Abstract:
A finishing member for masonry walls allows for simple installation and accurate placement of caulking around windows and doors in cavity wall construction. This invention accommodates a wide variety of window or door frame profiles, particularly those having an outwardly directed channel such as so called J-channel frames, for the detailing and finishing work required for proper installation of a window or door into a masonry veneer or cavity wall construction without requiring a highly skilled and labor intensive installation.

Description:
[0001]     This is a continuation in part of U.S. patent application Ser. No. 10/602,198 filed Jun. 24, 2003, which in turn claims the benefit of U.S. Provisional Patent Application Ser. No. 60/391,333, filed Jun. 25, 2002, each of which is hereby incorporated by reference entirely. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     This invention relates to masonry veneer or cavity wall construction and, more particularly, to devices used in association with window and door installations in a veneer/cavity wall system for proper transition between the window or door installation and the masonry veneer.  
         [0003]     Wall systems having a masonry exterior are typically constructed of at least one vertical layer of masonry and at least a second vertical layer of a material forming a back-up system. The back-up system may be constructed of lumber, light gauge steel studs or of a concrete masonry unit. The masonry and back-up system are typically bonded together by horizontal metallic ties spaced apart vertically. A space is often provided in such wall systems (e.g., cavity wall systems) between the masonry and back-up system for moisture drainage. Normally, a 1 to 2 inch air space between the masonry and back-up system is adequate to provide drainage. Insulation may also be placed in the space to improve the energy efficiency of masonry buildings.  
         [0004]     Masonry veneer, and cavity wall construction in general, has many advantages and is commonly utilized in residential and commercial construction. Problems often arise during construction, however, in maintaining a proper transition between the wall structure and window, door and other openings or discontinuities in the wall. For example, the dimensioning of the window or door frame installed in the wall is frequently different and incompatible with the thickness, geometry and dimensions of the masonry veneer or cavity wall construction. Caulk is often used along the wall jamb and header in an effort to provide a water tight seal and aesthetic transition to the window or door frame.  
         [0005]     One example of a window or door frame is called a J-channel frame which has an outwardly directed open channel along the jamb portions of the frame. The J-channel frame is specifically designed for use on siding clad exterior walls and not masonry exterior walls. The often rough cut ends of the siding are inserted into and concealed within the channel of the frame to present a neat and finished appearance at the transition from the wall to the frame. Nevertheless, the J-channel frame is often used with masonry walls for a variety of reasons. In such cases, the channel is vacant and must be flashed for a proper installation and must receive a backer material for the effective placement of caulking and sealant.  
         [0006]     However, due to the incompatibility of the J-channel frame with the masonry veneer, effective and aesthetic caulk application is nearly impossible. As a result, the detailing and finishing work required for proper installation of a window or door into a masonry veneer or cavity wall construction is typically very labor intensive, non-uniform and highly dependent upon the skill and experience of the particular contractor or tradesman performing the installation particularly when a J-channel is used. Because of the importance and wide spread popularity of such masonry structures, a better method for proper and consistent installation of windows and doors in such construction is needed.  
       SUMMARY OF THE INVENTION  
       [0007]     This invention provides a solution to these and other problems in the art and allows an efficient and reliable installation for a water tight and an aesthetically pleasing transition from surrounding the window or door to the masonry veneer. Generally, in one embodiment this invention includes a backer unit or finishing member installed adjacent the J-channel window frame or door frame to provide a proper transition from the frame to the masonry wall structure. In one embodiment, the finishing member has a generally L-shaped configuration with a first leg of the member being mounted in the cavity defined by the channel of the J-channel frame. The second leg of the finishing member projects generally perpendicularly from the first leg and between the forward edge of the window or door J-channel frame and the masonry outer wall. In one embodiment, the first leg is frangibly joined to the second leg by a perforated joint for selective separation of the second leg from the first leg.  
         [0008]     After the finishing member is installed adjacent to the frame and the inner and outer wall construction is complete, the terminal end portion of the second leg is removed by being torn along the frangible joint. After the terminal end portion is removed, a recess is exposed at a juncture with the frame and the remainder of the finishing member. A bead of caulk or similar finishing material is applied in the recess to provide a smooth and aesthetically pleasing transition from the J-channel frame to the masonry wall. Additionally, the juncture between the frame and the wall is sealed by the caulk bead to inhibit and/or prevent the entry of moisture or other foreign material and the void in the J-channel is substantially filled.  
         [0009]     Advantageously, the finishing member is readily adaptable for use with a wide variety of window and door J-channel or other frame designs and construction specifications without requiring highly skilled or specialized installation and construction techniques. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]     The objectives and features of the invention will become more readily apparent from the following detailed description taken in conjunction with the accompanying drawings in which:  
         [0011]      FIG. 1  is an exemplary view of a window installation in a masonry wall;  
         [0012]      FIG. 2  is a perspective cross sectional view taken along line  2 - 2  in  FIG. 1  of a transition between the wall jamb and a J-channel window frame according to one embodiment of this invention;  
         [0013]      FIG. 3  is a cross sectional plan view taken along line  2 - 2  of  FIG. 1  showing the transition between the wall jamb and window frame shown in  FIG. 2 ; and  
         [0014]      FIG. 4  is a perspective view of a finishing member according to one embodiment of this invention adapted to be used in the frame of  FIGS. 1-3 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0015]     Referring to  FIG. 1 , an exemplary window installation  10  in a masonry wall  12  is shown. The window installation  10  includes a perimeter window frame  14 , one or more window panes  16 , and a window opening  18  in the wall defined by a pair of jambs  20  and a header  22  above and a sill  24  below the window frame  14 . Although one example of a window installation is shown in  FIG. 1 , this invention is readily applicable for a variety of closure elements in openings in the wall such as other types of window installations, frame designs, doors and the like.  
         [0016]     As shown more clearly in  FIGS. 2-3 , the masonry wall  12  for the exterior of a building, in one embodiment, is comprised of an outer wall of masonry or brick veneer  26  and an insulated interior wall  28 . The brick veneer outer wall  26  is constructed from a plurality of bricks or blocks  30  arranged in a vertical pattern. Each brick  30  is of a substantially rectangular shape having a uniform length, height and depth. The brick veneer  26  is built up by placing one layer of bricks  30  over another layer, with the upper layer vertically offset from the lower layer by a distance of approximately one-half the length of a brick  30 . Thus, as shown in  FIG. 1 , a brick  30  on one layer is positioned directly over the space between two bricks  30  on the layer immediately beneath it. The spaces between adjacent bricks  30  and between adjacent layers of bricks are filled with mortar  32 . Alternatively, the veneer  26  may be stone or other masonry components.  
         [0017]     The interior wall  28  includes wood framing studs  34 , dry wall  36 , and outer sheathing material  38 . Other materials may be used as is well known in the art. For example, a liner board (not shown) as disclosed in U.S. patent application Ser. No. 10/417,761 filed Apr. 17, 2003 and hereby incorporated by reference, may be used on the outer sheathing material  38 . In any event, the building wall  12  is constructed so that there is a small cavity or airspace A between the back side of the brick veneer  26  and the outer surface of the interior wall  28 . The airspace A between the back side of the brick veneer  26  and the surface of the interior wall  28  is usually at least about one to two inches deep, although the exact dimension may vary depending upon the nature of the construction.  
         [0018]     Referring to  FIGS. 2-4 , a first embodiment of a finishing member  40  is shown installed in the installation  10  to provide a proper transition from the window frame  14  to the wall  12 . The member  40  is installed along the jambs  20  of the window opening  18  in cooperation with the corresponding portions of the window frame  14 . As shown in  FIGS. 2 and 3 , a nailing flange  46  is typically provided from the portion of the window frame  14  adjacent the jamb  20  and extending to the outer surface of the inner wall  28 . Nails or other mechanical fasteners (not shown) are inserted through the nailing flange  46  into the sheathing material  38 , thereby securing the window frame  14  in position.  
         [0019]     The cross-sectional configuration of the J-channel frame  14  includes an outwardly directed open channel  48  joined to the proximal end of the nailing flange  46  along the jamb portion. As previously stated, the J-channel frame  14  and the outwardly open channel  48  are typically intended for use with siding clad walls in which the rough cut edges of the siding are inserted into the open channel  48  and concealed therein for a finished and aesthetically pleasing appearance to the installation. Nevertheless, commonly the J-channel frame design is utilized with masonry walls  12  and previously the channel  48  was improperly flashed or sealed or not filled at all.  
         [0020]     The channel  48  is generally U-shaped in which a bight portion  50  of the channel  48  separates a pair of channel side walls  52 ,  54 . A forwardmost surface  56  of the J-channel frame  14  is separated from the adjacent channel side wall  54  by a connecting leg  58  of the frame  14  as shown in  FIGS. 2-3 .  
         [0021]     In one embodiment, the finishing member  40  is generally L-shaped, in which a first leg  42  of the member  40  is inserted into the channel  48  of the frame  14 , and a second leg  44  of the member  40  projects generally perpendicular to the plane of the wall  12  and is juxtaposed to the outer wall or veneer  26  at the window opening  18  to provide a transition from the window frame  14  to the wall  12 . Commonly, a standard backer rod is used to fill a gap between a frame and the wall  12  and provide a surface on which caulk or other sealant can be applied to provide a sealed transition between the standard frame and the wall  12 . However, the gap and spacing between the J-channel frame  14  and the wall  12  is significantly larger, deeper (on the order of ⅛ to 1/4 inch or greater) and of a geometry that is not compatible for standard backer rod materials. The standard backer rod materials would not be secure in the gap nor provide a stable backing for the application of the caulk or sealant. Therefore, a proper transition from the window frame  14  to the wall  12  that is effectively sealed against wind, rain, and other elements as well as aesthetically pleasing is often difficult if not impossible. The wide variety, sizes and configurations of window frames  14  available from various manufacturers increases the complexity and difficulty with providing a proper transition from the window frame  14  to the wall  12 . Nevertheless, the finishing member  40  of this invention provides a solution.  
         [0022]     The finishing member  40  also allows for expansion and contraction of the window frame  14  relative to the wall  12  during a variety of climatic conditions. In one embodiment, the member  40  is made of closed cell foam and bends, contracts, expands or deflects to accommodate of the wall  12  relative to the frame  14 . In combination with the beads of caulk as appropriate, the finishing member  40  of this invention serves as a backer material and provides for a durable, reliable, easily installed and sealed transition from the window frame  14  to the wall  12 . In certain other embodiments, the member  40  is extruded from a variety of thermoplastic or other polymeric materials. Alternatively, the member  40  may be aluminum or other materials resistant to rust and weather.  
         [0023]     In one embodiment of the invention, the leg  42  of the member  40  is approximately 7/8″ in length and ⅝″ thick; whereas the leg  44  is approximately 5/8″ in length and ¼″ thick, although other dimensions of the member  40  are possible within this invention as compatible with the frame  14  configurations and sizes.  
         [0024]     Referring to  FIG. 4 , a perspective view of the finishing member  40 , according to this invention, is shown. In this embodiment, the member  40  is generally L-shaped in which the first leg  42  is adapted to mount to the frame  14  and be inserted in the channel  48 , and the second leg  44  of the member  40  projects generally perpendicular to provide a transition from the frame  14  to the wall  12 . The second leg  44  is constructed of closed cell foam and includes a terminal end portion  60  joined to a remainder of the member  40  by a frangible connection  62  such as a series of perforations to provide for the convenient and easy removal of the terminal end portion  60 . The second leg  44  may include multiple spaced connections  62  for use with a variety of configurations.  
         [0025]     During installation of the finishing member  40  and in construction of the cavity wall  12 , the inner wall  28  is constructed with an opening  18  for the window, door or other installation. The frame  14 , is inserted into the opening  18  and the member  40  is mounted to the channel of the frame  14  as previously described. The outer veneer wall  26  is constructed with courses of masonry units  30  and mortar  32 . After construction of the outer veneer wall  26  is completed, the terminal end portion  60  of the second leg  44  may be removed along the frangible connection  62  thereby exposing a recess at the juncture between the frame  14 , the remainder of the member  40  and the wall  12 . As shown in  FIG. 3 , the recess may be filled with a bead of caulk  64  to provide an aesthetically pleasing transition from the frame  14  to the wall  12 , as well as sealing the juncture between the frame  14  and the wall  12 .  
         [0026]     From the above disclosure of the general principles of the present invention and the preceding detailed description of at least one preferred embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, I desire to be limited only by the scope of the following claims and equivalents thereof.