U.S. patent application number 10/833722 was filed with the patent office on 2005-11-17 for door and window sill gasket.
Invention is credited to Bushberger, Todd E..
Application Number | 20050252131 10/833722 |
Document ID | / |
Family ID | 35308058 |
Filed Date | 2005-11-17 |
United States Patent
Application |
20050252131 |
Kind Code |
A1 |
Bushberger, Todd E. |
November 17, 2005 |
Door and window sill gasket
Abstract
A door and window sill gasket is adapted to seal the frame of
doors and windows against moisture, air and insects. The gasket
includes a water resistant compressible material having an upper
surface, a lower surface and at least one edge. The lower surface
of the compressible material is attached to an adhesively-coated
top face of a rubberized asphalt sealing membrane providing an
air/water infiltration barrier and having an adhesively-coated
lower face covered by a removable release liner. The membrane
includes a flexible, covered flange extending outwardly from the at
least one edge of the compressible material.
Inventors: |
Bushberger, Todd E.;
(Milwaukee, WI) |
Correspondence
Address: |
William L. Falk
ANDRUS, SCEALES, STARKE & SAWALL, LLP
Suite 1100
100 East Wisconsin Avenue
Milwaukee
WI
53202-4178
US
|
Family ID: |
35308058 |
Appl. No.: |
10/833722 |
Filed: |
April 28, 2004 |
Current U.S.
Class: |
52/411 |
Current CPC
Class: |
E06B 1/70 20130101; E06B
1/62 20130101; E06B 2001/628 20130101 |
Class at
Publication: |
052/411 |
International
Class: |
E04B 005/00 |
Claims
I claim:
1. A door and window sill gasket adapted to seal the frame of doors
and windows against moisture and/or air and insects, the gasket
comprising: a water resistant compressible material having an upper
surface, a lower surface, and at least one edge, the lower surface
of the compressible material being attached to an adhesively-coated
top face of a rubberized asphalt sealing membrane providing an
air/water infiltration barrier and having an adhesively-coated
lower face covered by a removable release liner, the membrane
including a flexible, covered flange extending outwardly from the
at least one edge of the compressible material.
2. The gasket of claim 1, wherein the flexible covered membrane
includes a silicon release liner removably attached to the top face
of the membrane.
3. The gasket of claim 1, wherein the flexible covered membrane
includes a drain material attached to the top face of the
membrane.
4. The gasket of claim 1, wherein the upper surface of the
compressible material is downwardly sloped towards the flange.
5. The gasket of claim 1, wherein the membrane is highly elastic
and has an elongation of up to 500 percent.
6. The gasket of claim 1, wherein the compressible material is
comprised of closed cell polyethylene foam.
7. The gasket of claim 1, wherein a rear edge of the compressible
material is provided with a backdam.
8. The gasket of claim 3, wherein the drain material is formed by a
flexible, plastic sheet provided with a plurality of raised dimples
forming a series of flow paths along the sheet.
9. A method of providing a sill gasket at a bottom of door or
window framework having a horizontal bottom member located between
a pair of spaced apart vertical side members, the method comprising
the steps of: providing a water resistant compressible material
having an upper surface, a lower surface, and at least one edge,
the lower surface of the compressible material being attached to an
adhesively-coated top face of a rubberized asphalt sealing membrane
providing an air/water infiltration barrier and having an
adhesively-coated lower face covered by a removable release liner,
the membrane including a flexible, covered flange extending
outwardly from the at least one edge of the compressible material;
removing the release liner from the lower face of the membrane and
adhesively securing the membrane with the attached compressible
material horizontally across an entire length of the bottom member
such that opposed ends of the membrane extend vertically along and
are adhesively attached to the inside surfaces of the door jam
structural members with the flange of the membrane projecting
forwardly from the subfloor; folding and adhesively applying the
flange of the membrane to respective front surfaces of the bottom
member and the spaced apart side members; and securing the
threshold to at least the upper surface of the compressible
material along the subfloor.
10. A method of providing a sill gasket to create positive flow of
water leaked into a window away therefrom and to prevent moisture
infiltration between a window frame and a framework having a top
member, a bottom member and side members, each having a front
surface defining a window opening, the method comprising the steps
of: providing a water resistant, compressible material having an
upper surface, a lower surface, and at least one edge, the upper
surface sloping downwardly towards the at least one edge, the lower
surface of the compressible material being attached to an
adhesively-coated top face of a rubberized asphalt sealing membrane
providing an air/water infiltration barrier and having an
adhesively-coated lower face covered by a removable release liner,
the membrane including a flexible, covered flange extending
outwardly from the at least one edge of the and having a drain
material attached to the top face of the membrane; removing the
release liner from the lower face of the membrane and adhesively
securing the membrane with the attached compressible material and
one portion of the flange with the drain material along inner
surfaces of the bottom and side members of the window opening
framework with a remaining portion of the flange with the drain
material extending forwardly from the bottom member of the window
opening framework; folding and adhesively applying the remaining
portion of the flange with the drain material to the front surface
of the bottom member of the window opening framework; setting the
window frame in the window opening on top of the drain material and
fastening the window frame to the respective front surfaces of the
top, bottom and side members of the framework; and applying a
sealing tape over peripheral edges of the window frame along the
top and side members of the framework.
11. A method of providing a sill gasket at bottom of door or window
framework having a horizontal bottom member located between a pair
of spaced apart vertical side members, the method comprising the
steps of: providing a water resistant compressible material having
an upper surface, a lower surface, and at least one edge, the lower
surface of the compressible material being attached to an
adhesively-coated top face of a rubberized asphalt sealing membrane
providing an air/water infiltration barrier and having an
adhesively-coated lower face covered by a removable release liner,
the membrane including a flexible, covered flange extending
outwardly from the at least one edge of the compressible material;
removing the release liner from the lower face of the membrane and
adhesively securing the membrane with the attached compressible
material horizontally across an entire length of the bottom member
such that opposed ends of the membrane extend vertically along and
are adhesively attached to the inside surfaces of the spaced apart
side members with at least a portion of the covered flange of the
membrane projecting forwardly from the bottom member; and folding
and adhesively applying the flange of the membrane to respective
front surfaces of the bottom member and the spaced apart side
members.
Description
FIELD OF THE INVENTION
[0001] The present invention generally relates to building products
and, more particularly, pertains to a sealing gasket for doors and
windows.
BACKGROUND OF THE INVENTION
[0002] One of the most common failure points for unwanted air
and/or moisture in a building envelope is around doors and windows.
Controlling air and/or moisture is a serious concern which may
result in exterior and interior damage if not prevented or
corrected in a timely manner. Recent studies have shown that the
extent of such damage has run into millions of dollars annually. In
addition, heat losses caused by air leakage around building
openings have taken on new significance due to today's high energy
costs. Sealing to date has been imperfectly accomplished by
caulking or using a putty-like compound around openings between
door and window frames to seal the gaps and prevent inward seepage
of air and/or water into the building. There is often a further
problem with bugs entering through the same gaps.
[0003] In the case of a door, the caulking is typically placed
between a threshold and the subfloor, but this does not stop
moisture getting into the subfloor face. After a period of time,
moisture from melting snow or driving rain leads not only to
swelling, rotting and warpage of the subfloor and structural
framing, but also racks the door frame out of square and ruins the
finish flooring above the subfloor. Once this happens, the door
will need constant adjustments and, more than likely, the finish
flooring will need to be replaced. The moisture and humidity along
with the drying and shrinking of lumber also crack the caulk so
that air, water, mold and insects may infiltrate under the
threshold into the building.
[0004] In window installations, caulking around the window has been
the known installation and application method. However, this has
proven to be a failed system because over long term, the caulking
cannot withstand the constant expansion and contraction of the
window itself or the substrate. Test studies show that after
several years in operation, almost 100 percent of all windows
either leaked through the window flange or the window itself. This
water leakage along with water intrusion caused by precipitation
leads to structural damage such as rotting of the window sills and
mold.
[0005] Given these problems, there remains a need for an improved
sealing gasket for ensuring a weather-tight barrier for door and
window installations.
SUMMARY OF THE INVENTION
[0006] It is a general object of the present invention to provide a
door and window sealing gasket which overcomes the deficiencies of
the prior art.
[0007] It is also an object of the present invention to provide a
door and window sealing gasket which is 100 percent waterproof, and
is mold and mildew resistant.
[0008] It is another object of the present invention to provide a
door and window sealing gasket which stops unwanted air and/or,
moisture and bug infiltration and protects sills from rotting.
[0009] It is an additional object of the present invention to
provide a sealing gasket which helps prevent subfloors from
swelling and structural framing from warping.
[0010] It is a further object of the present invention to provide a
sealing gasket which helps stop moisture intrusion to the subfloor
causing eventual destruction to the finish flooring.
[0011] Still another object of the present invention is to provide
a sealing gasket which is energy efficient to reduce monthly
utility costs.
[0012] Yet a further object of the present invention is to provide
a door and window sealing gasket which is self-adhering to a
variety of surfaces such as concrete, wood and metal.
[0013] One other object of the present invention is to provide a
door and window sealing gasket which features an easy peel and
stick application that offers a savings in labor costs.
[0014] An extra object of the present invention is to provide a
door and window sealing gasket employing a rubberized, waterproof,
modified asphalt with a high degree of elongation.
[0015] It is another object of the present invention to provide a
method of supplying a sill gasket between a threshold and a
subfloor.
[0016] It is also an object of the present invention to provide a
method of supplying a sill gasket between a window frame and a
window framework defining a window opening.
[0017] It is yet another object of the present invention to provide
a door and window sealing gasket which utilizes commercially
available materials for the manufacture thereof.
[0018] In one aspect of the invention, a door and window sill
gasket is adapted to seal the frame of doors and windows against
moisture, air and insects. The sill gasket includes a water
resistant, compressible material having an upper surface, a lower
surface, and at least one edge. The lower surface of the water
resistant compressible material is attached to an adhesively-coated
top face of a rubberized asphalt sealing membrane providing an
air/water infiltration barrier and having an adhesively-coated
lower face covered by a removable release liner, the membrane
including a flexible covered flange extending outwardly from the at
least one edge of the water resistant, compressible material.
[0019] In the door sill gasket, the flexible covered membrane
includes a silicon release liner removably attached to the top face
of the membrane. In the window sill gasket, the flexible covered
membrane includes a drain material attached to the top face of the
membrane. Also in the window sill gasket, the upper face of the
water resistant compressible material is downwardly sloped towards
the flange. The membrane in both the door and window sill gaskets
is highly elastic and has an elongation of up to 500 percent.
[0020] In another aspect of the invention, there is contemplated a
method of providing a sill gasket to prevent air and moisture
infiltration between a threshold and a subfloor located at the
bottom of a pair of spaced apart structural members defining a door
jam. The method includes the steps of providing a water resistant
compressible material having an upper surface, a lower surface, and
at least one edge, the lower surface of the compressible material
being attached to an adhesively-coated top face of a rubberized
asphalt sealing membrane providing an air/water infiltration
barrier and having an adhesively-coated lower face covered by a
removable release liner, the membrane including a flexible, covered
flange extending outwardly from the at least one edge of the
compressible material; removing the release liner from the lower
face of the membrane and adhesively securing the membrane with the
attached compressible material horizontally across an entire length
of the subfloor such that opposed ends of the membrane extend
vertically along and are adhesively attached to the inside surfaces
of the door jam structural members with the flange of the membrane
projecting forwardly from the subfloor; folding and adhesively
applying the flange of the membrane to respective front surfaces of
the subfloor and the door jam structural members; and securing the
threshold to at least the upper surface of the compressible
material overlying the subfloor.
[0021] Still another aspect of the invention contemplates a method
of providing a sill gasket to create positive flow of water leaked
into a window away therefrom and to prevent moisture infiltration
between a window frame and a framework having a top member, a
bottom member and side members, each with a front surface defining
a window opening. The method includes the steps of providing a
water resistant compressible material having an upper surface, a
lower surface and at least one edge, the upper surface of the
compressible material sloping downwardly towards the at least one
edge, the lower surface of the compressible material being attached
to an adhesively-coated top face of a rubberized asphalt sealing
membrane providing an air/water infiltration barrier and having an
adhesively coated lower face covered by a removable release liner,
the membrane including a flexible, covered flange extending
outwardly from the at least one edge of the compressible material
and having a drain material attached to the top face of the
membrane; removing the release liner from the lower face of the
membrane and adhesively securing the membrane with the attached
compressible material and one portion of the membrane with the
drain material along inner surfaces of the bottom and side members
of the window opening framework with a remaining portion of the
flange of the membrane projecting forwardly from the bottom member
of the window opening framework; folding and adhesively applying
the remaining portion of flange of the membrane with the drain
material to the front surface of the bottom member; setting the
window frame in the window opening on top of the drain material and
fastening the window frame to the respective front surfaces of the
top, bottom and side members of the framework; and applying a
sealing tape over peripheral edges of the window frame along the
top and side members of the framework.
[0022] Various other objects, features and advantages of the
invention will be made apparent from the following description
taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The drawings illustrate the best mode presently contemplated
of carrying out the invention.
[0024] In the drawings:
[0025] FIG. 1 is a perspective view of a sill gasket embodying the
present invention;
[0026] FIG. 2 is a sectional view taken on line 2-2 of FIG. 1;
[0027] FIG. 3 is a fragmentary, perspective view of a partial
installation of the sill gasket in FIG. 1 on a door sill;
[0028] FIG. 4 is a view like FIG. 3 showing a finished installation
of the sill gasket;
[0029] FIG. 5 is a view like FIG. 4 showing the installation of a
threshold over the sill gasket;
[0030] FIG. 6 is a perspective view of an alternative embodiment of
the sill gasket used in window installations;
[0031] FIG. 7 is a sectional view taken on line 7-7 of FIG. 6;
[0032] FIG. 8 is a fragmentary, perspective view of a partial
installation of the sill gasket of FIG. 6 on a window sill;
[0033] FIG. 9 is a view like FIG. 8 showing a finished installation
of the sill gasket;
[0034] FIG. 10 is a front view of a finished installation of the
sill gasket with the window installed;
[0035] FIG. 11 is a partial sectional view of FIG. 10;
[0036] FIG. 12 is an enlarged detail view of the drain material
used in the gasket of FIG. 6; and
[0037] FIG. 13 is a sectional view taken on line 13-13 of FIG.
12.
DETAILED DESCRIPTION OF THE INVENTION
[0038] Referring now the drawings, FIGS. 1-5 illustrate a sill
gasket 10 for sealing a door frame 12 against moisture, air and
insect infiltration.
[0039] As seen in FIGS. 1 and 2, the sill gasket 10 includes a
layer of a water resistant, compressible material 14 preferably
constructed of closed cell polyethylene foam or similar material
such as rubber or the like, having an upper surface 16, a lower
surface 18, a front edge 20, a rear edge 22 and a pair of opposed
side edges 24, 26. The lower surface 18 of the material 14 is
attached to an adhesively-coated top face of a peel and stick
rubberized, waterproof, modified asphalt sealing membrane 28 for
providing an air/water/insect infiltration barrier. The membrane 28
has an adhesively-coated lower face covered by a peel away release
liner 30, typically made of paper. The membrane 28 includes a
flexible, covered gasket flange 32 which extends outwardly from the
front edge 20 of the material 14. Preferably, a silicon release
liner 34 is removably attached to an adhesively-coated top face of
the gasket flange 32. The rubberized, waterproof, modified asphalt
membrane 28 preferably has a thickness of about 40 mil. Most
notably, the membrane 28 is highly elastic with an elongation of up
to 500 percent. The membrane 28 is commercially available from the
Protecto Wrap Company of Denver, Colo.
[0040] Referring now to FIGS. 3, 4 and 5, the door frame 12
includes a horizontally extending, subfloor 36 extending
transversely across the bottom of a pair of spaced apart,
vertically extending, door jam or framing members 38, 40. A
sheathing material 42, such as OSB or plywood, is applied across
the front of the door frame 12.
[0041] In order to place the sill gasket 10 in the bottom of the
door frame 12, an installer removes the paper release liner 30 from
the lower face of the membrane 28 and adhesively secures the
membrane 28 with the foam 14 attached and facing upward
horizontally across an entire length of the door sill 36 such that
opposed ends of the membrane 28 extend vertically along and are
attached to short lengths of the inside surfaces of the door jams
38, 40 with the flange 32 of the membrane 28 extending forwardly
from the subfloor 36 as shown in FIG. 3. Next, the installer folds
the flange 32 downwardly and adhesively applies the flange 32 to
respective front surfaces of the subfloor 36 and door jams 38, 40
or the sheathing 42 attached thereto as shown in FIG. 4. Once this
is done, a conventional threshold 44 is fastened, such as by
mechanical fasteners or the like, at least to the upper surface 16
of the foam 14 and preferably also to the subfloor 36 itself as
shown in FIG. 5.
[0042] Turning now to FIGS. 6 and 7, there is shown an alternative
embodiment of the sill gasket identified by the reference numeral
46. This sill gasket design is used chiefly to prevent water and
insect infiltration in window installation. In this version, the
foam 14 has its rear edge 22 modified with an upstanding finger 23,
and its upper surface 16 sloped downwardly towards the front edge
20 for a reason to be explained below. In addition, the release
liner 34 on the top face of the flange 32 is replaced by a drain
member 48. As seen in FIGS. 12 and 13, the drain member 48 is
preferably a thin sheet made of a water resistant, flexible plastic
or other material having a plurality of raised dimples 49 which
form a series of flow paths 51 so that water will flow freely along
the drain member 48. It should be understood, however, that the
drain member 48 contemplates other designs which promote free flow
of water from the sloped surface 16 of foam 14.
[0043] Referring now to FIGS. 8 and 9, a framework 50 includes a
bottom member or window sill 52 extending across the lower ends of
a pair of spaced side members 54, 56, and a top member 58 connected
transversely to the upper ends of the side members 54, 56. The four
sided framework 50 defines an opening or a window frame 60 having a
window 62 as seen in FIGS. 10 and 11. A sheathing material 64 is
applied across the front of the framework 50.
[0044] To position the sill gasket 46 at the bottom of the
framework 50, as seen in FIG. 8, the installer removes the paper
release liner 30 from the lower face of the membrane 28, and
adhesively secures the membrane 28 with the foam 14 attached along
inner surfaces of the entire length of the window sill 52 and short
lengths of the side members 54, 56. During installation, a short
length of the flange 32 with drain member 48 is attached to the
front edge of bottom member 52 and side members 54, 56, and the
remainder of the flange 32 projects forwardly from the sill or
bottom member 52, as best seen in FIG. 11. Next, the installer
folds the flange 32 downwardly and adhesively applies the flange 32
to the front surface or sheathing material 64 adjacent sill 52 as
seen in FIG. 10. The sill gasket 46 is fully installed at this
point such that the upper surface 16 of the foam 14 slopes towards
the front of the framework 50 so as to direct any water which leaks
from the window along flow paths 51 of the drain member 48 and
positively out of the window opening. Next, the window frame 60 is
positioned in the window opening of the framework 50 so that a
peripheral window frame flange 66 overlaps marginal portions of the
top member 58, side members 54, 56, and the sheathing material 64
as illustrated in FIG. 10. The bottom of window frame 60 is
conveniently supported on the drain member 48. The window frame 60
is held in place by inserting mechanical fasteners 68 through the
window flange 66 into the framework 50. Finally, it is suggested
that a sealing tape 70 having a removable release liner is applied
to overlap the window flange 66 and the sheathing material 64 along
the front surfaces of the top member 58 and side members 54,
56.
[0045] With this construction, any moisture that leaks into the
window through window flange 66 or the window itself can be
channeled with positive flow forwardly and outwardly by the
particular downward slope of the foam 14 and be quickly directed
down and away from the window by the flow paths 51 of drain member
48. Such moisture is prevented from escaping rearwardly by the
finger 23 at the rear of foam 14 which acts as a backdam. Any
moisture intrusion from rain or snow is prevented from entering the
window by the gasket 46 and the sealing tape 70.
[0046] FIG. 11 depicts the window installation of the sill gasket
46 in cross section and shows the rear of the window sill 52
provided with drywall 72. Window trim 74 may be placed between the
rear of the window frame 60 and the drywall 74. Also, a layer of
Tyvek protective house wrap (not shown) may be optionally placed
over the sheathing material 64 before the sill gasket 46 is
applied.
[0047] When installing door sill gasket 10 or window sill gasket
46, it should be appreciated that the tremendous elasticity of the
membrane 28 enables an installer to easily pull and position the
flange 32 onto the sheathing material 42 or 64 as desired. The
membrane 28 has a particular construction which is air and moisture
impermeable and helps define a long lasting, effective sealing
gasket which is 100 percent waterproof, and is mold and mildew
resistant. As a result, subfloors and sills are prevented from
rotting, swelling and warping, finish flooring is not destroyed,
and energy losses are abated with a noticeable savings in energy
costs. In the case of the window sill gasket 46, the compressible
material or foam 14 adds to the versatility of enabling more or
denser insulation to be "chinked in" around the window than can be
done with a hard substrate. The sealing gasket 10 or 46 features a
simple peel and stick application which contributes to a further
savings in labor costs, and is adherent to a variety of materials
including wood, concrete and metal.
[0048] While the invention has been described with reference to a
preferred embodiment, those skilled in the art will appreciate that
certain substitutions, alterations and omissions may be made
without departing from the spirit thereof. Accordingly, the
foregoing description is meant to be exemplary only and should not
be deemed limitative on the scope of the invention set forth with
the following claims.
* * * * *