
snap together feature.
[0074] Referring now to FIG. 2 which is a side view of the sill pan
embodiment of FIG. 1, the base 30 has a slope from the rear portion
of the sill pan to the front portion The front support ridge 31 is
solid through the base so that it rests on the bottom and the rear
support ridge 32 is also solid, thereby transmitting the weight of
the window or door to the support area for the sill. Wall thickness
for the walls can be approximately 1/8 of an inch thick. In one
embodiment the front support pedestal has a width of approximately
3/4 of an inch, and the rear support pedestal has a width of
approximately 1 inch.
[0075] As shown in the FIGS. 1 and 2, this embodiment includes a
rear wall 25 and a downward extending lip 23. The rear wall may
include offsets (not shown) to provide a drain path between the
rear wall and the window or door. The downward extending lip 23 may
include an offset to provide a drain path between the sill pan and
the siding or other materials installed around the window or door.
These offsets create a drain path for moisture which might become
present in the sill.
[0076] In this embodiment the front ridge may further include a gap
34 between the support ridge and the sides and may further include
a drain channel 33 to permit the drainage of moisture. The corner
pieces include a side upward lip 24 and a downward lip 28.
[0077] Referring now to FIG. 3 which is a front view of the
embodiment of FIG. 1, the front support ridge 31 includes gaps 33
and 34 for drainage.
[0078] FIG. 4 is an exploded view of an embodiment with a base
element and end elements. In this case the extruded middle piece 16
includes a first channel 44 and a second channel 45. The right
corner element 15A includes a first tab 46 which fits into the
first channel 44, and a second tab 47 which fits into the second
channel 45. The left corner element 15B also includes a first tab
46 which fits into the first channel 44, and a second tab 47 which
fits into the second channel 45. The tabs and channels create an
interlocking between the middle piece and the corner elements.
[0079] FIG. 5 is an enlarged detail view of the right end element
15A of the embodiment of FIG. 4. In this embodiment, the corner
element includes a first tab 46 or alignment extension which may be
inserted into the first channel 44 in the base portion; a second
tab or alignment extension 47 may be inserted into the second
channel 45 in the base portion; and an overlapping lip 42.
DETAILED DESCRIPTION OF EMBODIMENT--METHOD OF MANUFACTURING
EXTRUDED BASE
[0080] It is desirable to provide a relatively low cost product
which can be used for construction in all price ranges of housing.
In one embodiment of the current invention, a base unit is provided
which can be manufactured by extrusion to a common long length,
such as 16 feet, and cut to a desired length.
[0081] In this embodiment the base has longitudinal features, such
as illustrated in FIGS. 1 and 2, that can be extruded. For
instance, the cross section of the base is consistent throughout
the length so that the rear support is the same height throughout
the length of the base, and the front support is the same height
throughout the length of the base.
[0082] A drill or cut operation may be included to provide one or
more drain slots in the support member front support so that water
may drain from the sill pan.
[0083] End segments which are molded or otherwise produced may be
attached to a desired length of base in order to provide a
completed sill pan flashing unit.
DETAILED DESCRIPTION OF EMBODIMENT--METAL SILL PAN
[0084] A metal sill pan or a plastic sill pan may be manufactured
by extrusion as described above.
[0085] Referring now to FIG. 6, which is another metal embodiment
of the invention, the sill pan may include a center support ridge
39 which includes drain-hole areas. In this example the sill pan is
fabricated from a metal such as stainless steel. Other metals such
as copper, lead, or aluminum may also be used.
[0086] The metal sill pan may also be produced by welding or
otherwise securing the metal members.
DETAILED DESCRIPTION OF EMBODIMENT--SILL PAN WITH EXTRUDED BASE
SECTIONS JOINED BY CONNECTORS TO FORM A DESIRED LENGTH
[0087] In this embodiment the middle base may be constructed from
two or more relatively short pieces which are joined by connector
segments on one or both ends to achieve a desired length. In one
connector embodiment, each end of the connector includes tabs such
as 46 and 47 shown in FIGS. 4 and 5. These tabs fit into channels
44 and 45 on the base unit segments. The sill pan also comprises
end pieces which may be snapped onto or glued to the ends of the
base unit.
DETAILED DESCRIPTION OF EMBODIMENT--FIBERGLASS
[0088] In this embodiment, the door or window is supported by a
rear support element and a front support element of a fiberglass
sill pan.
[0089] FIG. 7A is a top view of a fiberglass sill pan which
includes a rear support 32 and a front support 51 which tapers in
plan toward drainage openings 52. This taper directs water to the
drainage openings. The drainage openings such as gaps, holes, or
slots are typically provided at the ends of the front support, and
may also be provided at one or more locations along the length of
the support. Alternatively, weep holes may be provided in the front
support. The weep holes may be formed as part of a molding
operation in fiberglass or as a post extrusion process step for
metal or plastic sills.
[0090] FIG. 7B is a cross section view of the fiberglass sill pan
of FIG. 7A, and FIG. 7C is a front view of the sill pan. The rear
wall may include a lip 53, The front edge of the rear support 32
may be tapered for ease of manufacture. In this embodiment, the
sill pan includes a sloping drain surface 54. In this example, the
fiberglass base does not have a solid surface on the bottom, and
the front and rear support ridges extend to the bottom of the sill
pan, and no additional supports are required for the sloping drain
surface 54. If the sloping drain surface were load-bearing, then
additional supports may be provided.
DETAILED DESCRIPTION OF EMBODIMENT--ALTERNATE FIBERGLASS SILL
PAN
[0091] FIGS. 12A and 12B are front perspective views of an
alternate fiberglass sill pan. In this embodiment, the window or
door is supported by a rear support 32 and a front support 31. In
this embodiment, the front support is not tapered as in the
previous example. Drain slots 33 and 34 are provided in the front
support in order to remove water from the sill pan.
DETAILED DESCRIPTION OF EMBODIMENT--EXTRUDED BASE WITH ALTERNATE
INTERLOCKING END PIECES
[0092] FIG. 8 is an exploded view of an alternate embodiment with a
base element 16 and corner end elements 15A and 15B. In this
embodiment, the end pieces are designed to fit over cut down
portions to the front support 31 and rear support 32 and rear wall
25 so that the front and rear supports are essentially constant
height across the assembled sill pan. In this embodiment, the base
element 16 is typically produced by extrusion, and right and left
end pieces 15A and 15B are typically molded, such as by injection
molding.
[0093] Referring now to FIG. 9 which is an enlarged detail view of
a right end element 15A for the embodiment of FIG. 8, the end
element includes a an overlapping lip 35 which fits over a portion
of the right end of the base. The overlapping lip includes a rear
portion which fits over a portion of the rear wall of the right end
of the base, a rear support portion which fits over a portion of
the rear support of the right end of the base, a middle portion
which fits over a portion of the right end of the base between the
rear support and the front support, a front support portion which
fits over a portion of the front support of the right end of the
base, and a front lip portion which fits over a portion of the
front lip of the right end of the base. Preferably, the overlapping
lip overlaps the right end of the base in a manner that keeps the
rear support and the front support substantially level across the
sill. This end piece, also described as a lock-in corner, is
preferably molded such as by injection molding, or vacuum
forming.
[0094] Referring now to FIG. 10 which is a perspective view of a
lock-in channel base plate 16 for the embodiment of FIG. 8, the
right end of the base plate or lock in channel plate is preferably
provided with incisions 61 on the front support plate 31, on the
rear ridge 32, and on the rear upward lip 25. In one embodiment,
these incisions are prepared after cutting a standard length of
extruded sill pan base, such as a 16 foot length, to a desired
length. The incisions remove a portion of the right end of the
front support plate 31, the rear ridge 32, and the rear upward lip
25 as shown in FIG. 10. This removal may be accomplished by cutting
a plastic or metal piece to the desired depth with a hacksaw or
other cutting tool. In some cases, the cut material may be removed
by a chisel. In other cases a special cutting tool may be
provided.
[0095] Referring now to FIG. 11 which is a cross sectional view of
the base element for the embodiment of FIG. 8, the base plate
includes a keyed channel 50 for receiving a keyed profile 36 from
the corner element. In some embodiments, the rear upward lip 25 may
be extended downward or back and downward, to provide a surface
that can be nailed or screwed into the window or door framing
elements. The base preferably includes a plurality of channels that
can be used to accept an excess of a sealant or adhesive that may
be used to set the window or door sill. Although it is desirable to
provide a level window or door opening, in practice it is often
difficult to achieve a level framing. In such cases, the sill pan
may be set on an adhesive, such as PL 400 or PL Premium, by Osi
Sealants, Inc.; or on a sealant such as NP1 by Sonneborn, by
Chemrex.
[0096] In one embodiment, a window may be set into the sill pan and
attached to the front ridge, by an adhesive. Drainage holes or
slots in the front ridge are open, or will open, to direct the
moisture to the outside.
DETAILED DESCRIPTION OF EMBODIMENT--EXTRUDED PLASTIC BASE WITH UV
RESISTANCE
[0097] In this embodiment, the base is extruded from a plastic such
as PVC, polyvinyl chloride. The plastic includes ultraviolet light
(UV) inhibitors that prevent the UV light from breaking down the
plastic.
DETAILED DESCRIPTION OF EMBODIMENT--EXTRUSION AND CUTTING
PROCESS
[0098] It is desirable to develop an extrusion process for plastic
or metal sills. In some embodiments, door or window supports may be
provided in a lateral orientation to permit the supports to be
extruded. In an alternate embodiment, the base unit may be extruded
as a solid piece and then post-processed with a cutting operation
to remove material.
[0099] For example, the base plate can be extruded with no slope on
the top surface 60 as illustrated in FIG. 13A, so that the top
surface is parallel with the bottom surface. After extrusion, the
base plate can be inserted in a tool, such as punch press, saw, or
combination, or device to make incisions in the top surface. In one
embodiment, incisions 62, as shown in FIG. 13B, have a downward
slope towards the front of the sill pan, and may be perpendicular
to the sill pan or at an angle with respect to the sill pan. For
example, incisions can be 3" wide, and 1/2" apart. Incisions create
drainage channels, and spaces between incisions create offsets to
permit a drain path. Offsets typically have a coplanar surface and
are used as support for installation of windows and doors.
[0100] In another post-extrusion processing example, an extrusion
creates the middle piece or lock-in channel plate 16 as described
in embodiments above. The top surface of the sill pan 30 is sloped
toward the front of the sill pan. The extruded section has a front
support ridge 31 and a rear support ridge 32 which are typically
coplanar. One or more intermediate ridges may be provided between
the front ad rear support ridge. After extrusion, this middle
section 16 can be inserted in a tool, such as punch press or saw,
or other device that makes cuts in the front and intermediate
ridges in order for water to drain downwardly and outwardly through
the ridges. The bottom of the incisions 63 as shown in FIG. 14B
would have coplanar surface with the sloping top surface 30 of the
lock-in channel plate. For example, incisions can be 1/2" wide, 12"
apart. This embodiment shows example with perpendicular incisions
on the front ridge, and other incision orientations are possible.
In another embodiment, the auxiliary ridges may drain to the ends
of the ridge, without additional drain slots in the middle of the
ridges. This embodiment shows example with perpendicular incisions
on the front ridge, and other incision orientations are
possible.
DETAILED DESCRIPTION OF EMBODIMENT--EXTRUDED BASE WITH ALTERNATE
INTERLOCKING END PIECES
[0101] FIG. 15A is an exploded top perspective view of a base 300
which may be extruded and corner units 400 and 450 which are
typically molded. The base includes a rear wall 310, a rear support
320, a base top surface 331 which may be sloped, a front support
335 with drain gaps 340, and a front face 350. In this embodiment,
the drain gaps are preferably provided on 6" centers. FIG. 15B is a
top perspective view of the assembled base 300 and corner units 400
and 450 of FIG. 15A. FIG. 15C is a top perspective view of an
alternate embodiment of a right end element 450 which includes a
nail slot in the side flange 452. In this embodiment, the nail slot
has a height of about 0.13 inches.
[0102] FIG. 16 is a detailed cross section view of the base 300 of
FIG. 15A. In this example, the front support 330 overlaps the front
face 350, and includes an inset rear face 332. The rear support 320
includes recesses 322, 323, and 324 for engaging tabs from a corner
element. In one example, the base has a depth of about 4.688", a
front support width of about 0.722", a rear support width of about
0.989", and rear wall and front face thicknesses of about 0.94". In
this embodiment the base top surface has a slope of about 1.7
degrees.
[0103] FIGS. 17A and 17B are front and rear perspective views of a
right corner unit 400 which includes a front face 440 and a side
face 442. In this example, the corner unit has several overlap
features to snap or press fit with a base unit so that the sill pan
can be assembled without glue or adhesive if desired. An overlap
tab 410 is provided with a width selected to form a press fit
between the front edge of the rear support 320 and the inset rear
face 332 of the front support 330. In this example, the tab has a
convex front face 411 to fit with the inset rear face 332 of the
front support. The width of tab 410 is preferably slightly tapered
on the end so that the fit becomes tighter as the corner is
inserted on the base 300. This tab has a top surface 412 that
aligns with the top surfaces of the rear and front supports. In
this example, the corner unit also includes a rear wall 430 and a
lip 432 which overlap the base rear wall 310, and a front inset
portion 436 which overlaps the front face 350 and front end of the
front support 330.
[0104] FIG. 17C is a bottom perspective view of the right corner
unit 400 which shows rear tabs 422, 423, and 424 which mate in the
base section recesses 322, 323, and 324 respectively. These tabs
are also preferably slightly tapered on the ends.
[0105] In this example, the left corner unit 450 is symmetrical to
the right corner unit and includes similar tabs and overlap
features.
[0106] This embodiment permits a sill pan base section to be cut to
a desired length in the field for fitting a particular opening. The
corner piece elements are then installed on the base section, and
the assembled sill pan is placed on the bottom of the rough
opening. The window or door is then installed on top of the sill
pan and inside the rough opening.
DETAILED DESCRIPTION OF EMBODIMENT--ADJUSTABLE SLIDING JOINT
[0107] In this embodiment, the sill pan comprises a first section
which includes a first corner and a portion of the base, and a
second section which includes a second corner and a portion of the
base. These sections are designed to slide together without
adhesive in a manner that provides for a framing tolerance of
several inches. For wider openings a third center section is
provided.
[0108] Each portion of base includes a lower part offset from an
upper part. In one section, the upper part extends past the lower
part, and in the other section the lower part extends past the
upper part. These extensions provide an installation tolerance. For
instance, a typical 3' door requires a framed rough opening of
361/2" to 39". It is desirable to provide a sill pan which will fit
into the opening regardless of the actual dimension of the rough
framing.
[0109] FIG. 18A is a top perspective view of an assembled two-part
sliding joint sill pan having a first section 100 which overlaps a
portion of a second section 200. In this example, the first section
100 includes a rear wall 110, a rear support 120, a sloped base top
surface 130, a front support 140 with drain gaps 142, and a front
face 150. The first section also includes dams 170, 171, and 172.
The second section 200 includes a rear wall 210, a rear support
220, a front face 250, and an end dam 270. In this example, the
first section includes a right corner, and the second section
includes a left corner. The second section end dam 270 is snapped
or glued between the rear support and the front support of the
second section so that it retains accumulated water over the sloped
base top surface 230 and directs that water to drain forward rather
than toward the first section 100.
[0110] FIG. 18B is an exploded top perspective view of the two-part
sliding joint sill pan of FIG. 18A. In this embodiment, the second
section 200 includes an end portion with ribs 260 which support the
overlapping end of the first section. The support ridges 260
preferably have a downward slope toward the front of the sill. The
support ridges 260 define base drain channels 262 for draining any
moisture toward the front of the sill pan. The base channels 262
are preferably also sloped toward the front of the sill pan. The
front end of the support ridges 260 overlap the front face 250 so
that there is a drainage area provided between the front faces of
the top part an bottom part. The end portion also includes channels
264 and 265 for aligning with ribs 164 and 165 of the first section
as shown in FIG. 18C which is a bottom perspective view of the
assembled sill pan. The ribbed end portion of the second section
extends 3" beyond the end dam 270.
[0111] FIG. 18D is a top perspective view of the second section 200
showing details of the end dam 270, the ribs 260, drain channels
262, and alignment channels 264 and 265.
[0112] FIG. 18E is a bottom perspective view of the second section
200 showing a flat bottom surface 270.
[0113] FIG. 18F is a top perspective view of the first section 100
showing details of dams 170, 171, and 172 which are preferably
molded with the section.
[0114] FIG. 18G is a bottom perspective view of the first section
100 showing details of aligning ribs 164 and 165.
[0115] FIG. 19A is a top perspective view of an assembled two-part
sliding joint sill pan where the sections 100 and 200 have been cut
to a desired length.
[0116] FIG. 19B is an exploded top perspective view of the two-part
sliding joint sill pan of FIG. 19A which shows the first section
100 cut at a point past the dam 171 and the dam 170 (not shown). In
this example, the end portion of the second section 200 has also
been shortened. The shortened first section and the shortened
second section are assembled as shown FIG. 19C which is a bottom
perspective view of the assembled sill pan. In some cases it may
not be necessary to cut either side, because the sliding joint
feature will accommodate a range of lengths. In other cases, it is
only necessary to cut one of the sections in order to create a sill
pan with the desired length.
[0117] In this example, the top part extends 5" beyond the top
part. A typical minimum overlap between the first section and the
second section is about 11/2", so that the working range of this
embodiment has a range of about 61/2" in width. This working range
may be utilized by increasing the overlap of the sections.
[0118] The top surfaces 130 and 230 of the first section and the
second section may be continuously sloping. In other embodiments,
the profile of the top surfaces of the sill pan may be flat in the
rear and front and sloping in the middle. This variable profile may
enhance the interlocking between the top part and the bottom
part.
[0119] The top part and bottom part sections are typically
fabricated separately, and the first section is inserted over the
second section. The assembly may be glued in the factory, but is
designed to be snapped together without adhesive in the field.
[0120] This embodiment may be fabricated from a plastic such as PVC
or a metal such as aluminum. Parts can be made by injection
molding, or blow-molding plastic/PVC, or aluminum casting, or with
other materials and manufacturing methods.
[0121] This embodiment provides sliding joints to accommodate
variations within a range of window or door size, and in rough
opening size without cutting the sill. Alternately, the sill pan
can be shortened in the field by cutting a portion from the mating
end of each section.
[0122] Referring now to FIG. 20A and 20B which are top perspective
assembled and exploded views of a sill pan, an optional cap section
280 may be installed over the exposed rib extensions of the second
section.
[0123] In this embodiment, sill pans may include one or more
additional middle sections such as shown in FIGS. 21A-21C. In this
embodiment, each middle extension 180 has a first end, like the end
of the first section, that slides over a ribbed extension; and a
second end, like the end of the second section, which is a ribbed
extension. Thus the sliding joints in the middle section are like
the sliding joint of the two-section embodiment. The sections are
preferably joined by overlapping the ends without adhesive.
[0124] In this embodiment, the adjustable sill pan provides a
drainable, sloped sill pan flashing for windows and doors, with a
recessed slope for easy drainage and a horizontal mounting surface
for windows and doors. The sliding joint design concept has a first
one-piece left corner section, and a second one-piece right corner
section. The first and second pieces partially slide into each
other to provide an adjustable length sill pan. Additional middle
extensions may be inserted to allow the sill pan to accommodate
larger rough openings. The sliding joint design can accommodate a
range of dimensions in window/door size, and in rough opening size,
without cutting the pan. A further range of rough openings and
standard sizes for windows and doors can be accommodated by cutting
the portion of the sliding joint in the field. The sill pan can be
assembled quickly without glue joints or adhesives, so that the
installation can be performed regardless of temperature, under any
weather conditions the parts can be made out of injection molding,
or blow-molding plastic/PVC, or aluminum casting, or other
materials and manufacturing methods. The preferred minimum overlap
is 1.5". In this embodiment, a portion of the second section is
designed to slide underneath a portion of the first section, and
has a recessed slope with perpendicular ribs, to channel any water
that may accumulate in the joint, or on the lower section, to the
exterior of the wall cavity. There are built-in dams on the upper
surfaces of all sections to prevent water from upper surfaces from
spilling to a lower portion. The upper portion of all sections has
a recessed slope and longitudinal ridges for installation of
windows and doors, with cuts in the front ridge for drainage.
DETAILED DESCRIPTION OF EMBODIMENT--SLIDABLE CORNER ELEMENTS
[0125] FIGS. 23A-B are top perspective view of another embodiment
of a slidably adjustable sill pan base. In this embodiment, a left
corner element 630 and a right corner element 635 fit adjustably
over a base element 600. A cap element 640 may be inserted over the
exposed base unit between the corner elements. FIG. 23C is a bottom
perspective view of the assembled pan.
[0126] FIGS. 23D-E are top and perspective views of a left corner
element for the sill pan of FIG. 23A. The corner element includes
front and rear supports and a dam element as discussed in
embodiments above. The corner element includes ribs 633 and 634 for
aligning with corresponding channels in the base unit.
[0127] FIGS. 23F-G are top and perspective views of a right corner
element for the sill pan of FIG. 23A. The corner element includes
front and rear supports and a dam element as discussed in
embodiments above. The corner element includes ribs 633 and 634 for
aligning with corresponding channels in the base unit.
[0128] FIGS. 23H-I are top and perspective views of a base unit for
the sill pan of FIG. 23A. The base unit includes a plurality of
support ridges 610. The support ridges define base drain channels
620 which are preferably sloped toward the front of the base unit
in order to draining any moisture toward the front of the sill pan.
The recessed surface between the support ridges may slope towards
the front. In some embodiments, the support ridges may also slope
to the front of the sill pan. The base unit also includes channels
631 and 632 for aligning with ribs 633 and 634 of the corner
sections 630 and 635.
[0129] In one embodiment, the base element is cut to a desired
rough opening width after allowing for the corner sections. The
base can be cut to rough opening size or slightly less.
[0130] In one embodiment, corner sections fit on top of the base
unit, and no adjustment in the length of the base unit is needed
due to corners. Corners should overlap the base sufficiently for
the weight of windows and doors to be transferred to the structure.
This assembly is easily accommodates thermal expansion or
contraction of windows and doors and the wall structure, due to
sliding joint design. The corner sections are then assembled on the
base unit, and may be adjusted by sliding the corner sections along
the ends of the base unit. The corners are preferably placed on
ends of the base unit with the slide-in joint and without glue.
[0131] FIGS. 23J-K are top and perspective views of a cap element
640 for the sill pan of FIG. 23A. The corner element includes front
and rear supports and dam elements as discussed in embodiments
above. The cap element may be cut to length to fit between the
corner pieces. The cap element may include ribs 633 and 634 to snap
into the channels 631 and 632 of the base unit. In some
embodiments, there may be more than one base section and more then
one top plate assembling the unit. For example, base section and
top plate could be manufactured in 38" lengths, and then either cut
to smaller size to fit the opening or multiple pieces used for
wider openings. The top plate should generally be the length of the
base plate minus two corners that are installed on the base
plate.
DETAILED DESCRIPTION OF EMBODIMENT--PLASTIC SILL PAN WITH REAR AND
FRONT DRAINAGE CHANNELS
[0132] FIG. 22A which is a top perspective view of an alternate
embodiment of the invention. In this embodiment, the sill pan has a
base 500 which may have a downwardly sloping top surface or a
relatively flat top surface. In the case of a relatively flat top
surface, a portion of the moisture that collects on the base is
dissipated by evaporation. In this embodiment, the sill pan has a
plurality of ridge supports 510 that may be provided with a regular
or an irregular spacing. Irregular spacing of the ridge supports
permits more supports to be placed closer to the ends of the sill
pan in areas that typically bear more of a door or window load than
the central portions.
[0133] The sill pan includes a rear wall 520 which preferably
includes offsets 522. These offsets provide rear drainage channels
524 which permit moisture to drain from the rear of the window or
door through the rear drainage channels into base drainage channels
514 formed between the support ridges 510. The sill pan includes a
front plate 530 which extends downward from the front edge of the
base. The front plate preferably includes offsets 532, which
provide front drainage channels 534 for the base drainage channels
514. The combination of the rear drainage channels, the base
drainage channels, and the front drainage channels provides a
continuous drain path for moisture which may accumulate on the
sill.
[0134] Each end of the sill pan base 500 includes a side plate 550
which may include offsets 552 (not shown) to provide side drainage
channels 554 (not shown) to the base. The offsets may be angled in
order to provide bracing to a molded corner section, The end pieces
preferably include a front plate 505 which extends above and below
the base. The sill pan is typically secured to the framing by
staples across the corners of the front plate 505, or by bending a
nail over the front plate 505.
[0135] FIG. 22B which is a bottom perspective view of an alternate
embodiment of the invention illustrates a flat base 560 for the
sill pan.
* * * * *