U.S. patent application number 11/642070 was filed with the patent office on 2007-08-02 for self-adhered flange for use with non-flanged windows.
Invention is credited to Barbara Klimowicz O'Rourke.
Application Number | 20070175107 11/642070 |
Document ID | / |
Family ID | 36178067 |
Filed Date | 2007-08-02 |
United States Patent
Application |
20070175107 |
Kind Code |
A1 |
O'Rourke; Barbara
Klimowicz |
August 2, 2007 |
Self-adhered flange for use with non-flanged windows
Abstract
An elongated flange material for forming a flange and a method
for use in sealing a non-flanged window, door, or other
fenestration product in a wall opening, wherein the flange material
comprises at least one top coversheet and at least one bottom
coversheet with a pressure-sensitive adhesive layer sandwiched
between the two coversheets, wherein the coversheets occupy an
appreciable width of the flange but do not extend across the entire
width of the flange and thereby are offset with respect to each
other thereby providing opposing first and second exposed surfaces
of the pressures sensitive adhesive layer. Alternatively, the
flange material comprises a nonporous flexible sheet with top and
bottom pressure-sensitive adhesive layer on opposite sides along
opposite edges of the nonporous flexible sheet.
Inventors: |
O'Rourke; Barbara Klimowicz;
(Newark, DE) |
Correspondence
Address: |
E I DU PONT DE NEMOURS AND COMPANY;LEGAL PATENT RECORDS CENTER
BARLEY MILL PLAZA 25/1128
4417 LANCASTER PIKE
WILMINGTON
DE
19805
US
|
Family ID: |
36178067 |
Appl. No.: |
11/642070 |
Filed: |
December 20, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11011669 |
Dec 14, 2004 |
|
|
|
11642070 |
Dec 20, 2006 |
|
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Current U.S.
Class: |
52/58 |
Current CPC
Class: |
E06B 1/62 20130101; E06B
2001/628 20130101 |
Class at
Publication: |
052/058 |
International
Class: |
E04D 13/14 20060101
E04D013/14 |
Claims
1. A self-adhering flange material, comprising: an elongated
nonporous flexible sheet having top and bottom major surfaces and a
width between a first edge and a second edge; a top
pressure-sensitive adhesive layer adhered to the top surface of the
flexible sheet along the first edge over a portion of the width of
the flexible sheet; and a bottom pressure-sensitive adhesive layer
adhered to the bottom surface of the flexible sheet along the
second edge over a portion of the width of the flexible sheet.
2. The flange material of claim 1 further comprising release paper
covering the opposing top and bottom pressure-sensitive adhesive
layers.
3. The flange material of claim 2 wherein the release paper is
perforated such that the release paper may be removed in strips
having a width less than the width of the pressure-sensitive
adhesive surface that the release paper covers.
4. The flange material of claim 1 wherein the pressure-sensitive
adhesive is selected from the group consisting of butyl rubber
adhesive, bituminous adhesive, acrylic, neoprene, epdm-based
polymer and combinations thereof.
5. The flange material of claim 1 wherein the nonporous flexible
sheet is selected from the group consisting of nonporous nonwoven
sheets, nonporous films, nonporous coated papers, nonporous coated
nonwoven sheets, nonporous nonwoven-film laminates, nonporous
plastic and nonporous metal.
6. A flange for sealing interfaces between fenestration products
and walls comprising the flange material of any of claims 1-5.
7. A method for installing a non-flanged window into a wall opening
whereby the interface between the window and the wall is sealed,
the method comprising the steps of: a) adhering the top
pressure-sensitive adhesive surface of a head piece of the flange
material according to claim 1 to the top surface of the head of the
window and the outer surface of the upper portion of each jamb of
the window; b) adhering a separate jamb piece of the flange
material according to claim 1 to the outer surface of the entire
length of each jamb of the window, thereby covering the head piece
of the flange material adhered to each jamb in step (a); c)
installing the window in the wall opening such that the head of the
window is located at the top of the wall opening and the unadhered
portions of the head piece and jamb pieces of flange material of
step (a) and step (b) extend outward from the wall; d) adhering the
unadhered portions of the pieces of flange material of step (a) and
step (b) to the wall above and adjacent each jamb of the window
such that the head piece covers an upper portion of the jamb
pieces.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. Ser. No.
11/011,669, filed on Dec., 14, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention is directed to materials and methods for
sealing windows and other fenestration products from moisture
intrusion.
[0004] 2. Description of Related Art
[0005] Flanges or nailing fins on windows, doors and other
fenestration products, in which the flange is integral to and
continuous with the window frame, provide a surface that is fully
connected to the window for adhesive flashing materials to adhere
to, enabling the flashing product to create a continuous watertight
seal at the window-wall interface in structures, such as buildings.
However, flanges are not present in all windows or fenestration
products (hereinafter referred to as "windows"). Non-flanged
windows and windows with brickmold frames (hereinafter referred to
as "brickmold windows") are prone to moisture intrusion, due to
difficulty in achieving a continuous flashing integration between
the window and the wall. Thus, the typical installation method for
these types of windows involves a bead of building sealant between
the fenestration product and the wall, which is not a durable,
continuously integrated moisture seal and is prone to failure after
environmental exposure. This results in a higher tendency for
moisture damage to the window and the surrounding wall, including
rot and mold growth. No known methods exist to install non-flanged
and brickmold windows in a way that effectively seals the
window-wall interface with a continuous integration of self-adhered
flashing to prevent moisture intrusion. It would be desirable to
have a product and window installation method, which would
integrate the window-wall interface in window systems using windows
without flanges.
[0006] In addition, applied rigid flanges, which may or may not be
integral to the window can be problematic in sealing the
window-wall interface due to bending or cracking of the flange, or
poor joint sealing. It would be desirable to have a product and
window installation method that would obviate the need for rigid
flanges.
SUMMARY OF THE INVENTION
[0007] This invention is a self-adhering flange material for
sealing interfaces between fenestration products and walls,
comprising at least one top coversheet and at least one bottom
coversheet with a pressure-sensitive adhesive layer sandwiched
between the two coversheets, wherein the coversheets occupy an
appreciable width of the flange but do not extend across the entire
width of the flange and thereby are offset with respect to each
other thereby providing opposing first and second exposed surfaces
of the pressures sensitive adhesive layer.
[0008] In another embodiment, the invention relates to a
self-adhering flange material comprising:
[0009] an elongated nonporous flexible sheet having top and bottom
major surfaces and a first edge and a second edge defining a width
therebetween;
[0010] a top pressure-sensitive adhesive layer adhered to the top
surface of the flexible sheet along the first edge over a portion
of the width of the flexible sheet; and
[0011] a bottom pressure-sensitive adhesive layer adhered to the
bottom surface of the flexible sheet along the second edge over a
portion of the width of the flexible sheet.
[0012] This invention also encompasses various methods for
installing fenestration products into walls using the subject
flange materials.
Definitions
[0013] The term "flanged windows" refers to windows, doors, or
other fenestration products that include a flange or nailing fin
intended to cover any space between the window frame and the rough
opening in the wall. The flange or fin may be integral to the
fenestration product, or may be applied.
[0014] The term "non-flanged windows" refers to windows that do not
include a flange intended or nailing fin to cover the space between
the window frame and the rough opening in the wall.
[0015] The term "brickmold frame" refers to decorative trim
attached to or integral to the window frame that covers any space
between the window frame and the opening in the wall into which the
window is installed. The term "brickmold window" refers to a window
having a brickmold frame.
[0016] The term "window jamb" or "jamb" refers to the side of the
window frame. The window jamb is typically vertical.
[0017] The term "window sill" or "sill" refers to the bottom
portion of the window frame. The window sill is typically
horizontal.
[0018] The term "window head" or "head" refers to the top portion
of the window frame. The window head is typically horizontal.
[0019] The term "window" refers to any window, door, or other
fenestration products intended to be installed in an opening in a
wall.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate, without
limitation, the presently contemplated embodiments of the invention
and, together with the description, serve to explain the principles
of the invention.
[0021] FIG. 1 is a perspective cross-sectional view of one
embodiment of the flange material of the invention.
[0022] FIG. 2 is a cross-sectional view of another embodiment of
the flange material of the invention.
[0023] FIG. 3 is a cross-sectional view of another embodiment of
the flange material of the invention.
[0024] FIGS. 4 through 6 are perspective views useful in
illustrating the method of installing the flange material of the
invention on a non-flanged window frame, and subsequently
installing the window in an opening in a wall.
[0025] FIG. 7 is a cross-sectional view of yet another embodiment
of the flange material of the invention.
[0026] FIGS. 8 through 13 are perspective and side views of a
brickmold window frame useful in illustrating the method of
installing the window into an opening in a wall in such a way that
the flange material of the invention is formed as the window is
installed.
[0027] FIGS. 14 through 17 are perspective and plan views of a
brickmold window frame useful in illustrating the method of
installing the window into an opening in a wall using the flange
material of the invention to seal the window to the wall.
[0028] FIG. 18 is a cross-sectional view of yet another embodiment
of the flange material of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The flange material of this invention can be applied to all
non-flanged windows, brickmold windows and windows having applied
flanges to form a self-adhering flange that provides a means for
achieving a continuous moisture seal integration of the window-wall
interface. The flange additionally prevents moisture from entering
around fasteners, such as nails, that penetrate the flange material
and the window frame. As further described below in various
installation methods, pieces of flange material are positioned at
the window wall interface to form the flange. Upon installation,
the flange typically comprises a head piece of flange material
positioned at the top of the window-wall interface and two jamb
pieces of flange material positioned at the sides of the window
wall interface.
[0030] As depicted in FIG. 1, one embodiment of flange material 10
is an elongated laminate structure formed from at least one top and
one bottom coversheet (12 and 16, respectively) with a
pressure-sensitive adhesive layer 14 sandwiched between the two
coversheets. The coversheets occupy an appreciable width of the
flange but do not extend across the entire width of the flange and
thereby provide an apparent overlap with respect to each other.
Release papers 18 that cover the adhesive surfaces are not
necessarily required but aid considerably in handling and during
installation as will be presented in the various installation
methods to be described below. For purposes of convenience in
designating portions of the flange material in FIG. 1, the width of
one release paper is labeled as 10a and the portion of the second
and opposite release paper is designated as 10c. A portion 10b can
designate the extent of overlap between the first and second
coversheets in the width of the flanges.
[0031] If desired, the flange material can be fabricated in the
field. For example, flange material 20 as shown in FIG. 3 can be
fabricated by contacting an elongated portion of the adhesive
surfaces 22 of two pieces of flexible self-adhering flashing 21
together such that the flashing pieces overlap as represented by
portion 20b and an elongated portion of each of the two adhesive
surfaces as represented by 20a and 20c remain exposed. When
fabricated in the field, the flange material of the invention can
utilize, for example, flexible self-adhering flashing material that
will provide a durable moisture seal to the window-wall interface.
Various sizes and styles of suitable flashing material are DuPont
FlexWrap.TM. flexible flashing or DuPont StraightFlash.TM.
flashing, available from E.I. du Pont de Nemours and Company,
Wilmington, Del. (hereafter DuPont).
[0032] There is a method for installing a non-flanged window into a
wall opening whereby the interface between the window and the wall
is sealed using either of the flange materials described above in
FIG. 1 or 3. The method described as follows uses the flange
material of FIG. 1 and as illustrated in FIGS. 4-6, however it is
recognized that the structure depicted in FIG. 1 is not intended to
limit the steps of the method. It is further noted that FIG. 4
includes notation indicating whether the view is from inside or
outside of the structure. These notations are used in FIG. 4 and
other figures as matter of convenience. The steps of the method are
as follows: [0033] a) adhering a first adhesive surface as
represented by 10a of a piece of the flange material (the "head
piece" 111) to the outer surface of the head 121 of the window and
extending to the outer surface of the upper portion of each jamb of
the window; [0034] b) adhering a first adhesive surface as
represented by portion 10c of a second piece of the flange material
(the "jamb piece" 112) to the outer surface of the entire length of
each jamb 122 of the window, thereby overlapping the head piece
adhered to each jamb in step (a) as shown in FIG. 4; [0035] c)
installing and securing the window 114 in the opening of wall 250,
per normal procedures, such that the head of the window is located
at the top of the wall opening and the remaining unadhered
portions, as represented, for example, by portion 10c in FIG. 1 of
the head piece and jamb pieces of step (a) and step (b) extend
outward from the wall as shown in FIG. 5; [0036] d) adhering the
remaining unadhered portions of the pieces of flange material of
step (a) and step (b) to the wall above the head of the window and
adjacent each jamb of the window such that the head piece covers an
upper portion of each of the jamb pieces in a shingled manner as
shown in FIG. 6.
[0037] The window is thereby sealed to the surrounding wall and any
water that contacts the outer surface of the head piece will be
directed downward below the top of the jamb pieces so that there is
virtually no opportunity for the water to penetrate the window-wall
interface.
[0038] Another embodiment of the invention is useful for sealing
brickmold windows. According to this embodiment as shown in FIG. 7,
the flange material 30 is an elongated material having a coversheet
32 on one surface thereof and a pressure sensitive adhesive 34 on
the other surface thereof. The pressure sensitive adhesive surface
is covered with release paper 36 that has perforations 37 extending
along substantially parallel lines that are also substantially
parallel with the lengthwise edges of the flange. As previously
note in embodiments above, release papers are not necessarily
required but aid considerably in handling and during installation.
The release paper covers three elongated portions of the adhesive
surface (30a, 30b and 30c), the portions defined by the
perforations in the release paper. It is noted that the number of
perforations and the resultant defined portions can vary as may be
required for proper installation. The flange of this embodiment is
suitable for the installation of windows having brickmold
frames.
[0039] One method for installing a brickmold window into a wall
opening whereby the interface between the window and the wall is
sealed is described in the following steps as Brickmold Method 1.
This method may also be applied to windows having integral and
applied flanges. The window is sealed by means of a flange material
as shown in FIG. 7 having release paper perforated along two
length-wise lines. Although the method will be described by
reference to FIG. 7, there is no intent to limit the steps of the
method. In this method, the flange is formed as the window is
installed. This method is illustrated in FIGS. 8-13. [0040] a) A
first adhesive surface exposed by removing portion 30a of release
paper 36) of a piece of flange material ("head piece" 211) is
adhered to the upper surface 221 of the window frame such that the
line formed between portion 30a and the remaining width-wise
portion of the head piece (represented by 30b and 30c together) is
positioned in the corner between the upper surface of the window
frame and the back surface 223 of the brickmold frame of the
window. The presence of the release paper on the remaining
width-wise portion of the flashing provides a straight edge,
facilitating positioning the flange material in the corner. [0041]
b) A second adhesive surface exposed by removing the central
portion 30b of release paper 36, of the head piece is adhered to
the back surface 223 (i.e., the interior-facing side) of the
brickmold frame of the window. The remaining edge portion 30c of
release paper remains adhered to and covering the corresponding
adhesive surface. [0042] c) As shown in FIG. 8, a cut is made in
the head piece 211 in the corners between each window jamb and the
back surface of the brickmold frame on both sides of the window
frame and the head piece of flashing on both sides of the window
frame is adhered to the outside (upper) surface 222 of each window
jamb. [0043] d) As shown in FIG. 9, a first adhesive surface
exposed by removing portion 30a of release paper 36 of another
piece of self-adhering flashing material (the "jamb piece" 212) is
adhered to the outer surface 222 of one of the window jambs such
that the line formed between portion 30a and the remaining
width-wise portion of the jamb piece (represented by 30b and 30c
together) is positioned in the corner between the outer surface of
the window jamb and the back surface of the brickmold frame.
Preferably, the top of the jamb piece 212 should not extend more
than about one inch above the window head. [0044] e) A second
adhesive surface exposed by removing the central portion 30b of
release paper 36, of the jamb piece is adhered to the back surface
223 (i.e., the interior-facing side) of the brickmold frame. The
remaining edge portion 30c of release paper remains adhered to the
corresponding adhesive surface. [0045] f) As shown in FIG. 9, a cut
is made in the jamb piece directly above the adhered portion 30a
along the outside corner between the outer surface of the jamb and
the outer surface of the head, and the portion of the jamb piece
above the cut is adhered to the top surface 221 of the window head.
[0046] g) Steps (d)-(f) are repeated on the other window jamb using
a separate jamb piece of flange material (i.e., a third piece of
flange material). A side view of the window frame with the
installed pieces of flange material is shown in FIG. 10. [0047] h)
As shown in FIG. 11, the window frame is then installed in the
opening in the wall 250 per the window manufacturer's recommended
procedure. As shown in FIG. 12, the remaining edge portion 30c of
release paper 36 is intact on each piece of flange material so that
the remaining release paper is facing out away from the wall (on
the outside surface of the wall) surrounding the window. [0048] i)
The remaining, third adhesive surface of one of the jamb pieces is
exposed along one side of the window by removing the remaining
portion of release paper. [0049] j) As shown in FIG. 13, the
adhesive surface of a covering piece of flashing 300 is adhered
directly to the exposed third adhesive surface and the adjacent
wall surface thereby forming a strong adhesive-to-adhesive seal
(forming the flange) and sealing one side of the window to the
wall. [0050] k) Steps (i)-(j) are repeated on the other side of the
window. [0051] l) Optionally, the remaining release paper is
removed from the head piece and a drip cap is installed over the
top of the window frame, and then covered by a piece of covering
flashing overlapping the top of the drip cap and the wall. [0052]
m) If a drip cap is not used, the remaining release paper is
removed from the head piece and a covering piece of flashing is
adhered overlapping the top of the head piece and the wall.
[0053] Another method for installing a brickmold window frame into
a wall opening is designated as Brickmold Method 2, whereby the
interface between the window and the wall is sealed includes the
following steps. Again, this method may be used to install windows
having integral and applied flanges. In this method, the flange is
prepared first, and then attached to the window before the window
is installed. The flange material as depicted in FIG. 2 may be used
advantageously in this method. For purposes of convenience in
designating portions of the flange material in FIG. 2, the width of
one release paper is labeled as 18a and 18a' and the portion of the
second and opposite release paper is designated as 18c and 18c'. A
portion 18b can designate the extent of offset or overlap between
the first and second coversheets in the width of the flanges.
Further, it is recognized that the structure depicted in the figure
is not intended to limit the steps of the method.
[0054] The method for installing a brickmold window frame using the
aforementioned flange is described as follows and illustrated in
FIGS. 14-17. [0055] a) A length of the flange material (the "head
flange" 311), advantageously several inches longer than the width
of the brickmold frame, is folded along one of the perforations 19
in the release paper to expose a line of adhesive as between 18a
and 18a'. [0056] b) The line of adhesive is positioned in the
corner along the top of the window frame between the back surface
323 of the brickmold frame and the upper surface 321 of the window
head. [0057] c) The release paper 18a is removed from the portion
of the head flange in contact with the back surface of the
brickmold frame and adhered to the back surface of the brickmold
frame. [0058] d) As shown in FIG. 14, the head flange is cut at the
outer corners between the upper surface of the window head and the
outer surfaces of the jambs, and folded down on the back surface of
the brickmold frame. [0059] e) Another length of the flange (the
"jamb flange" 312), advantageously a few inches longer than the
height of the brickmold frame is folded along one of the
perforations 19 in the release paper to expose a line of adhesive
as in step (a). [0060] f) As in FIG. 15, the line of adhesive on
the jamb flange is positioned in the corner along one side of the
window frame between the outer surface 322 of the jamb and the back
surface 323 of the brickmold frame so that the flange slightly
overlaps the head flange 311 and extends below the window frame.
[0061] g) The release paper 18a is removed from the portion of the
jamb flange in contact with the surface 322 of the jamb and adhered
thereto. The release paper 18a' is removed from the portion of the
jamb flange in contact with the back surface 323 of the brickmold
frame and adhered to the back surface of the brickmold frame.
[0062] h) As shown in FIG. 15, the jamb flange is cut at the outer
corners between the lower surface of the window frame and the outer
surface of the jamb and folded onto the back surface of the
brickmold frame. [0063] i) Steps (e) through (h) are repeated to
install a separate jamb flange on the other side of the window as
shown in FIG. 15. [0064] j) The window is installed in a wall
opening per the window manufacturer's recommended installation
procedure. The installed window is shown from the outside in FIG.
16. [0065] k) The remaining release paper 18c and 18c' is removed
from the head flange and the jamb flanges and the exposed adhesive
surfaces are adhered to the outside wall surface. [0066] l)
Optionally, most of the exposed adhesive on the head flange is cut
away, leaving a small amount of adhesive remaining along the edges
of the flange. [0067] m) Self-adhering flexible flashing material
310 is adhered over the intersection of the head and jamb flanges
as shown in FIG. 17.
[0068] The flange material may be applied to the window during
window fabrication. In this case, the window could be provided as
it is at the end of step (i) above, and the remaining steps (j)
through (m) would be carried out, for example, by the installers at
a building site.
[0069] In each of the previous embodiments, the pressure sensitive
adhesive used in the flange material of the invention can be butyl
rubber adhesive, bituminous adhesive, acrylic, or combinations
thereof (layers or blends). Additionally, the pressure sensitive
adhesive can be neoprene, polymers based on epdm (ethylene
propylene diene monomer) or other adhesives generally used in
construction applications. The thickness of the pressure sensitive
adhesive is between about 15 mils (0.38 mm) and 25 mils (0.64 mm).
The pressure sensitive adhesive provides a watertight seal around
fasteners that penetrate the flange material.
[0070] The material used as the coversheet material in the flange
material of the invention can be any nonwoven sheet, film, coated
paper, coated nonwoven sheet or nonwoven-film laminate suitable for
use in a flexible flashing material. The coversheets can be
polyolefin plexifilamentary film-fibril sheet, available under the
tradename Tyvek.RTM. from DuPont.
[0071] Alternatively, the coversheet of the flange can be made from
a relatively rigid material such as metal or plastic formed into
the required shape for the various installations noted above. The
rigid material would have a pressure-sensitive adhesive layer
applied to provide attachment to the windows and building
structure.
[0072] FIG. 18 illustrates another embodiment of the flange
material 40 of the invention. According to this embodiment, flange
material 40 is an elongated laminate structure formed from an
elongated nonporous flexible sheet 42 having top and bottom major
surfaces and a width between a first edge 42A and a second edge
42B. A top pressure-sensitive adhesive layer 44 is adhered to the
top surface of the elongated nonporous flexible sheet along edge
42A over a portion of the width thereof, and a bottom
pressure-sensitive adhesive layer 46 is adhered to the bottom
surface of the elongated nonporous flexible sheet along edge 42B
over a portion of the width thereof. The top and bottom
pressure-sensitive adhesive layers are therefore offset with
respect to each other in terms of width, and are opposing top and
bottom exposed surfaces of pressure-sensitive adhesive. The
opposing top and bottom pressure-sensitive adhesive layers occupy
an appreciable width of the flange but do not extend across the
entire width of the flange. The opposing top and bottom
pressure-sensitive adhesive layers can each have a width of half
the total width of the flange, or a width of greater than half the
total width of the flange, or a width of less than half the total
width of the flange. The opposing top and bottom pressure-sensitive
adhesive layers can have equal or unequal widths. The top and
bottom pressure-sensitive adhesive layers are covered with optional
release papers 48. The nonporous flexible sheet 42 can be any
nonporous sheet material including nonwoven sheet, film, coated
paper, coated nonwoven sheet or nonwoven-film laminate suitable for
use in a flexible flashing material, or a nonporous relatively
rigid material such as sheet metal or plastic. By "nonporous" is
meant that the sheet does not allow liquid water to penetrate from
one side to the other.
[0073] The method for installing a non-flanged window into a wall
opening whereby the interface between the window and the wall is
sealed using the flange 40 according to this embodiment of the
invention is similar to that described above and is illustrated in
FIGS. 4-6. The method for installing a brickmold window frame into
a wall opening whereby the interface between the window and the
wall is sealed using the flange 40 according to this embodiment of
the invention is similar to that described above as "Brickmold
Method 2" and is illustrated in FIGS. 14-17.
[0074] As will be appreciated by the skilled artisan, although
reference is made herein to adhering the flange material to a wall,
it is also expected that the flange material of the invention can
be adhered to a wall covered by a weather resistive barrier
sheet.
[0075] It may be further appreciated that the flange can likewise
include a sill piece appropriately installed to form a total
barrier system around the wall-window interface to further preclude
moisture intrusion.
Test Methods
[0076] The installations were tested for air leakage using ASTM E
283.
[0077] The installations were tested for water resistance using
ASTM E 331.
[0078] The durability of the selected installations was then
evaluated by subjecting the walls first to thermal cycling and
re-testing for air leakage and water resistance, and secondly by
subjecting the walls to wind load using ASTM E 330 for one hour in
the positive direction and one hour in the negative direction, and
then re-testing for water resistance. The thermal cycling of
exterior walls was conducted according to AAMA (American
Architectural Manufacturers Association) 501.5. Standard Test
Method for Exterior Windows, Curtain Walls and Doors for Water
Penetration using Dynamic Pressure.
EXAMPLES 1-4
[0079] A series of laboratory tests was designed to determine water
resistance, air leakage resistance, and durability of installation
using different methods and different flashing materials.
Installations were carried out installing JELD-WEN.RTM. double hung
wood windows (available from JELD-WEN, Klamath Falls, Oreg.) with
applied brickmold frames into wood frame walls. The testing was
conducted in two phases. First, air and water resistance of window
installations were evaluated. Secondly, air and water resistance
were evaluated after thermal cycling followed by wind loading.
[0080] Four test walls were constructed for the testing. All four
walls were constructed using Spruce-Pine-Fir nominal 2 in.times.4
in lumber and covered with oriented strand board sheathing applied
to 16 in on center studs. All walls were 5 ft wide by 7 ft 6 in
high and contained one brickmold window unit. The window used in
each case was a JELD-WEN.RTM. wood double hung window with applied
brickmold. The windows were each 2 ft 10 in wide.times.3 ft 4 in
high. Four different flashing installations methods were utilized
as described below in Examples 1-4.
Example 1
[0081] A wall unit as described above was wrapped with Tyvek.RTM.
HomeWrap.RTM. (available from E.I. du Pont de Nemours and Company,
Wilmington, Del.) prior to installing the window. DuPont
FlexWrap.TM. (available from E.I. du Pont de Nemours and Company)
was installed on the sill per normal installation procedures
recommended by the manufacturer and an adhesive foam tape was
installed under the DuPont FlexWrap.TM. to form a back dam.
[0082] In this installation, 4 in wide DuPont StraightFlash.TM.
(available from E.I. du Pont de Nemours and Company) flashing
having three perforated sections of release paper was the primary
part of the flange material system. Head and jamb pieces of DuPont
StraightFlash.TM. were installed on the head and sides of the
window prior to installation of the window into the rough opening,
using the above-described Brickmold Method 1.
[0083] With the final pieces of the release liner still covering
the adhesive on the flashing installed on the brickmold window
frame, the window was installed per manufacturer's recommended
procedure. Next, the final pieces of release paper remaining on the
window were removed, exposing a strip of butyl adhesive on the
exterior of the wall adjacent the window on each side. Next,
another covering piece of 4 in wide DuPont StraightFlash.TM.
flashing with similarly perforated release paper was applied over
this as follows. One of the release papers along the edge of the
flashing was removed, and the edge of the exposed butyl was placed
flush adjacent the corner between the outer surface of the
brickmold frame and the exterior surface of the wall such that the
edge of the butyl touched the inside of the corner. Once the butyl
edge adhered to the inside corner, the rest of the exposed butyl
strip was laid down onto the already installed, exposed butyl strip
adjacent the window. This created a very strong butyl to butyl
seal. This seal created the flange material.
[0084] The procedure for installing a covering piece of flashing
was repeated on other side of the window.
[0085] Finally, the flange material system was completed and
integrated into the wall by removing the last two strips of release
paper from the covering pieces of flashing and laying the exposed
butyl adhesive smoothly onto the exterior wall surface to complete
the seal of the window-wall interface.
[0086] A metal drip cap was installed and the DuPont
StraightFlash.TM. was installed over the drip cap followed by a
flap of the previously installed Tyvek.RTM. HomeWrap.RTM.. The
Tyvek.RTM. HomeWrap.RTM. was taped over the drip cap and tape was
applied in a shingled fashion to avoid leakage.
[0087] Air and water resistance of this window installation are
given in Table 1. Air and water resistance after thermal cycling
and water resistance after wind loading of this window installation
are given in Table 2.
Example 2
[0088] A wall unit as described above was wrapped with Tyvek.RTM.
HomeWrap.RTM. prior to installing the window. DuPont FlexWrap.TM.
was installed on the sill and an aluminum angle was installed under
the DuPont FlexWrap.TM. to serve as a back dam.
[0089] The flange material was prefabricated by attaching two 4 in
wide pieces of DuPont StraightFlash.TM. together. The flange
material was installed on the window at the window head and then
the jambs.
[0090] The window was installed using Brickmold Method 2 and the
final pieces of release papers were removed and adhered to the
Tyvek.RTM. HomeWrap.TM.. The remaining exposed butyl on the top
flange was cut away and the remaining exposed flange area was
covered with a 6 in to 8 in long piece of 4 in wide DuPont
StraightFlash.TM..
[0091] Air and water resistance of this window installation are
given in Table 1. Air and water resistance after thermal cycling
and water resistance after wind loading of this window installation
are given in Table 2.
Example 3
[0092] A wall unit as described above was wrapped with Tyvek.RTM.
HomeWrap.RTM. after the window was installed. DuPont FlexWrap.TM.
was installed on the window sill and an aluminum angle was
installed under the DuPont FlexWrap.TM. to serve as a back dam. The
flange material was prefabricated by attaching two 4 in wide pieces
of DuPont StraightFlash.TM. together. The flange material was
installed on the window jambs. At the head of the window, a 4 in
wide piece of DuPont StraightFlash.TM. was adhered to the top of
the window frame and the back of the decorative brickmold with the
final piece of release paper facing out above the decorative
brickmold using Brickmold Method 2.
[0093] The window was installed, then the rest of the release paper
on the flange material was removed and the flange material was
adhered to the wall. A drip cap was installed at the head of the
window and a piece of DuPont StraightFlash.TM. was placed over the
drip cap. Then the wall was wrapped with Tyvek.RTM. HomeWrap.RTM.
and the joints were taped.
[0094] Air and water resistance of this window installation are
given in Table 1. Air and water resistance after thermal cycling
and water resistance after wind loading of this window installation
are given in Table 2.
Example 4
[0095] The window was installed into a wall unit as in Example 2
(that is using Brickmold Method 2) except that the wall unit was
wrapped with Tyvek.RTM. HomeWrap.RTM. after the window was
installed. The flange material for the head was fabricated in a "T"
configuration by cutting a smaller piece of flashing the width of
the window frame and centering it on a relatively larger piece of
flashing.
[0096] Air and water resistance of this window installation are
given in Table 1. Air and water resistance after thermal cycling
and water resistance after wind loading of this window installation
are given in Table 2. TABLE-US-00001 TABLE 1 Air Air Air Air Air
Air Infiltration Infiltration Infiltration Exfiltration
Exfiltration Exfiltration Water Water Ex. at 0.56 psf at 1.57 psf
at 6.24 psf at 0.56 psf at 1.57 psf at 6.24 psf Test at Test at No.
(cfm/ft.sup.2) (cfm/ft.sup.2) (cfm/ft.sup.2) (cfm/ft.sup.2)
(cfm/ft.sup.2) (cfm/ft.sup.2) 0.56 psf 1.56 psf 1 0.33 0.60 1.28
0.40 0.73 1.70 Pass Pass 2 0.29 0.53 1.15 0.33 0.62 1.37 Pass Pass
3 0.16 0.28 0.65 0.13 0.26 0.63 Pass Pass 4 0.09 0.18 0.45 0.13
0.26 0.67 Pass Pass
[0097] TABLE-US-00002 TABLE 2 Air Air Air Air Air Air Infiltration
Infiltration Infiltration Exfiltration Exfiltration Exfiltration
Water Water Static Static Water Water Ex. at 0.56 psf at 1.57 psf
at 6.24 psf at 0.56 psf at 1.57 psf at 6.24 psf Test at Test at
Load at Load at Test at Test at No. (cfm/ft.sup.2) (cfm/ft.sup.2)
(cfm/ft.sup.2) (cfm/ft.sup.2) (cfm/ft.sup.2) (cfm/ft.sup.2) 0.56
psf 1.56 psf +10.42 psf -10.42 psf 0.56 psf 1.56 psf 1 0.39 0.74
1.69 0.34 0.62 1.30 Pass/ Pass/ Pass Pass Pass/ Pass/ Leak.sup.1
Leak.sup.2 Leak.sup.1 Leak.sup.2 2 0.36 0.63 1.40 0.32 0.54 1.15
Pass/ Pass/ Pass Pass Pass/ Pass/ Leak.sup.1 Leak.sup.1 Leak.sup.1
Leak.sup.1 3 0.14 0.26 0.63 0.20 0.28 0.65 Pass Pass/ Pass Pass
Pass Pass/ Leak.sup.1 Leak.sup.1 4 0.13 0.26 0.67 0.09 0.18 0.45
Pass Pass Pass Pass Pass Pass/ Leak.sup.3 .sup.1Water laying on
front edge of sill plate. .sup.2Water percolating at right side of
bottom corner of sill plate. .sup.3Water entered at the right side
interior window sill leg.
In both Tables 1 and 2 cfm means cubic feet per minute and psf
means pounds per square foot.
[0098] None of the leaks observed involved the installed flange
material of the invention. None of the leaks were considered to be
significant. In all examples, even after static load testing, the
water did not get past the installed flange material of the
invention to the interior plane of the installed window. These
results demonstrate the durability of the flange in use.
* * * * *