Abstract:
An improved plastic, e.g., vinyl, window construction includes an exterior casing rigidly mounted to a window frame and which may advantageously be preattached to the window frame, allowing the window construction to be installed as a single unit. The exterior casing may include an exterior sill and may be constructed to provide the appearance of a traditional wooden window. In another aspect, a window construction with an integrated interior casing is also provided. In yet a further aspect, a method for manufacturing a plastic window construction with integrated exterior casing is provided.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    The present invention relates generally to a window construction for mounting in the walls of buildings such as homes and the like and, more particularly, to an improved window construction or module having integrated sill and casing members. Although the invention will be shown and described herein primarily by way of reference to double hung windows, it will be recognized that the present invention is equally applicable to all manner of windows, including but not limited to, single-hung windows, casement windows, sliding windows, bay windows, picture windows, curved windows, round windows, and other types of residential and commercial windows.  
           [0002]    Window assemblies in both the new construction and replacement window markets commonly incorporate plastic materials and it is known to manufacture windows and window components entirely from plastic, most typically vinyl, i.e., from extruded members which are cut and assembled to form the window frame, sashes, and so forth. Such window assemblies typically include multiple components which must be installed and secured to each other on site, thereby increasing the time and labor cost for installation. Furthermore, such materials lack the often-desired traditional appearance of wooden windows having a wooden exterior sill and wooden exterior casing. Where a traditional appearance is desired for plastic window installations, wooden or synthetic exterior casings and sill members may be applied by craftsmen in the field, thus increasing the cost of installing the windows.  
           [0003]    Also, an interior casing/extension jamb is conventionally applied after the window has been installed into the rough window opening to give a desired finished appearance on the interior side of the window. This likewise requires skilled craftsmen to apply, thus increasing the cost and time for installation of the windows.  
           [0004]    When multiple components are installed in the field, sealing members such as gaskets, adhesives, caulking, and the like must also be installed on-site for the protection against the entry of moisture or other environmental contamination.  
           [0005]    The present invention provides a new and improved window construction and method that overcome the above-referenced problems and others.  
         SUMMARY OF THE INVENTION  
         [0006]    In one aspect, a window construction for mounting in an opening in a wall of a structure includes a window frame for being received in said opening in the wall. An integrated exterior casing is fastened to said frame and has a mounting face on an inwardly facing surface thereof for engagement and rigid mounting against an aligned, outwardly facing surface of the window frame.  
           [0007]    In another aspect, a window construction comprises a rectangular window frame for being received in the opening in the wall. The window frame includes upper and lower horizontally extending frame members and first and second vertically extending frame members. The window frame is adapted to carry one or more window sashes. The window construction further comprises an integrated exterior casing, which includes a first exterior casing member fastened to the upper horizontally extending frame member and second and third integrated casing members fastened to the first and second vertically extending frame members, respectively. Also, an integrated exterior sill is attached to the lower horizontally extending frame member. The integrated exterior casing and the integrated exterior sill combine to circumscribe the window frame. Each of the first, second, and third exterior casing members and the exterior sill member have a mounting face on an inwardly facing surface thereof for engaging and rigid mounting against an aligned, outwardly facing surface of the window frame.  
           [0008]    In another aspect of the present invention, a method for manufacturing a window construction for installation within an opening formed in a wall of a structure comprises forming a window frame for being received in said opening in the wall and forming an integrated exterior casing. Prior to installing the window construction in the opening in said structure, the integrated exterior casing is attached to the window frame.  
           [0009]    In still another aspect, a method for manufacturing a window construction for installation within an opening formed in a wall of a structure is provided. A rectangular window frame having upper and lower horizontally extending frame members and first and second vertically extending frame members and adapted to carry one or more window sashes is formed for being received in the opening in the wall. An integrated exterior casing is formed and comprises a first exterior casing member for attachment to the upper horizontally extending frame member and second and third integrated casing members for attachment to the first and second vertically extending frame members, respectively. An integrated exterior sill is formed for attachment to the lower horizontally extending frame member. Prior to installing the window unit in the opening in the structure, the integrated exterior casing and integrated exterior sill are attached to the window frame. The exterior casing and exterior sill thus combine to circumscribe the window frame.  
           [0010]    In yet another aspect, a window construction for mounting in an opening in wall of a structure is provided including a rectangular window frame for being received in the opening in the wall. The window frame has upper and lower horizontally extending frame members and first and second vertically extending frame members and is adapted to carry one or more window sashes. An integrated exterior casing includes a first exterior casing member fastened to the upper horizontally extending frame member and second and third integrated casing members fastened to the first and second vertically extending frame members, respectively. An integrated exterior sill is attached to the lower horizontally extending frame member. The integrated exterior casing and integrated exterior sill circumscribe the window frame. Each of the first, second, and third exterior casing members have an exterior-most exterior facing surface which is substantially flush with an adjacent, exterior facing surface of the window frame.  
           [0011]    One advantage of the present invention resides in the fact that window installation is simplified. By integrating the exterior sill and casing and, optionally, the interior casing into the window module, the time consuming and potentially more cumbersome steps of installing these components on-site is eliminated.  
           [0012]    Another advantage is that window assembly is made faster, less sensitive to operator error, more suited to centralized or automated assembly procedures, thereby reducing possible failure modes and warranty issues.  
           [0013]    Still another advantage of the invention resides in the provision of a window module which gives the appearance of a traditional wooden window.  
           [0014]    Yet a further advantage is found in the large contact area between the window frame and the integrated exterior casing and sill, thereby allowing rigid mounting therebetween.  
           [0015]    Still further benefits and advantages of the invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the preferred embodiments.  
           [0016]    It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description, serve to explain the principles of the invention. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]    The following detailed description may be best understood when read in reference to the accompanying drawings wherein:  
         [0018]    [0018]FIG. 1 is a perspective view of a window module with integrated exterior sill and casing members in accordance with a preferred embodiment of the present invention;  
         [0019]    [0019]FIG. 2 is side-sectional view taken along the lines  2 - 2  of FIG. 1;  
         [0020]    [0020]FIG. 3 is an enlarged side-sectional view illustrating an exemplary exterior casing member profile and means of attachment to the window frame; and  
         [0021]    [0021]FIG. 4 is an enlarged side-sectional view illustrating an exemplary exterior sill member profile and means of attachment to the window frame;  
         [0022]    [0022]FIGS. 5 and 6 illustrate embodiments of the present invention employing curved frame and casing sections; and  
         [0023]    [0023]FIG. 7 is a side-sectional view of a further exemplary exterior casing profile in accordance with the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0024]    Referring now to the drawings, wherein like reference numerals refer to like components throughout the several views, there appears a window construction  10  (as viewed from the exterior in FIG. 1) according to an exemplary embodiment of the present invention.  
         [0025]    Unless indicated otherwise, all directional or positional terms used herein, such as “upper,” “lower,” “horizontal,” “vertical,” etc., and variations thereof refer to a direction or orientation relative to the window as it is intended to be installed in a building or structure. Thus, “exterior” and “interior” and variant forms thereof refer to directions or orientations relative to the exterior and interior, respectively, of the building or structure in which the window is to be installed. The terms “inward” and “outward, and variant forms thereof, will be used to refer to directions or orientations which are generally along the plane of the window, with the term “inward” and variants thereof referring to a direction or orientation relative to more central portion of the bounded area of the window unit or window opening, and with “outward” and variants thereof referring to a direction or orientation away from a central portion of the bounded area of the window unit or window opening. Finally, the terms “axial,” “axially,” etc., refer to directions generally parallel to a longitudinal axis of a referenced elongate member, such as the frame members, exterior casing members, and exterior sill members.  
         [0026]    The window construction  10  comprises four sections which are attached to form a frame  12 . The attachment may be made via mechanical fasteners, welding (e.g., ultrasonic or, more preferably, hot welding), bonding, or any combination thereof. The four sections are preferably formed via an extrusion process, although other methods of forming the frame sections, such as molding, are also contemplated. Although the present invention is described by way of reference to a rectangular window, it will be recognized that the window frame and exterior casing may include one or more curved sides or members. For example, the curved frame and exterior casing sections may be bent to a desired shape or radius, e.g., during or after the extrusion process, molding the sections to the desired shape, and so forth.  
         [0027]    The four frame sections include an upper or head frame section  14 , a pair of vertically extending side or jamb frame sections  16 , and a lower or sill frame section  18 . The window module  10  further includes upper and lower sashes  20  and  22 , respectively. The sashes  20  and  22  are slideably received within the window frame  12 , e.g., within tracks or guide rails  32  formed on or attached to the side frame sections  16 . Additionally, the sashes may carry certain hardware components, such as locks, release mechanisms for removing the sashes, environmental barriers, and the like. A lip  38  may also be provided to retain an optional screen or storm window (not shown).  
         [0028]    An upper exterior casing member  24  and two vertically extending side exterior casing members  26  are attached to the respective upper and side frame sections  14  and  16 . An exterior sill member  28  is attached to the lower frame member  18 . The exterior casing and sill members are likewise preferably formed via an extrusion process, although other methods, such as molding, are also contemplated.  
         [0029]    As best shown in FIG. 2, the depicted exemplary embodiment shows interior casing members  30 , which may optionally be pre-attached to the frame  12  during the manufacture of the window, e.g., at a window assembly plant or other centralized location.  
         [0030]    The depicted window frame members  14 ,  16 , and  18  according to a preferred embodiment are adapted to receive both the respective integrated exterior casing members  24 ,  26 , and exterior sill member  28 , as well as the optional interior casing members  30 .  
         [0031]    The cross-sectional profiles of the window frame member  14  and the exterior casing member  24 , and their manner of attachment, are best seen in FIG. 3. However, the discussion below with respect to window frame member  14  and casing member  24  is equally applicable to the vertically extending members  16  and  26 , as well.  
         [0032]    Again, the window frame members  14 ,  16 , and  18  as well as exterior casing members  24  and  26  and exterior sill member  28  are preferably formed by extruding a plastic material, preferably vinyl. It will be recognized that the extrusion profiles are not limited to the specific embodiments shown and other geometrical cross-sectional configurations are also contemplated.  
         [0033]    The exterior casing member  24  includes a base layer or mounting surface  40  and a main body portion  42 . The main body portion includes axially extending hollow regions  44  and one or more interior structural panels  46 .  
         [0034]    Extending outwardly (upwardly extending in the orientation shown) from an interior facing surface  48  of the main body portion  42  is a fin or flange  50  for fastening the window unit  10  to the building at a plurality of places spaced about the periphery of the window unit  10 , e.g., via nails, screws, or other like fasteners  52  (shown in phantom). Optionally, bores  54  may be pre-drilled or otherwise pre-formed in the nailing flange  50 .  
         [0035]    Extending outwardly (upwardly extending in the orientation shown) from an exterior facing surface  56  of the main body portion  42  is a casing flange  58 . In the depicted embodiment, the casing flange  58  includes an axially extending channel  60 , thereby providing a transverse dimension  62 , sized, e.g., to give the window unit  10  an exterior appearance of having a traditional wooden casing.  
         [0036]    A channel  64  is defined by the nailing flange  50 , the main body portion  42  and the casing flange  58 . The channel is adapted to receive a siding material (not shown) applied over exterior sheathing material of the building. The siding material may be applied within the channel  64  to cover the nailing flange  50 , such that the exterior facing surface of the main body portion  42  and the casing flange  58  combine to give the appearance of a wooden trim material.  
         [0037]    The casing member  24  and like exterior casing members  26  may be mitered, or otherwise joined to give an exterior appearance of a miter joint at the corners  34  (FIG. 1), e.g., to give the appearance of wooden casing about the top and vertical sides of the window unit  10 . A fastening boss  88  may be formed in the cross-sectional profile of the exterior casing members  24  and  26 , e.g., for receiving a screw-type fastener for adjoining the casing members at corners  34  and/or for adjoining the sill member  28  to the vertical casing members  26 . As an alternative to mechanical fasteners, or in addition thereto, the exterior casing members may be fastened via a welding process, such as ultrasonic or more preferably hot welding, a bonding process, or the like.  
         [0038]    The base member  40  of the casing member  24  engages an outwardly facing (upward in the orientation shown) surface  80  of the frame member  14 . The frame member  14 , as depicted, includes a plurality of axially extending channels  82  and structurally reinforcing panels  84  formed therein. It will be recognized that the particular pattern of channels and reinforcement panels shown is exemplary only. The base member  40  includes an interiorly extending lip  72  for receiving a plurality of screw or other type of fasteners  74  for adjoining the casing member ( 24 , 26 ) to its corresponding frame section ( 14 ,  16 ).  
         [0039]    An exterior facing surface  90  of the frame member  14  includes an axially extending recess  92 . An interior facing surface  94  of the frame member likewise has an axially extending recess  96  formed therein. A recess  70  may be formed on the surface  40 .  
         [0040]    An axially extending fastener  66  is integral with and extends from the base member  40  of the casing member  24 . The fastener  66  is adapted to be received within the recess  92  of the frame member  14 . In the embodiment depicted, the fastening member  66  has a generally L-shaped or hook-shaped cross-section and preferably includes a tooth or protrusion  68  to provide secure engagement within the recess  92 . The combination of the fastener  66  and the screw-type or other fasteners  74  combine to provide a rigid attachment between the exterior casing members and the window frame. This rigid means of attachment improves the structural integrity of the window unit  10  and advantageously allows the pre-attachment of the exterior casing members to the unit off-site, e.g., at a centralized plant or manufacturing facility, thereby reducing installation costs, while also minimizing the likelihood of breakage during storage, handling, and transportation of the completed window constructions.  
         [0041]    In the depicted embodiment, the recess  92  and the hook  66  are positioned to provide a generally smooth or flush transition from the exterior facing surface  56  of the casing member  24  and the exterior facing surface  90  of the window frame section  14 . A like flush relationship is also preferably provided between the casing members  26  and the frame sections  16 .  
         [0042]    Optionally, the interior wood casing panel  30  may be pre-attached to the window unit  10 . In the depicted embodiment, a generally L-shaped fastener or bracket  102  is secured within a rabbet  100  formed on an interior edge  104  of casing member  30 . The L-shaped fastener  102  may be secured via staple, nails, screw, or other fastener  106 . The L-shaped bracket may be a single elongate member extending in the axial direction of the frame member  14  and the casing member  30 , or, more preferably, may comprise plural discrete fasteners, axially spaced apart along the frame member  14  and the casing member  30 .  
         [0043]    The L-shaped fastener  102  has a cross-sectional profile adapted to be received within the recess  96  of the frame member  14 . In the embodiment depicted, the fastening member  102  includes a tooth or protrusion  108  to provide secure engagement and retention within the recess  96 .  
         [0044]    As best seen in FIG. 4, the exterior sill member  28  and interior casing member  30  is attached to the lower frame section  18  in a manner similar to that described above by way of reference to FIG. 3. The exterior sill  28  includes an upper or mounting surface  120  and a main body portion  122 . The main body portion  122  includes axially extending hollow regions  124  and one or more interior structural panels  126 . Again, it will be recognized that the pattern of channels and interior structural panels depicted is exemplary only.  
         [0045]    Extending outwardly (downwardly in the orientation shown) from the body portion  122  is a nailing fin or flange  130  for fastening the window unit  10  to the building at a plurality of places spaced along the flange  130 , e.g., via nails, screws, or other like fasteners  52 . Optionally, bores  54  may be pre-drilled or otherwise pre-formed in the nailing flange  130  at a plurality of spaced-apart locations along the nailing flange  130 .  
         [0046]    Extending in the exterior direction from the body portion  122  is a hollow sill member  138 . In the depicted embodiment, the sill member  138  includes an axially extending channel  140 , and is preferably of a size and shape having the appearance of a traditional wooden sill. One or more interior reinforcing panels, such as panel  146  may also be provided. In the preferred embodiment, the upper surface  142  of the sill member  138  is sloped downwardly toward the exterior side to allow drainage of moisture away from the interior side of the window  10 .  
         [0047]    A channel  144  is defined between the nailing flange  130 , the main body portion  122  and the sill member  138 . The channel is adapted to receive a siding material applied over the exterior sheathing material of the building. The siding material may be applied within the channel  142  to cover the nailing flange  126 . The channel  144  in combination with the top channel  64  and like side channels forms an annular channel about the periphery of the window unit  10 .  
         [0048]    An end cap or plug  148  (see FIG. 1) may be applied to each end of the hollow sill member  138  to close the ends and give the appearance of a traditional, solid wood sill.  
         [0049]    The mounting surface  120  of the sill member  28  engages an outwardly facing (downward in the orientation shown) surface  160  of the frame member  18 . The frame member  18 , as depicted, includes a plurality of axially extending channels  162  and structurally reinforcing panels  164  formed therein. Again, it will be recognized that the cross-sectional profile depicted is exemplary only. The mounting surface  120  further includes an interiorly extending lip  152  for receiving a plurality of screws or other type of fasteners  74  for adjoining the sill member  28  to the frame section  18 .  
         [0050]    An exterior facing surface  170  of the frame member  18  includes an axially extending recess  172 . An interior facing surface  174  of the frame member likewise has an axially extending recess  176  formed therein. A recess  150  may be formed on the surface  120 .  
         [0051]    An axially extending fastener  146  is integral with and extends from the mounting surface  120  of the exterior sill member  28 . The fastening member  146  is adapted to be received within the recess  172  of the frame member  18 . In the depicted embodiment, the fastening member  146  has a generally L-shaped or hook-shaped cross-section and preferably includes a tooth or protrusion  148  to provide secure engagement and retention within the recess  172 . The combination of the fastener  146  and the fasteners  74  combine to give a rigid attachment between the exterior sill member  18  and the frame section  18 . This rigid means attachment improves the structural integrity of the window unit  10  and advantageously allows the pre-attachment of the exterior sill member off-site, e.g., at a centralized plant or manufacturing facility, thus reducing installation costs, while minimizing the likelihood of breakage or damage during storage, handling, and transportation of the completed units.  
         [0052]    In the depicted embodiment, the optional interior wood casing panel  30  is shown pre-attached to the window unit  10 . Specifically, a generally L-shaped fastener or bracket  102  is secured within a rabbet  100  formed on an interior edge  104  of casing member  30 . The L-shaped fastener  102  may be secured via a staple, nail, screw, or other fastener  106 . The L-shaped bracket  102  may be an elongate member extending in the axial direction along the frame member  18  and the casing member  30 , or, more preferably, may comprise plural discrete fasteners, axially spaced apart along the frame member  18  and the casing member  30 .  
         [0053]    The L-shaped fastener  102  has a cross-sectional profile adapted to be received within the recess  176  of the frame member  18 . In the embodiment depicted, the fastening member  102  includes a tooth or protrusion  108  to provide secure engagement within the recess  176 .  
         [0054]    In the above embodiment, the window frame sections  14 ,  16 , and  18  and the corresponding exterior casing member  24 ,  26 , or sill member  28  are depicted as separately formed and attached as described above. This advantageously allows like frame members to be employed with or without the exterior casing and sill members, as desired. However, in an alternative embodiment (not shown), each window frame member and its respective exterior casing or sill member may be formed as a single, monolithic extrusion or molded member.  
         [0055]    Referring now to FIG. 5, the window construction  510  comprises a upper, curved frame member or section  514 , two vertically extending frame sections  16 , and a base frame member  18 , which are attached or joined to form a frame  512  bounding window  22  mounted therein.  
         [0056]    An upper, curved exterior casing member  524  and two vertically extending side exterior casing members  26  are attached to the respective upper and side frame sections  514  and  16 . An exterior sill member  28  is attached to the lower frame member  18 . The exterior casing and sill members are likewise preferably formed via an extrusion process, although other methods, such as molding, are also contemplated. The curved frame and casing members  514  and  524  may be formed by formed, for example, heating a straight extruded member and bending to a desired radius or other curved shape.  
         [0057]    The casing members  524 ,  26 , and  28  each include a nailing fin  550 ,  50 , and  130 , respectively, defining a peripheral channel  564  about the window  510 . Although the curved frame member  514  and the curved casing member  524  are depicted as semi-circular, it will be recognized that other curved shapes may be employed, circular, oval, elliptical, ogival, or portions thereof such as quarter round, hemi-elliptical, and the like, or any other desired curved shape. Likewise, the present invention can be readily adapted to any desired shape, which may be curvilinear, rectilinear, or a combination of rectilinear and curvilinear segments.  
         [0058]    Referring now to FIG. 6, a window construction  610  comprises a curved frame  612 , which may be formed from multiple curved segments, attached or joined together, bounding window  22  mounted therein.  
         [0059]    A curved exterior casing  622  is attached to the frame  612  and in the case of a segmented frame  612 , may be segmented in the same manner. The casing  622  includes a nailing fin  650  and defines a peripheral channel  664  about the edge of the window  610 . Although the window member  610  is depicted as circular, it will be recognized that other curved, rectilinear, polygonal, or any other geometrical shape may be employed.  
         [0060]    Referring now to FIG. 7, there is illustrated a profile of an exterior casing member  724  in accordance with a further embodiment of the present invention. The exterior casing member  724  includes a base layer or mounting surface  740  and a main body portion  742 . The main body portion includes an axially extending hollow region  744  and may optionally include one or more interior structural panels (not shown).  
         [0061]    Extending outwardly (upwardly extending in the orientation shown) from an interior facing surface  748  of the main body portion  742  is a fin or flange  750  for fastening to a building as detailed above.  
         [0062]    Extending outwardly (generally upwardly extending in the orientation shown) from an exterior facing surface  756  of the main body portion  742  is a casing flange  758 .  
         [0063]    A channel  764  is defined by the nailing flange  750 , the main body portion  742  and the casing flange  758 . The channel is adapted to receive a siding material applied over exterior sheathing material of the building. The siding material may be applied within the channel  764  to cover the nailing flange  750 , such that the exterior facing surface of the main body portion  742  and the casing flange  758  combine to give the appearance of a wooden trim material.  
         [0064]    Plural casing members  724  may be mitered, or otherwise joined (mechanically fastened or welded) to give an exterior appearance of a miter joint as described above, e.g., to give the appearance of wooden casing about the top and vertical sides of a window unit. Optionally, the casing may be used in conjunction with a sill member, such as sill member  28  (see FIG. 4), or, alternatively, may be used on all sides of a window. The casing member  724  may be straight or curved, as described above.  
         [0065]    The base member  740  of the casing member  724  engages an aligned facing surface of a corresponding window frame member, in the same manner as described above.  
         [0066]    An axially extending fastener  766  is integral with and extends from the base member  740  of the casing member  724 . The fastener  766  is adapted to be received within the a complimentary recess of the window frame member as described above. In the embodiment depicted, the fastening member  766  has a generally L-shaped or hook-shaped cross-section and preferably includes a tooth or protrusion  768  to provide secure engagement within the recess. A screw fastener may also be used to secure the tongue member  772  to the corresponding window frame member as described above to provide a secure, rigid attachment between the exterior casing members and the window frame, thereby minimizing problems of breakage during transport and handling. Advantageously, the hook  766  and the complimentary recess are positioned to provide a generally smooth or flush transition from the exterior facing surface  756  of the casing member  724  and an exterior facing surface of the window frame. It will be further recognized that the casing member  724  may likewise be employed in conjunction with a window frame receiving or adapted to receive an integrated or preattached interior casing or extension jamb as described above.  
         [0067]    The invention has been described with reference to the preferred embodiments. Obviously, modifications-and alterations will occur to others upon a reading and understanding of this specification. The forms hereinbefore described being merely explanatory and exemplary, it is intended that the invention be construed as including all such modifications and alterations.