U.S. patent application number 10/811637 was filed with the patent office on 2005-09-29 for method for installing a fenestration unit in a composite panel.
Invention is credited to Burton, Cordell R., Chiarella, Julio.
Application Number | 20050210824 10/811637 |
Document ID | / |
Family ID | 34988103 |
Filed Date | 2005-09-29 |
United States Patent
Application |
20050210824 |
Kind Code |
A1 |
Burton, Cordell R. ; et
al. |
September 29, 2005 |
Method for installing a fenestration unit in a composite panel
Abstract
A method of installing a fenestration unit in a composite panel
using a foam material, and to a composite panel with the
fenestration unit installed using a foam material, where the foam
material is the primary attachment structure. A rough opening is
created in the composite panel where the rough opening has a
perimeter larger than a perimeter of the frame of the fenestration
unit. Then the fenestration unit is positioned in the rough opening
with a space between the perimeter of the frame of the fenestration
unit and the perimeter of the rough opening of the composite panel.
A foam material is delivered into at least a portion of the space
to fixedly adhere the fenestration unit to the insulating core of
the composite panel. The foam material typically provides the
primary structural attachment between the fenestration unit and the
composite panel.
Inventors: |
Burton, Cordell R.; (Pella,
IA) ; Chiarella, Julio; (Pella, IA) |
Correspondence
Address: |
FAEGRE & BENSON LLP
PATENT DOCKETING
2200 WELLS FARGO CENTER
MINNEAPOLIS
MN
55402
US
|
Family ID: |
34988103 |
Appl. No.: |
10/811637 |
Filed: |
March 29, 2004 |
Current U.S.
Class: |
52/745.15 |
Current CPC
Class: |
E04F 21/0015 20130101;
E06B 1/58 20130101 |
Class at
Publication: |
052/745.15 |
International
Class: |
E04G 021/00 |
Claims
What is claimed is:
1. A method of installing a fenestration unit, the method
comprising the steps of: creating a rough opening in a composite
panel having an insulating core, the rough opening having a
perimeter larger than an outer perimeter of a frame of the
fenestration unit; positioning the fenestration unit inside the
rough opening; and delivering a foam material into at least a
portion of a space between the perimeter of the frame of the
fenestration unit and the perimeter of the rough opening of the
composite panel, the foam material fixedly adhering the
fenestration unit to the insulating core of the composite
panel.
2. The method of claim 1 wherein the foam material provides a sole
structural attachment between the fenestration unit and the
composite panel when the foam material is substantially cured.
3. The method of claim 1 wherein the foam material provides at
least 50% of an attachment force that resists separation of the
fenestration unit from the composite panel along a direction
generally perpendicular to a major surface of the composite
panel.
4. The method of claim 1 wherein the foam material provides about
80% of an attachment force that resists separation of the
fenestration unit from the composite panel along a direction
generally perpendicular to a major surface of the composite
panel.
5. The method of claim 1 wherein the foam material provides about
95% of an attachment force that resists separation of the
fenestration unit from the composite panel along a direction
generally perpendicular to a major surface of the composite
panel.
6. The method of claim 1 comprising selecting a foam material that
is compatible with a material of the insulating core of the
composite panel.
7. The method of claim 1 comprising fixedly adhering the foam
material to at least one side surface of an outer layer of the
composite panel at the rough opening.
8. The method of claim 1 comprising selecting a low expansion
adhesive foam.
9. The method of claim 1 wherein the step of delivering a foam
material into a space includes delivering the foam material around
at least a portion of the perimeter of the frame of the
fenestration unit.
10. The method of claim 1 wherein the step of delivering the foam
material includes delivering the foam material around the entire
perimeter of the frame of the fenestration unit.
11. The method of claim 1 comprising attaching a fin on the frame
of the fenestration unit to an outer surface of an outer layer of
the composite panel.
12. The method of claim 11 comprising locating a sealant material
between the fin and the outer surface of the outer layer.
13. The method of claim 11 comprising attaching the fin to the
outer layer using fasteners.
14. The method of claim 1 comprising delivering the foam material
into recesses located in the perimeter of the frame.
15. The method of claim 1 comprising applying an intermediate
adhesion promoting material to at least one of the perimeter of the
frame and the insulating core exposed by the rough opening.
16. The method of claim 1 comprising assembling the composite panel
on-site.
17. The method of claim 1 comprising prefabricating the composite
panel at a remote location.
18. The method of claim 1 wherein the step of creating the rough
opening in the composite panel occurs on-site.
19. The method of claim 1 wherein the step of creating the rough
opening in the composite panel occurs at a remote location.
20. The method of claim 1 wherein the insulating core comprises a
polymeric foam material.
21. A method of installing a fenestration unit in a composite panel
including an insulating core, the method comprising the steps of:
creating a rough opening in the panel, the rough opening having a
perimeter larger than a perimeter of a frame of the fenestration
unit; positioning the fenestration unit inside the rough opening;
and delivering a low expansion adhesive foam around at least a
portion of the perimeter of the frame of the fenestration unit to
fixedly adhere the fenestration unit to the insulating core of the
composite panel, wherein the foam provides a primary structural
attachment between the fenestration unit and the composite panel
when the foam material is substantially cured.
22. A wall structure comprising: a fenestration unit including a
frame; a composite panel comprising an insulating core; a rough
opening created in the composite panel receiving the frame of the
fenestration unit, the rough opening having a perimeter larger than
a perimeter of the frame of the fenestration unit; and a foam
material deposited between at least a portion of the perimeter of
the frame of the fenestration unit and the perimeter of the rough
opening of the composite panel to fixedly adhere the fenestration
unit to the insulating core of the composite panel.
23. The wall structure of claim 22 wherein the foam material
provides a sole structural attachment between the fenestration unit
and the composite panel when the foam material is substantially
cured.
24. The wall structure of claim 22 wherein the foam material
provides at least 50% of an attachment force that resists
separation of the fenestration unit from the composite panel along
a direction generally perpendicular to a major surface of the
composite panel.
25. The wall structure of claim 22 wherein the foam material
provides about 80% of an attachment force that resists separation
of the fenestration unit from the composite panel along a direction
generally perpendicular to a major surface of the composite
panel.
26. The wall structure of claim 22 wherein the foam material
provides about 95% of an attachment force that resists separation
of the fenestration unit from the composite panel along a direction
generally perpendicular to a major surface of the composite
panel.
27. The wall structure of claim 22 wherein the foam material is
compatible with a material of the insulating core of the composite
panel.
28. The wall structure of claim 22 wherein the foam material is
fixedly adhered to at least one side surface of an outer layer of
the composite panel at the rough opening.
29. The wall structure of claim 22 wherein the foam material
comprises a low expansion adhesive foam.
30. The wall structure of claim 22 wherein the foam material is
delivered around at least a portion of the perimeter of the frame
of the fenestration unit.
31. The wall structure of claim 22 wherein the foam material is
delivered around the entire perimeter of the frame of the
fenestration unit.
32. The wall structure of claim 22 comprising a fin on the frame of
the fenestration unit attached to an outer surface of an outer
layer of the composite panel.
33. The wall structure of claim 32 comprising a sealant material
located between the fin and the outer surface of the outer
layer.
34. The wall structure of claim 32 comprising fasteners attaching
the fin to one of the outer layers.
35. The wall structure of claim 22 comprising recesses located in
the perimeter of the frame adapted to receive the foam
material.
36. The wall structure of claim 22 comprising an intermediate
adhesion promoting material applied to at least one of the
perimeter of the frame and the perimeter of the rough opening.
37. The wall structure of claim 22 wherein the insulating core
comprises a polymeric foam material
38. A wall structure comprising: a fenestration unit including a
frame; a composite panel comprising an insulating core; a rough
opening created in the composite panel receiving the frame of the
fenestration unit, the rough opening having a perimeter larger than
a perimeter of the frame of the fenestration unit; and a foam
material deposited around at least a portion of the perimeter of
the frame of the fenestration unit to fixedly adhere the
fenestration unit to the insulating core of the composite panel,
wherein the foam material provides the primary structural
attachment between the fenestration unit and the composite
panel.
39. A composite panel having an insulating core located between
outer layers, the composite panel comprising a fenestration unit
having a frame, wherein the frame of the fenestration unit is
fixedly adhered to the insulating core of the composite panel by a
foam material that is deposited between the frame and side surfaces
of a rough opening of the composite panel.
40. The panel of claim 39 wherein the foam material provides the
sole structural attachment between the fenestration unit and the
composite panel.
41. The panel of claim 39 wherein the foam material is compatible
with a material of the insulating core of the composite panel.
42. The panel of claim 39 wherein the foam material provides a
primary structural attachment between the fenestration unit and the
composite panel when the foam material is substantially cured.
43. The panel of claim 39 wherein the foam material provides at
least 50% of an attachment force that resists separation of the
fenestration unit from the composite panel along a direction
generally perpendicular to a major surface of the composite
panel.
44. The panel of claim 39 wherein the foam material provides about
80% of an attachment force that resists separation of the
fenestration unit from the composite panel along a direction
generally perpendicular to a major surface of the composite
panel.
45. The panel of claim 39 comprising an intermediate adhesion
promoting material applied to at least one of the frame and the
insulating core exposed by the rough opening.
46. The panel of claim 39 wherein the insulating core comprises a
polymeric foam material.
Description
FILED OF THE INVENTION
[0001] The present invention relates to a method of installing a
fenestration unit in a composite panel using a foam material, and
to a composite panel with the fenestration unit installed using a
foam material, where the foam material is the primary attachment
structure. The present method can be used with prefabricated and
on-site constructed composite panels. The present method is also
directed to building structures constructed using the composite
panels of the present invention.
BACKGROUND OF THE INVENTION
[0002] Composite panels are gaining increasing acceptance in
building construction in replacing the conventional combination of
drywall sheets and rolls of fiberglass insulation. In their basic
form, composite panels generally include an insulating core, such
as insulating foam, positioned between two outer layers. Additional
layers may be included for some applications. The outer layers are
generally constructed of a rigid material such as gypsum or
cementous composite, oriented strand board, plywood, metal
sheeting, or an agricultural board product such as strawboard.
[0003] Typically, a fenestration unit is installed in a composite
panel by cutting a hole in the panel and building a wood frame
around the perimeter of the hole. The fenestration unit is then
located in the framed opening, shimmed from the interior of the
building, and nailed to the wood frame from the interior of the
fenestration unit and/or from the exterior of the building through
a plurality of pre-punched holes in nailing fins attached to the
fenestration unit. Once the fenestration unit is secured in place,
the installation is completed by locating insulation in the cavity
between the wood frame and the fenestration unit.
BRIEF SUMMARY OF THE INVENTION
[0004] The present invention relates to a method of installing a
fenestration unit in a composite panel using a foam material. The
present invention is also directed to a composite panel with the
fenestration unit installed using a foam material and to a building
structure constructed from the present composite panels. The foam
material is preferably the primary attachment structure. The
present method can be practiced without the conventional wood or
metal frame located in the rough opening formed to receive the
fenestration unit.
[0005] In one embodiment, a rough opening is created in the
composite panel. The rough opening has a perimeter larger than a
perimeter of the frame of the fenestration unit. The fenestration
unit is then positioned in the rough opening so that a space is
formed between the perimeter of the frame of the fenestration unit
and the perimeter of the rough opening of the composite panel. A
foam material is delivered into the space to fixedly adhere the
fenestration unit to the insulating core of the composite panel.
The insulating core is typically constructed from a polymeric foam
material.
[0006] The foam material preferably provides the primary structural
attachment between the fenestration unit and the composite panel
when the foam material is substantially cured. In another
embodiment, the foam material is the sole structural attachment
between the fenestration unit and the composite panel. The foam
material preferably provides at least 50% of an attachment force
that resists separation of the fenestration unit from the composite
panel along a direction generally perpendicular to a major surface
of the composite panel. The cured foam material preferably provides
about 70%, and more preferably about 80%, and most preferably about
95%, of the attachment force.
[0007] The foam material is preferably compatible with a material
of the insulating core of the composite panel. A low expansion
adhesive foam is preferred. The foam material may be delivered to
fixedly adhere to at least one side surface of an outer layer of
the composite panel at the rough opening. The foam material is
typically delivered around at least a portion of the perimeter of
the frame of the fenestration unit. The foam material is preferably
delivered around the entire perimeter of the frame of the
fenestration unit. In one embodiment, an intermediate adhesion
promoting material is applied to at least one of the perimeter of
the frame and the insulating core exposed by the rough opening.
[0008] In one embodiment, the frame of the fenestration unit
includes a fin attached to an outer surface of an outer layer of
the composite panel. A sealant material can optionally be located
between the fin and the outer surface of the outer layer.
Optionally, one or more mechanical fasteners can be used to attach
the fin to the outer layer of the composite panel.
[0009] In one embodiment, the perimeter of the frame includes
recesses adapted to receive the foam material. The peripheral side
surface of the fenestration unit includes recesses into which the
foam material flows. The recesses increase the resistance to the
forces acting on the fenestration unit perpendicular to the outer
surface of the composite panel.
[0010] The composite panel can be assembled on-site or
prefabricated in a remote location. Similarly, the rough opening
can be created on-site or at the remote location.
[0011] The present invention is also directed to a wall structure
comprising a fenestration unit including a frame and a composite
panel comprising an insulating core. A rough opening created in the
composite panel receives the frame of the fenestration unit. A foam
material is deposited between the perimeter of the frame of the
fenestration unit and the perimeter of the rough opening of the
composite panel to fixedly adhere the fenestration unit to the
insulating core of the composite panel.
[0012] The present invention is also directed to a composite panel
having an insulating core located between outer layers. The
composite panel includes a fenestration unit having a frame. The
frame of the fenestration unit is fixedly adhered to the insulating
core of the composite panel by a foam material that is deposited
between the frame and side surfaces of a rough opening of the
composite panel.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0013] FIG. 1a is a front view of a composite panel having a rough
opening for receiving a fenestration unit.
[0014] FIG. 1b is a horizontal cross-sectional view of the
composite panel of FIG. 1a taken along the line 1b-1b.
[0015] FIG. 1c is a vertical cross-sectional view of the composite
panel of FIG. 1a taken along the line 1c-1c
[0016] FIG. 2 is a front view of a window unit that is to be
installed in the rough opening of the composite panel of FIG.
1a.
[0017] FIG. 3 is a fragmentary cross-sectional view of a
fenestration unit installed in the rough opening of the composite
panel of FIG. 1a using a foam material in accordance with the
present invention.
[0018] FIG. 4 is a fragmentary cross-sectional view of an alternate
fenestration unit installed in the rough opening of the composite
panel of FIG. 1a using the foam material in accordance with the
present invention.
[0019] FIG. 5 is a fragmentary cross-sectional view of another
alternate fenestration unit installed in the rough opening of the
composite panel of FIG. 1a using the foam material in accordance
with the present invention.
[0020] FIG. 6 is a fragmentary cross-sectional view of a sill
region of a fenestration unit installed in the rough opening of the
composite panel of FIG. 1a using the foam material in accordance
with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The present invention relates to a simplified method for
installing a fenestration unit in a composite panel without the
typical intermediate frame of wood or metal in the rough opening.
The present invention is also directed to a composite panel with a
fenestration unit attached to the insulating core using a foam
material. No mechanical fasteners are required. As used herein,
"fenestration unit" refers to windows, doors, skylights, shutters,
and components thereof, such as window jambs, sills, heads, sash
stiles, sash rails, door thresholds, and the like.
[0022] FIGS. 1a-1c illustrate an exemplary composite panel 10. The
composite panel 10 generally includes an insulating core 16
positioned between two outer layers 12 and 14. The outer layers 12
and 14 are generally constructed of a rigid material such as gypsum
or cementous composite, oriented strand board, plywood, metal
sheeting, or an agricultural board product such as strawboard.
[0023] The insulating core 16 is typically a polymeric foam
material. In one embodiment, the insulating core is a homogeneous
material. Various additives, fillers, and the like can also be
added to the insulating core. Various reinforcing structures can
optionally be included in the insulating core, such as fiberglass,
woven and non-woven polymeric webs, and cellulose-based reinforcing
webs. Example of such structures are disclosed in U.S. Pat. No.
5,055,242 (Vane); U.S. Pat. No. 5,910,458 (Beer); U.S. Pat. No.
5,286,553 (Haraguchi); U.S. Pat. No. 4,983,453 (Beall); and U.S.
Pat. No. 6,080,482 (Martin).
[0024] The insulating core 16 can be provided as a prefabricated
sheet material or it can be extruded at the time the composite
panel is assembled. In one embodiment, the composite panel 10 is
prefabricated at a remote location, such as a factory. In another
embodiment, the composite panel 10 is constructed or assembled
generally at the installation site, or in some applications, at the
precise location where the composite panel 10 is to be installed.
Similarly, the rough opening 20 can be created at the remote
location or at the installation site. In one embodiment, the rough
opening 20 is created after the composite panel is erected at the
construction site. This embodiment provides the greatest
flexibility in locating the rough opening 20 in relation to the
structure being created. Examples of composite panels are disclosed
in U.S. Pat. Nos. 6,627,131 and 6,455,148.
[0025] To install the fenestration unit in the composite panel 10,
a rough opening 20, having an appropriate size for receiving the
fenestration unit, is created in a composite panel 10. In the
illustrated embodiment, the rough opening 20 has a height 44 and a
width 46 with four side surfaces 22, 24, 26, and 28. A variety of
methods can be used to create the rough opening 20 in the composite
panel 10, such as for example cutting with a circular or
reciprocating saw. In one embodiment, the rough opening 20 is
manufactured into the composite panel 10 at the factory where the
panel 10 is made. The present method, however, also permits the
rough opening 20 to be created in the field, preferably after the
composite panel 10 is erected as part of the final structure.
Creating the rough opening 20 in the field provides maximum
flexibility in locating the fenestration unit in the building
structure.
[0026] FIG. 2 shows a window unit 30 that is to be installed in the
rough opening 20 of the composite panel 10. The window unit 30 has
a shape generally corresponding to the rough opening 20. The window
unit 30 has a height 48 and a width 49 that are preferably slightly
smaller than the height 44 and the width 46 of the rough opening
20, respectively. The window unit 30 includes a window frame 40 and
a window pane 42. The window frame 40, which can be constructed of
wood, vinyl, aluminum, or a variety of other materials, includes
four peripheral side surfaces 32, 34, 36, and 38. The present
invention is not limited by the shape or construction of the
fenestration unit.
[0027] Although the rough opening 20 as shown in FIGS. 1a-1c and
the window unit 30 in the illustrated embodiments are rectangular,
the present invention is not limited to any particular shape. The
rough opening 20 has a perimeter slightly larger than a perimeter
of the window frame 40 of the window unit 30, so that the window
unit 30 can be received in the rough opening 20 during
installation.
[0028] The next step is to position the window unit 30 inside the
rough opening 20. The side surfaces 22, 24, 26, and 28 of the rough
opening 20 are located generally opposite the peripheral side
surfaces 32, 34, 36, and 38 of the window unit 30, respectively.
Shims or spacers are typically used to temporarily retain the
window unit 30 in the desired position within the rough opening
20.
[0029] FIG. 3 is a cross-sectional fragmentary view of a composite
panel 10 with a fenestration unit installed in the rough opening 20
using a foam material 50 in accordance with the present invention.
Space 51 preferably extends around the perimeter of the window
frame 40 and the perimeter of the rough opening 20 of the composite
panel 10. After the fenestration unit, such as a window unit 30, is
positioned inside the rough opening 20, the foam material 50 is
delivered into at least a portion of the space 51. The space 51
between the perimeter of the window frame 40 and the perimeter of
the rough opening 20 is preferably between about 1/8" and about
1".
[0030] The foam material 50 is typically stored under pressure in a
suitable container and can be extruded from the container through a
tube into the space 51. When the foam material 50 is cured, it
functions as an adhesive to retain and seal the window frame 40 to
the side surfaces 22, 24, 26, and 28 of the rough opening 20 of the
composite panel 10. The cured foam material 50 also functions as a
weather resistive barrier to prevent moisture and air from moving
through the space 51 between the interior and exterior of the
building. Therefore, other insulation materials, such as
conventional insulation foam or sealant are typically not required
during installation.
[0031] In the illustrated embodiment, the interfaces between the
side surfaces 22, 24, 26, and 28 of the rough opening 20 and the
peripheral side surfaces 32, 34, 36, and 38 of the window frame 40,
respectively, are substantially the same. Consequently, only the
interface between the peripheral side surface 38 of the window
frame 40 and the side surface 28 of the rough opening 20 will be
described in detail.
[0032] The side surface 28 of the rough opening 20 includes an edge
surface 17 of the insulating core 16 and edge surfaces 19 and 21 of
the outer layers 12 and 14. In accordance with the present
invention, the foam material 50 wets onto and adheres to the edge
surface 17 of the insulating core 16 and the peripheral side
surface 38 of the window frame. In one embodiment, the foam
material also wets onto and adheres to one or both of the edge
surfaces 19 and 21 of the outer layers 12 and 14. In another
embodiment, the foam material 50 only wets onto and adheres to the
edge surface 17 of the insulating core 16. In the illustrated
embodiment, the foam material 50 wets onto and adheres to the edge
surface 21 of the outer layer 14 and a portion of the edge surface
17 of the insulating core 16, but not the edge surface 19 of the
outer layer 12.
[0033] The peripheral side surface 38 of the window frame 40
optionally includes recesses 39 into which the foam material 50
flows. The recesses 39 increase the resistance to the forces F
acting on the window unit 30 perpendicular to the outer surface 15
of the composite panel 10.
[0034] The foam material 50 is preferably applied all the way
around the perimeter of the window frame 40. In another embodiment,
the foam material 50 is applied around only a portion of the
perimeter of the window frame 40. The foam material 50 may fill the
entire space 51, or only a portion thereof.
[0035] The foam material 50 is preferably compatible with the
insulating core 16 of the composite panel 10. In some embodiments,
the insulating core 16 exposed in the rough opening 20 and/or the
peripheral side surface 38 of the frame 40 on the fenestration unit
30 are treated or coated with an intermediate adhesion promoting
material 55 that enhances the compatibly and/or bonding strength
with the foam material 50. The intermediate adhesion promoting
material 55 is preferably a liquid that can be sprayed or brushed
onto the insulating core 16 or the peripheral side surface 38 on
the frame 40.
[0036] Depending upon the intermediate adhesion promoting material
55 selected, it may be substantially or partially cured before the
foam material 50 is applied. In another embodiment, the
intermediate adhesion promoting material 55 is part of an
activation process. In one embodiment, the intermediate adhesion
promoting material 55 is an adhesive that is permitted to at least
partially cure before the foam material 50 is applied. As used
herein, the phrase "compatible" refers to materials that
essentially complete wets and that chemical bonds with the
insulating core and/or an intermediate adhesion promoting material
applied to the insulating core exposed in the rough opening or
applied to the peripheral side surface of the frame of the
fenestration unit.
[0037] In one embodiment, the foam material 50 is provided in a
container with a tube fluidly coupled to the foam material. The
foam material 50 is delivered to the space 51 by inserting the tube
about 10% to about 90% of the depth of the space 51 and delivering
the foam material 50. Delivering a foam material 50 that fills less
than the entire space 51 provides the foam material 50 with enough
room for expansion during curing. Alternatively, the space 51 is
substantially filled with the foam material 50. The foam material
50 is permitted to expand beyond the outer surfaces of the outer
layers 12 and 14. After the foam material 50 is substantially
cured, the excess foam material 50 is trimmed using a knife or
other appropriate tool.
[0038] For some applications, it is important not to deposit an
excessive amount of the foam material 50 in the space 51. If
excessive expanding foam material 50 is delivered into the space
51, pressure may be generated on the window frame 40. If the window
frame 40 is deformed (e.g., bowed), the operation of the window
unit 30 may be compromised.
[0039] The substantially cured foam material 50 preferably provides
the primary structural attachment between the window unit 30 and
composite panel 10, without the need for an intermediate frame or
wood, metal or the like. As used herein, "primary structural
attachment" refers to a mechanism that provides at least 50% of an
attachment force that resists separation of a fenestration unit
from a composite panel along a direction generally perpendicular to
a major surface of the composite panel. That is, the shear
characteristics of the foam material 50 are substantially greater
than the anticipated force F. In the preferred embodiment, the
cured foam material 50 preferably provides about 70%, and more
preferably about 80%, and most preferably about 95%, of the
attachment force.
[0040] In another embodiment, the substantially cured foam material
50 provides the sole structural attachment between the window unit
30 and composite panel 10. As used herein, "sole structural
attachment" refers to a mechanism that provides 100% of an
attachment force that resists separation of a fenestration unit
from a composite panel along a direction generally perpendicular to
a major surface of the composite panel, excluding any attachment
force provided by fins.
[0041] Since the cured foam material 50 provides excellent adhesion
and supplies a primary structural attachment, nails, screws and
other mechanical fasteners are typically not required for
installation, although mechanical fasteners can optionally be used
to initially align the fenestration unit in the rough opening
and/or to supplement the primary structural attachment. Embodiments
using the foam material 50 and the nails and other fasteners in
accordance with the present invention will be discussed below.
[0042] Table I below lists the expansion information of various
commercially available foam materials. The test results demonstrate
that Hilti CF511 and Hago Gun Foam produce no bowing of the window
frames in jambs and cure more quickly than other foam
materials.
1TABLE I Foam material Expansion information PUR Fill Moderate
expansion. Easy to clean up. Producing 1/4" bow in jambs. Hilti
CF511 Moderate expansion. Easy to clean up. Producing no bow in
jambs. EZ Seal Very prolonged expansion. Hard to clean up.
Producing no bow in jambs. Hago Gun Foam Moderate expansion. Easy
to clean up. Producing no bow in jambs. Hilti CF162 Low expansion.
Difficult to be filled in the space. Having a very hard substance
and little flexibility.
[0043] Table II below lists cohesive failure data of various foam
materials when tensile loads are applied to the foam materials. The
test results demonstrate that Hilti resists higher tensile loads
than Dow and Hago.
2 TABLE II Tensile stress causing cohesive failure (average of five
samples of each Foam material material) - Pounds per square inch
(PSI) Dow 4.6 PSI Hilti 12 PSI Hago 6.6 PSI
[0044] Table III below lists shear strength data for the foam
material. The test results demonstrate that Hilti resist higher
load than Dow and Hago.
3 TABLE III Shear stress causing cohesive failure (average of four
samples of each Foam material material) - Pounds per square inch
(PSI) Dow 5.33 PSI Hilti 8.76 PSI Hago 5.96 PSI
[0045] Curing the foam material 50 usually takes about 1-24 hours.
Any cured foam material 50 extending out of the space 51 is
trimmed. After the foam material 50 is substantially completely
cured, the operation of the window unit 30 is checked. If the
window unit 30 works properly, trim and sidings can be installed to
cover the exterior surface 15 of the outer layer 14.
[0046] FIG. 4 is a cross-sectional fragmentary view of an alternate
fenestration unit 130 installed in the rough opening 20 of the
composite panel 10 using the foam material 50 in accordance with
the present invention. After the fenestration unit 130 is
positioned in the rough opening 20, the foam material 50 is
delivered into the space 151 between the perimeter of the frame 140
and the perimeter of the rough opening 20 of the composite panel
10. Similar to the embodiment in FIG. 3, the space 151 between the
perimeter of the window frame 140 and the perimeter of the rough
opening 20 is preferably between about 1/8"and about 1".
[0047] In the illustrated embodiment, a jamb extension 174 can be
added to the interior of the window unit 130. The form material 50
is also delivered into a space between the jamb 174 and the
composite panel 10. The foam material 50 wets onto and adheres to a
peripheral side surface 138 of the window frame 140, an edge
surface 175 of the jamb 174, the edge surface 17 of the insulating
core 16, the edge surface 19 of the outer layer 12, and the edge
surface 21 of the outer layer 14. As has been described in the
previous embodiment, the cured foam material 50 preferably provides
the primary structural attachment between the fenestration unit 130
and composite panel 10.
[0048] The fenestration unit 130 further includes a fin 168
attached to its frame 140. The fin 168 can be either attached all
the way around the perimeter of the frame 140 or attached to a
portion of the frame 140. A sealant material 170, such as
polyurethane, is preferably located between the fin 168 and the
exterior surface 15 of the outer layer 12 of the composite panel
10. The cured sealant material 170 functions as an extra weather
resistive barrier in addition to the cured foam material 50. In the
illustrated embodiment, one or more nails 172 can optionally be
used to fasten the fin 168 to the outer layer 12 of the composite
panel 10. The nails 172 provide an extra attachment force that
resists separation of the fenestration unit 130 from the composite
panel 10 in addition to the primary structural attachment provided
by the cured foam material 50.
[0049] FIG. 5 illustrates a cross-sectional fragmentary view of yet
another embodiment of fenestration unit 230 installed in the rough
opening 20 of the composite panel 10 using the foam material 50 in
accordance with the present invention. As has been described in the
previous embodiments, the foam material 50 is delivered into the
space 251 between the perimeter of the frame 240 and the perimeter
of the rough opening 20 of the composite panel 10, after the
fenestration unit 230 is positioned inside the rough opening 20.
The foam material 50 wets onto and adheres to a peripheral side
surface 238 of the window frame 240, the edge surface 21 of the
outer layer 14, and a portion of the edge surface 17 of the
insulating core 16, but not the edge surface 19 of the outer layer
12. As has been described in the previous embodiments, the cured
foam material 50 preferably provides the primary structural
attachment between the fenestration unit 230 and composite panel
10.
[0050] Similar to the fenestration unit 130 in FIG. 4, the
fenestration unit 230 includes a fin 268 attached to its frame 240.
A sealant material can be located between the fin 268 and the
exterior surface 15 of the outer layer 14 of the composite panel
10. One or more mechanical fasteners 272 can also be used to fasten
the fin 268 to the outer layer 12 of the composite panel 10. The
mechanical fasteners 272 provide an extra attachment force that
resists separation of the fenestration unit 230 from the composite
panel 10 in addition to the primary structural attachment provided
by the cured foam material 50.
[0051] In the illustrated embodiment, a first butyl-based window
flashing tape 282 can be applied from the frame 240 over the fin
268 onto the exterior surface 15 of the outer layer 14. A weather
resistive wrap 286 can be applied to lap over the fin 268 and the
first flashing tape 282. Further, a second butyl-based window
flashing tape 284 can be applied to the weather resistive wrap 286
adjacent to the fin 268. Finally, a siding 280 is installed to
cover the outer layer 14 of the composite panel 10.
[0052] In this embodiment, an L-shaped material 276 is installed to
cover a portion of the edge surface 17 of the insulating core 16,
the edge surface 19 of the outer layer 12, and the exterior surface
13 of the outer layer 12. The L-shaped material can be attached
using mechanical fasteners, adhesives or a variety of other
techniques know to those of skill in the art. The L-shaped material
276 is typically constructed of a rigid material such as gypsum
plywood, wood, plastic, metal, or composites thereof. Further, a
decorative wood trim 278 can optionally be mounted to the board 276
along a perimeter of the opening surrounded by the board 276.
[0053] FIG. 6 is a fragmentary cross-sectional view of a sill
region of a fenestration unit 330 installed in the rough opening 20
of the composite panel 10 using the foam material 50 in accordance
with the present invention. The fenestration unit 330 includes a
sill member 390 having a sloping top wall 392 attached to a frame
member 340. After the fenestration unit 330 is positioned inside
the rough opening 20, the foam material 50 is delivered into the
space 351 between the frame 340 and edge surface of the composite
panel 10. The foam material 50 can also optionally be delivered to
a space 53 underneath the sloping top wall 392 of the sill member
390. In this embodiment, the foam material 50 wets onto and adheres
to an inner surface of the sloping top wall 392, the edge surface
21 of the outer layer 14, and a portion of the edge surface 17 of
the insulating core 16, but not the edge surface 19 of the outer
layer 12. As has been described in the previous embodiments, the
cured foam material 50 preferably provides the primary structural
attachment between the fenestration unit 330 and composite panel
10.
[0054] Similar to the fenestration unit 130 in FIG. 4, the
fenestration unit 330 includes a fin 368 attached to its frame 340.
A sealant material can be located between the fin 368 and the
exterior surface 15 of the outer layer 14 of the composite panel
10. One or more mechanical fasteners 372 can also be used to fasten
the fin 368 to the outer layer 12 of the composite panel 10. The
mechanical fasteners 372 provide an extra attachment force that
resists separation of the fenestration unit 330 from the composite
panel 10 in addition to the primary structural attachment provided
by the cured foam material 50. In the illustrated embodiment, a
weatherproof tape 382 is optionally applied over the fin 368 onto
the exterior surface 15 of the outer layer 14.
[0055] Any of the composite panels disclosed herein can be used to
construct various structures, such as houses, garages and the like.
The composite panels are attached to each other and integrated into
the overall structure using conventional techniques known to those
of skill in the art.
[0056] All patents and patent applications disclosed herein,
including those disclosed in the background of the invention, are
hereby incorporated by reference. Although the present invention
has been described with reference to preferred embodiments, workers
skilled in the art will recognize that changes may be made in form
and detail without departing from the spirit and scope of the
invention. In addition, the invention is not to be taken as limited
to all of the details thereof as modifications and variations
thereof may be made without departing from the spirit or scope of
the invention. For example and although the target elements of
uniformly thick layers is disclosed, differing thickness might also
be incorporated into the target assembly.
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