Abstract:
A method and device are presented that creates a channel adjacent a nailing flange of a window in between the window and the rough opening that receives the window. The channel is created by establishing a barrier that prevents foam insulation inserted into the space between the window and the rough opening from reaching the nailing flange. The channel then ensures proper drainage of water that enters the window cavity down to the window sill. A gasket is presented that can be attached to the window or the rough opening to create the barrier. Alternatively, a disintegrating object or a wicking object can be used to impede the flow of insulation foam and to create the appropriate channel. The present invention is equally applicable to doors or other framed objects received into the exterior shell of a building.

Description:
PRIORITY 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 14/719,445, filed May 22, 2015 and now U.S. Pat. No. 9,422,762, which in turn is a continuation of U.S. patent application Ser. No. 14/285,786, filed May 23, 2014 and now U.S. Pat. No. 9,038,334 (the &#39;786 application). The &#39;786 application is a continuation of U.S. patent application Ser. No. 13/653,007, filed Oct. 16, 2012 (the &#39;007 application, and now U.S. Pat. No. 8,745,939). The &#39;007 application is a divisional application of U.S. patent application Ser. No. 11/584,328, filed on Oct. 18, 2006 (now U.S. Pat. No. 8,302,353), which in turn is a continuation-in-part of U.S. patent application Ser. No. 11/251,221, filed on Oct. 14, 2005, which in turn claimed the benefit of U.S. Provisional Application No. 60/619,343, filed on Oct. 15, 2004. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to the field of building construction. More particularly, the present invention provides a method and apparatus that prevents water intrusion into the walls of the building around a window, door, or other framed object. 
       BACKGROUND OF THE INVENTION 
       [0003]    A typical window  100  of the prior art is shown in  FIG. 1 . The window  100  may include one or more panes of glass  110 , which may be embedded in a single sash, or in an upper and lower sash such as in a double-hung window. The sash is secured in a frame  120 , which consists of two side jambs  130 , a top jamb  140 , and a sill  150 . The window frame  120  is typically made from wood, vinyl, aluminum, or fiberglass, but may be made from any durable, rigid material. 
         [0004]    Typically, a window is installed into a rough opening  200  in a house or building, as shown in  FIG. 2 . The rough opening  200  forms a window cavity  202  surrounded by a header  210 , two sides  220 , and a sill  230 . The header  210  must be constructed sufficiently sturdy to support the necessary roof loads, since these loads cannot be supported by the window unit  100 . This is especially important with large window units  100 , or when a “window wall” is created with multiple windows side-by-side. The rough opening  200  has an interior side  240  and an exterior side  250  relative to the building itself. The sill  230  is sloped toward the exterior side  250  to allow water that makes its way to the sill  230  to drain out the exterior of the building. The height and width of the window cavity  202  is constructed larger than the height and width of the window frame  120 ; typically about three-quarters of an inch (approximately two centimeters) larger in each direction. This leaves an approximately three-eighth inch space (about one centimeter) between the window  100  and the rough opening  200  on each of the four exterior faces  160  (the top  120 , sill  150 , and both sides  130 ) of the window  100 . 
         [0005]    To hold the window unit  100  in place, the unit  100  is generally constructed with a nailing or installation flange  170  near the exterior edge on each of the four faces  160  of the window frame  120 .  FIG. 3  shows the window  100  of  FIG. 1  sectioned along line  3 - 3 , and shows the relationship of the nailing flange  170  versus the rest of the window frame  120  and the glass  110 .  FIG. 4  shows the same section of window  100 , this time with the nailing flange  170  being used to secure the window frame  120  to one of the sides  220  of the rough opening  200 . The window  100  is installed so that the nailing flange  170  is on the building exterior  250 . Nails  300  are then placed through both the flange  170  and the side  220  of the rough opening  200 . These nails  300  are used around the circumference of the window  100 , preferably centering the window  100  in the opening  200 . 
         [0006]    Because the opening  200  is deliberately sized larger than the window  100 , a space  310  is created between the opening  200  and the window. Modern construction techniques involve creating a vapor barrier between warm moist air inside a house and the outside, cooler air. To complete the vapor barrier, it is necessary to extend the vapor barrier from the rough opening  200  of the house framing to the window  100  itself. To accomplish this, foam  320  is inserted into space  310  around all four faces  160  of window  100 . This foam  320  also serves to insulate this gap  310 . Most window manufacturers carefully advise the window installers to take steps to prevent the expanding foam  320  from warping the window frame  120 . In most cases, installers are instructed to use low expanding foam  320 . In addition, installers are instructed to begin inserting the foam  320  at the nailing flange  170 , but to avoid filling the entire space  310  all the way to the interior  240  of the rough opening  200  and window frame  120 . This should allow the expansion of the foam  320  within space  310  without warping the window frame  120 . 
         [0007]    To prevent water leakage under the nailing flange  170 , installers will generally place a sealant between the flange  170  and the exterior surface  250  of the rough opening  200 . Sill flashing is used on the sill  230  to provide a moisture barrier to prevent water that enters the window cavity  202  after installation of the window  100  from entering the wall under the sill  230 . Moisture in the window opening  202  will ideally pool on the sill flashing, where it will generally drain down the non-wood side of the exterior building paper. Any moisture that does not drain off the sill will remain on the sill flashing until it evaporates. Because of this, it is generally encouraged that sealant not be used on the bottom or sill nailing flange  170 , in order to allow for drainage and evaporation from outside. 
         [0008]    Unfortunately, this prior art technique of window construction and installation has caused various moisture and mold problems in today&#39;s buildings. What is needed is an improved construction and installation method for windows the does not cause these problems. 
       SUMMARY OF THE INVENTION 
       [0009]    The present invention prevents moisture that enters the window opening from entering the interior of the building by creating a channel behind the nailing flange of the window. Prior art windows and techniques encouraged foam insulation to be inserted between the window and the rough opening all the way to the nailing flange that is used to secure the window. This insulation prevented moisture from reaching the sill, from which it could drain or evaporate. Instead, the foam directed the water into the interior of the building. Alternatively, water that did reach the sill could become trapped behind the insulation and be prevented from draining or evaporating. In this case, the water may cause rotting inside the framing. 
         [0010]    The present invention creates a barrier in the space between the window and the rough opening that prevents the foam from reaching the nailing flange. On the interior side of this barrier, the foam is installed normally. On the exterior side of this barrier a channel is created. This channel preferably runs around the circumference of the window. The channel allows water that enters behind the nailing flange the ability to drain down to the window sill where it can drain or evaporate. 
         [0011]    To form the barrier, a gasket can be constructed around the perimeter of the window. This gasket is sized to engage the rough opening, such that it forms a barrier running from the window to the rough opening. Alternatively, the gasket can be sized to extend at least half way into the space between the window and the opening. 
         [0012]    The gasket can be attached to the window during window manufacture. Alternatively, the gasket can be sold separately and attached to the window at the installation site. The gasket may also be directly attached to the rough opening itself, where it will then engage the window frame when the window is installed. The gasket can be relatively straight, extending perpendicularly from the window or rough opening and then bending during window installation. Alternatively, the gasket can be curved. The curved gasket can be sized large enough to span a large space between the window and the rough opening, and can be compressed easily to span a much smaller space. If designed to engage the rough opening, the gasket should be flexible so as to bend during the insertion of the window. If actual engagement is not anticipated, the gasket can be rigid. Finally, the barrier can be formed with a disintegrating object that disintegrates once the insulation has be installed, or a wicking object that remains in the channel to block the foam insulation while still allowing water to reach the sill. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a perspective view of a prior art window. 
           [0014]      FIG. 2  is a perspective view of a rough opening for a window. 
           [0015]      FIG. 3  is a sectional view of a portion of the window of  FIG. 1  along line  3 - 3 . 
           [0016]      FIG. 4  is a sectional view of the portion of the window shown in  FIG. 3  attached to the rough opening of  FIG. 2 . 
           [0017]      FIG. 5  is a perspective view of a window of the present invention. 
           [0018]      FIG. 6  is a sectional view of a portion of the present invention window of  FIG. 5  taken along line  6 - 6 . 
           [0019]      FIG. 7  is a sectional view of the portion of the present invention window shown in  FIG. 6  attached to the rough opening of  FIG. 2 . 
           [0020]      FIG. 8  is a perspective view of a second embodiment of the present invention detached from a window. 
           [0021]      FIG. 9  is a sectional view of the second embodiment being used on a window in a rough opening. 
           [0022]      FIG. 10  is a sectional view of a third embodiment of the present invention being used in connection with a window in a rough opening. 
           [0023]      FIG. 11  is a sectional view of a fourth embodiment of the present invention in which the gasket has a rounded shape that is easily compressed. 
           [0024]      FIG. 12  is a sectional view of a fourth embodiment of the present invention showing a decomposing article being used in connection with a window in a rough opening. 
           [0025]      FIG. 13  is a sectional view of the fourth embodiment after the decomposing article has decomposed. 
           [0026]      FIG. 14  is a sectional view of a fifth embodiment of the present invention showing the use of a wicking article. 
           [0027]      FIG. 15  is a sectional view of a sixth embodiment of the present invention showing the use of a wicking element attached to the nailing flange of the window. 
           [0028]      FIG. 16  is a sectional view of the sixth embodiment of  FIG. 15  being used in connection with a window in a rough opening. 
           [0029]      FIG. 17  is a perspective view of a door frame of the present invention. 
           [0030]      FIG. 18  is a sectional view of a seventh embodiment of the present invention being used on a window in a rough opening. 
           [0031]      FIG. 19  is a section view showing the length of the seventh embodiment from  FIG. 18 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Recognition of the Problem 
       [0032]    The inventor of the present invention has discovered a significant problem with prior art windows and installation techniques as illustrated in  FIGS. 1, 2, 3 and 4  and described above. As explained above, the current thinking in window and building construction allows moisture that enters the window cavity to drain and evaporate at the sill. For this approach to function adequately, three requirements must be met. The moisture that enters the window cavity  202  must be able to flow down to the sill  230 . The sill  230  must be properly constructed to ensure a waterproof surface. And, the sill must be able to either drain the moisture to the outside  250  of the building, or must have enough ventilation to allow evaporation. 
         [0033]    Unfortunately, the construction technique described above does not allow the first requirement to be met. Moisture will often enter into the window cavity  202  at the top  120  and sides  130  of the window  100 . Assuming that there is no failure in the window itself, the moisture enters at these locations under the nailing flange  170 . While the sealant applied under the flange  170  should help prevent this, gaps or cracks in the sealant are inevitable. The moisture that seeps under the nailing flange  170  will enter the space  310  between the window  100  and the rough opening  200 . At this point, the foam  320  that was installed all the way to the nailing flange  170  will interfere with the ability of the moisture to find its way down to the sill  230 . The problem is that the foam material  320  is permitted to fill the space  310  all the way to the nailing flange  170 . At some point, the foam  320  will form a blockage against the nailing flange  170 , and prevent any further downward movement of the moisture toward the sill  230 . In addition, since the foam insulation  320  is never perfectly formed, cracks and gaps in the foam  320  form passageways that permit the water to move toward the interior  240  of the rough opening  200 . In fact, once the foam insulation  320  has formed a blockage with the nailing flange  170 , the only place for the water to go is toward the interior of the building. There the water remains, leading to water damage and molding issues. 
       First Embodiment of the Solution 
       [0034]    The present invention involves a plurality of techniques to ensure that the foam material  320  that is applied from the interior  240  of a building in the space  310  between the window  100  and the rough opening  200  is not allowed to reach the nailing flange  170 . By doing so, a channel or gap is created between the insulation  320  and the flange  170  that allows all moisture that enters anywhere around the edge of the window  100  to drain properly to the sill  230 . 
         [0035]    The first such technique is shown in  FIG. 5 . There a standard window  100  with a nailing flange  170  has been fitted with a gasket  400  around its circumference. This gasket  400  can be placed on each of the four peripheral faces  160  of the window frame  120 , and is positioned between the nailing flange  170  and the interior surface of the window  100 . While installing the gasket  400  around all four faces  160  of the window  100  is preferred, it is well within the scope of the present invention to install the gasket  400  on less than all of the circumference of the window. For instance, an installer or window manufacturer may refrain from installing the gasket  400  along the sill edge  150  of the window  100  to allow easier drainage at the sill  230  of the opening  200 . However, this is generally not preferred as foam material  320  that reaches the nailing flange  120  at the sill  230  can also prevent proper drainage of moisture. Modern building codes require the foam material  320  to complete the vapor barrier on all sides of a window  100 , and therefore the gasket  400  is preferably used on all sides as well. 
         [0036]    As shown in the cross-sectional view in  FIG. 6 , gasket  400  projects away from the window frame  120 , but does not extend as far as the nailing flange  170 . The purpose of the gasket  400  is to approach or engage the rough opening  200  when the window  100  is installed. The flexible gasket  400  can be formed and attached to the window frame in a variety of ways. In  FIG. 6 , it is shown that the gasket  400  is formed with a tongue  410  that fits into a groove in the window frame  120 . This tongue-and-groove connection is designed to prevent the gasket  400  from moving or otherwise disengaging with the window frame  120  during the installation of the window  100 . Of course, other protrusion and channel combinations could be used equally as well as the tongue and groove shown in  FIG. 6 , including protrusions on the window frame  120  that extend into channels or grooves on the gasket  400 . 
         [0037]    In a first embodiment, the gasket  400  engages and flexes against the opening  200  when the window  100  is inserted into the window. To help assist the tongue-and-groove fitting in securing the gasket  400 , the gasket  400  is also formed with a base section  420  that abuts the window frame  200 . This base section helps keep the gasket  400  relatively perpendicular vis a vis the exterior surface of the window frame  200 . When designed to engage the opening  200 , it is important to manufacture the gasket  400  out of a significantly flexible material to allow the gasket  400  to bend during insertion. 
         [0038]    One advantage of permanently attaching the gasket  400  on the peripheral faces  160  of the window  100  is that the gasket  400  can be added during the construction of the window  100  itself. In this way, the window manufacturer can be responsible for securely attaching the gasket  400 . The window  100  is then delivered to the construction site with the gasket attached, where the window installer can install the window  100  and gasket  400  combination in much the same as any ordinary window  100 . Window manufacturers may use any known technique to attach the gasket  400  to the window  100 , including protrusions and channels, or by nailing or stapling the gasket  400  directly to the window frame  120 . Alternatively, the gasket can be formed as an integral part of the window frame  120  itself. 
         [0039]    As shown in  FIG. 7 , the gasket  400  of this first embodiment will preferably contact the framing of the rough opening  200 , such as side  220 , thereby dividing the space  310  between the window  100  and the opening  200  in two. The portion of the space  310  closest the interior  240  of the building can be used for the foam material  320 . As the foam  320  is installed, it can be installed all the way up to the gasket  400 . This is similar enough to the prior art technique of installing the foam  320  all the way up to the nailing flange  170  so as to not require any significant change in foam installation techniques. 
         [0040]    The other portion of the space  310  divided by the gasket  400  is the gap or channel  500  formed adjacent the nailing flange  170 . Because the gasket  400  is formed on at least the top  140  and sides  130  of the window frame  120 , the formed channel  500  is ensured of existing at these locations as well. In this way, the gasket  400  will allow for any moisture that penetrates the opening around a window  100  to have the proper channel  500  to continue its movement down toward the sill  150  and ultimately out to the exterior  250  of the building. In addition, the gasket  400  itself serves as a barrier to any water or moisture that enters the channel  500 , and helps to prevent that water from entering into the interior or framing of the building. 
         [0041]    In this embodiment an entire width of the gasket structure  400  from one side  130  to the other side  130  of the window  100  is slightly larger than that of the largest recommended rough opening  200 , as defined by the window manufacturer. The gasket  400  should also be large enough to account for a non-centered window  100 , so that the gasket  400  will still engage the opening  200 . The gasket  400  should be rigid enough to hold its position in space  310  against insulation  320 , yet be flexible enough to handle a small space  310  that might be created in a non-centered window  100 . The flexibility should also be great enough so as not to hinder the simple installation of a window. In the preferred embodiment, the gasket  400  can be constructed of almost any material that can meet these basic properties, including open or closed cell foam plastics, natural or synthetic rubber, or the like. If a rigid gasket  400  is to be used, the choice of materials would be even broader, including wood, metal, and hard plastics. 
         [0042]      FIG. 8  shows a second embodiment of the present invention gasket  410 . This gasket  410  can be manufactured in one piece and sized for a particular window  100 . The gasket  410  can then be applied to the window  100  at the installation site. Preferably, the gasket  400  is applied over the window frame  120  from the interior side. As shown in the cross-sectional view in  FIG. 9 , the window  100  can be formed with a groove  412  for receiving the gasket  410 . Once the gasket  410  is installed in the groove  412 , it can either be nailed or stapled in place by the installer, or the elasticity of the gasket  410  can be relied to keep it in place. When installed, this second embodiment of the gasket  410  functions similar to gasket  400 , as can be seen by comparing  FIG. 9  with  FIG. 7 . 
         [0043]    Alternatively, a gasket  420  can be created that is designed to be installed directly onto the rough opening  200 , as shown in  FIG. 10 . In this Figure, the gasket  420  has been nailed to the opening  200  with a plurality of nails  422 , only one of which is shown in  FIG. 10 . Alternatively, gasket  420  can be attached with staples or adhesive to the opening  200 . This gasket  420  can be provided to window installers in strips, which can then be cut to the size of the opening  200 . Once the gasket  420  has been attached to the opening, the window  100  can be inserted. The frame  120  of the window  100  will then engage the gasket  420 , much like how the rough opening  200  engaged gaskets  410  and  400  during the window insertion process described above. Like the other embodiments  410 ,  400 , gasket  420  functions by forming a gap or channel  500  for the drainage of moisture and water. The gasket  420  further functions to prevent water from entering the interior of the house, and serves to prevent the insulation  320  from impeding the flow of moisture in the channel  500 . 
         [0044]      FIG. 11  shows another embodiment of a gasket  430  that can be used to create channel  500 . In this case, the gasket  430  has a rounded shape that is easily compressed. This allows the gasket to fill a relatively large space  310  between the window and the rough opening  200 , while still being able to easily be compressed for a smaller space  310 . This shape is called rounded in this invention description, and is defined by having a gasket that forms at least 270 degrees of a complete circle. 
         [0045]      FIG. 12  shows a fifth embodiment, in which a decomposing object  440  is placed adjacent to the nailing flange  170  after the window  100  is installed in the rough opening  200 . This object  440  has an interior face  442 , which servers to block the foam  320  from abutting the nailing flange  170  when the foam material  320  is injected into the space  310  between the window  100  and the rough opening  200 . To form channel  500 , the object  440  will then disintegrate, leaving only the channel  500 , as is shown in  FIG. 13 . Such an object  440  can be created using an inflatable balloon. The balloon can be inserted into the space  310  either already inflated or deflated (which is then inflated in place). The size of the balloon will easily conform to the shape of the space  310 , and can be pressed to abut the nailing flange  170 . When the insulation  320  is injected into space  310 , the interior face  442  of the balloon  440  will prevent the foam  320  from reaching the nailing flange  170 . When the foam insulation  320  has firmed up, the balloon can be deflated using a long thin pin inserted through the insulation  320 . Alternatively, the balloon  440  can be design to deflate over time. Furthermore, a portion of the balloon  440  can be secured to the header  210  to prevent the deflated balloon from interfering with water flow in the channel  500 . Other disintegrating objects  440  can be used, either now known or hereinafter developed. Ideally, the disintegrating object  440  will have an interior face  442  that can impede the flow of injected insulation  320 , and will disintegrate completely soon after the insulation  320  has firmed or solidified. 
         [0046]    Another embodiment of the present invention is to replace the disintegrating object  440  with a wicking object  450 , as shown in  FIG. 14 . The wicking object would be placed in space  310 , and would impede the flow of the insulation  320  at face  452 , just like the disintegrating object  440  shown in  FIG. 12 . However, the wicking object would not disintegrate after the foam  320  is installed, but would be designed to wick moisture around the window frame  120  toward the sill  230  of the rough opening  200 . In effect, the entire channel  500  would remain, but would stay filled with the wicking object  450 . The wicking object  450  would not impede the flow of moisture to the sill  230 , but would help wick the moisture to the sill  230 . The wicking object  450  could be made of a material that conveys the moisture via capillary action. Alternatively, the wicking object  450  could be formed of any material that would allow the flow of water while impeding the flow of foam  320 . For instance, the wicking object  450  could be formed of a porous, fibrous material that does not use capillary action but does allow water flow. One example of such a material is the Home Slicker® product sold by Benjamin Obdyke Incorporated, Horsham, Pa. Alternatively, traditional fiberglass insulation can be used since water is not absorbed by the glass fibers found in fiberglass insulation. Water that enters channel  500  would flow through the fiberglass fibers  450  down to the sill  230 . 
         [0047]      FIG. 15  shows a sixth embodiment of the present invention in which a wicking strip  460  is attached directly to the window frame  120 . In the preferred embodiment, the wicking strip  460  abuts against both the nailing flange  170  and the main portion of the window frame  120 . Alternatively, the wicking strip  460  could be attached to only one of these portions  120 ,  170  of the window  100 , so long as the strip  460  is positioned near both the nailing flange  170  and the window frame  120 . This wicking strip  460  will allow moisture to pass through it while impeding the progress of foam  320 , as shown in  FIG. 16 . Notice that the strip  460  in  FIG. 16  is not attached directly to the nailing flange  170 . The wicking strip  460  acts to stop the foam  320  at face  462  while partially filling gap  500 . As with the wicking object  450  that is positioned in the gap  500 , the wicking strip  460  that is pre-attached to the window  100  can move water through capillary action or by being a porous material that allows water to pass through. The moisture that enters gap  500  can flow down through the unfilled portion of the gap  500  or through the wicking strip  460  of the window frame  120 . The wicking strip  460  should be sized so as to position the barrier face  462  at a sufficient distance from the nailing flange so as to prevent the foam  320  from reaching the nailing flange  170  even when a portion of the gap  500  is not filled by the wicking strip  460 . 
         [0048]    The present invention is not limited to window frames  120 , but would be equally applicable to any framed item that is inserted into an opening of a building. For instance,  FIG. 17  shows a door  600  having a door frame  602 . This door  600  is also fitted with a nailing flange  604 , although such a flange would not be necessary for this invention. The gasket  470  of the present invention is attached to the periphery of the door frame  602 , preferably at least on the top and side of the door frame. This gasket  470  would function similar to the barriers  400 - 460  described above. 
         [0049]      FIG. 18  shows yet another embodiment of the present invention in gasket  480 . As shown in this figure, gasket  480  does not completely extend from window  100  to frame  200 . Nonetheless, the gasket  480  serves as a sufficient barrier to foam material  320  so as to create the same gap  500  as was created in the other embodiments. In this case, the foam material  320  extends somewhat into the gap, but not significantly. The foam material  320  would be considered to extend significantly into the gap if the foam  320  came into contact with the nailing flange  170 . When the gasket  480  does not engage another surface, it is possible for the gasket  480  to be constructed of a rigid material. Preferably, this gasket  480  will extend at least half way across the space between the window  100  and the frame  200 . 
         [0050]    Window frames  120  may be completely smooth on their exterior jamb surfaces, or they may have minor bumps and ridges  122  as shown in  FIG. 19 . These irregularities  122  on the relatively planar  124  face of the window frame  120  do not significantly impede the flow of foam  320  that is inserted into gap  310  between the roughed opening  200  and the window frame  120 . To impede the foam  320  and serve as a barrier as described above, the barrier  480  should extend significantly into the gap  310 , which is not the case with irregularities  122 . Typically, window manufacturers require a minimum one-quarter to three-eighth of an inch between the window frame  120  and the roughed opening  200 . Because this distance might be greater, it is preferred that the barrier  480  extend away from the generally planar face  124  of the window frame by a distance  482  approximately equal to this minimum distance. Consequently, one way of measuring the size of the barrier  480  of the present invention is by this distance  482 , which ideally is at least 0.20 inches. 
         [0051]    The many features and advantages of the invention are apparent from the above description. Numerous modifications and variations will readily occur to those skilled in the art. Since such modifications are possible, the invention is not to be limited to the exact construction and operation illustrated and described. Rather, the present invention should be limited only by the following claims.