Abstract:
A window casing system includes a kit to completely finish the insides of windows in homes and offices. An installer provides key measurements of the window opening height, width, and depth, to the factory. Custom pre-finished jambs, casings, sills, and aprons are then packaged and delivered in a kit to the jobsite for installation. Plastic fasteners with ribbed shanks are included in the kit for the installer to press into holes and dados in the jambs, casings, and sill to permanently join them together. The top corner miters of the side and top casings are joined with unique, ribbed plastic corner elbows for tight, perfectly aligned joints. The whole is then either nailed, glued, or otherwise fastened into the window opening.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention generally relates to building windows, and in particular to devices and methods for quickly and easily casing the insides of windows. 
         [0003]    2. Description of the Prior Art 
         [0004]    A typical window in a home or an office is dressed out with wood window casing to improve the looks and functionality. In the Victorian Era, window and door casings were elaborately designed and carved works of art that were installed and finished by artisans and craftsmen. In modern times, window casings, if installed at all, are simple and straightforward designs often cut on site from straight pieces of “one-by” lumber nailed up with finish nails and painted. 
         [0005]    A universal lack of budget, skill, or even attention to detail often results in window casings that are not straight, not consistent, and show obvious gaps where the materials were not cut to the exact lengths or angles needed. 
         [0006]    John L. Wetzel describes a window trim system in U.S. Pat. No. 4,811,533, issued Mar. 14, 1989. Wetzel describes a typical window casing that includes a horizontal wooden sill at the bottom that extends inside out past the wall and laterally beyond the left and right window opening edges. Inside the window opening there are two vertical side trim pieces that come out flush to the wall and a horizontal top trim piece that also comes out flush to the wall. A flat surround is built on the wall face joining the inside trim pieces and sill with a matching pair of left and right, and a top molding set back with some amount of “reveal” to add interest details. 
         [0007]    Wetzel attempts to provide an adjustable width molding that “dramatically reduces the carpentry skill involved.” Summary. His other goals are to reduce manufacturing and installation costs, and to be able to accommodate dimensional differences in the depths of the window frames being encountered. Essentially a ring consisting of four trim pieces  22 ,  24 ,  26 , and  28 , have dadoes so they can telescope on matching rabbets on four corresponding main trim pieces, jambs  20 ,  23 ,  25 , and  27 .  FIGS. 1-4 . Such telescoping takes up any gap that would otherwise be revealed with window frame  12 . The reveal left between the top and side wall-face casing pieces  15 ,  16 , and  18  with side and head jambs  20 ,  25 , and  27  is not controlled. The installer can easily get it wrong. 
         [0008]    What is needed is an inexpensive window casing system that provides quick and easy installations that are consistent and professional appearing every time. 
       SUMMARY OF THE INVENTION 
       [0009]    Briefly, a window casing system embodiment of the present invention includes a kit to completely finish the insides of windows in homes and offices. An installer takes key measurements of the window opening height, width, and depth, and selects an appropriate standard unit or sends custom measurements to the factory. Pre-finished jambs, casings, sills, and aprons are then packaged and delivered in a kit to the jobsite for installation. Plastic fasteners with ribbed shanks are included in the kit for the installer to press into holes and dados in the jambs, casings, and sill. The top corner miters of the side and top casings are joined with unique, ribbed plastic corner elbows for tight, perfectly aligned joints. The whole is either nailed or glued into the window opening. 
         [0010]    These and other objects and advantages of the present invention will no doubt become obvious to those of ordinary skill in the art after having read the following detailed description of the preferred embodiments that are illustrated in the various drawing figures. 
     
    
     
       IN THE DRAWINGS 
         [0011]      FIG. 1A  is a perspective exploded assembly view of a window casing system embodiment of the present invention; 
           [0012]      FIG. 1B  is a perspective view of the window casing system of  FIG. 1A  after being assembled; 
           [0013]      FIG. 2  is a perspective exploded assembly view of how the mitered ends of the casings are joined with H-connectors in a window casing system embodiment of the present invention; 
           [0014]      FIG. 3  includes top, end, and side views of the H-connector of  FIG. 2 ; 
           [0015]      FIG. 4  is a perspective exploded assembly view of how the mitered ends of the casings are joined with L-connectors in a window casing system embodiment of the present invention; 
           [0016]      FIG. 5  includes top and side views of the L-connectors of  FIG. 4 ; 
           [0017]      FIG. 6  is a perspective view of a zipper-tie embodiment of the present invention; 
           [0018]      FIG. 7  is an end view of a zipper-tie connecting a window jamb to a casing, as in  FIGS. 1A and 1B ; 
           [0019]      FIG. 8  is a flowchart of a method embodiment of the present invention for casing a window opening; and 
           [0020]      FIG. 9  is a cross-sectional diagram of a second type of zipper tie in an embodiment of the present invention similar to that shown in  FIGS. 1A ,  6 , and  7 . 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0021]      FIGS. 1A and 1B  represent a window casing system embodiment of the present invention, and is referred to herein by the general reference numeral  100 . A typical window casing system arrives on a jobsite as a ready-to-install kit  100  that comprises a sill  101 , left jamb  102  a header or top jamb  103 , and a right jamb  104  are all pre-measured and pre-cut at a factory to fit a particular window opening. In most cases of new construction, the installer is not required to do any cutting of the pieces on the jobsite to complete the installation. 
         [0022]    The width of sill  101  and jambs  102 - 104  are ripped at the factory to fit snuggly up against a window frame that protrudes into the window opening at the outdoors side. Therefore, good measurements are essential and particular kits  100  need to be matched up on the jobsite with their corresponding window openings. 
         [0023]    The sill  101  and jambs  102 - 104  are assembled together by the installer before being placed in their respective window openings using plastic ribbed-shank push-in fasteners  106 - 117 . For example, using ITW Fastex (Des Plaines, Ill.) PINE-TREE™ or CHRISTMAS-TREE™ clips. These are inserted by the installer through matching, corresponding holes drilled into sill  101  and jambs  102 - 104 . Assembly can be made a bit easier if the holes drilled through sill  101  and header jamb  103  are a bit larger in diameter than the blind holes drilled into the ends of each of the left and right jambs  102  and  104 . 
         [0024]    This subassembly can then be inserted and tacked in place with a few finish nails into the window opening. Each of the jambs  102 - 104  is provided with a full-length rectangular groove or dado  120 - 122  into which uniform-size plastic zipper ties  130 - 139  can be inserted and locked. Here, three are shown on each side and four along the header, but the best number of plastic zipper ties to use will vary with the particular window dimensions. The dimensions of the dado  120 - 122  depend on the uniform dimensions of the zipper ties  130 - 139 . Once a zipper tie is inserted into a dado, it will stay locked and secure against normal separation forces incurred during installation and intended use. In alternative embodiments of the present invention, the dados do not run full-length. Several short ones can be strategically placed to receive the individual zipper ties. However, a single continuous dado is the simplest and least expensive. 
         [0025]    The backsides of a left and right casing  140  and  141 , and a header or top casing  142  are correspondingly provided with full-length dados. However these are not visible in the views provided in  FIGS. 1A and 1B . The relative positions of the corresponding dados from the edges are placed by the factory such that there will be an attractive molding reveal. Such reveal will, by the nature of the construction described herein, be perfectly consistent and uniform with every installation. The installation further includes a bottom apron  144 . 
         [0026]      FIG. 1B  represents a fully assembled kit  100 . Such may be glued into the window opening instead of nailed when the jambs, casings, and sill have all been critically configured and sized properly. In alternative embodiments, all the pieces that show after installation may be pre-finished with several coats of special high-durability finishes at the factory before shipment to relieve the installer of the need to paint the finished installation. 
         [0027]      FIGS. 1A and 1B  did not show how the corner miter joints of side and top casings  140 - 142  are joined. These joints are especially critical, and how well the joints match up can be the measure of the quality of the installation. Perfect mitered joints are difficult or impossible to obtain by inexperienced and unskilled installers of conventional casings. 
         [0028]      FIG. 2  represents a first type of mitered casing joint, herein referred to by the general reference numeral  200 . An H-type joint  200  comprises matching miter ends  201  and  202  on window casings  203  and  204 . These are connected together by two H-connectors  205  and  206 . Four pockets  208 - 211  are routed into the mitered ends of casings  203  and  204  at corresponding and matching locations. An installer has only to match up the mitered ends  201  and  202 , align routed pockets  208 - 211 , and press in H-connectors  205  and  206 . Each window casing  203  and  204  includes a dado  212  and  213  to receive a zipper-tie connector  130 - 139  for joining to side and top window jambs  102 - 104 . More details on the zipper-tie connectors themselves are provided in  FIG. 6 . In one prototype embodiment that provided good results, the H-connectors were about ⅜″ wide, ⅜″ tall, and ¼″ thick. The router pockets  208 - 211  were machined to match. 
         [0029]    In  FIG. 2  it can be seen that the routed pockets  208 - 211  are not evenly distributed along the length of mitered edges  201  and  202 . This is deliberate. Better results are produced by grouping them nearer the outside corner. Costs can also reduced by being able to use fewer H-connectors. 
         [0030]      FIG. 3  provides detailed top, end, and side views of a typical H-connector  300 . Two legs  301  and  302  are joined by a crossbar  304 . Each leg  301  and  302  has a tapered end  306  and  307  to make insertion into router pockets  208 - 211  easier for the installer. 
         [0031]    In practice, the H-type joint  200  has proven to be relatively expensive to manufacture and softer materials like medium density fiberboard (MDF) cannot be used for the casings. Router pockets machined into MDF break-out too easily. 
         [0032]      FIG. 4  represents a second type of mitered casing joint, herein referred to by the general reference numeral  400 . An L-type joint  400  comprises matching miter ends  401  and  402  on window casings  403  and  404 . These are connected together by two ribbed plastic L-connectors  405  and  406 . Four dados  408 - 411  are cut square into the mitered ends of casings  403  and  404  at corresponding and matching locations. An installer has only to match up the mitered ends  401  and  402 , align dados  408 - 411 , and press in L-connectors  405  and  406 . Each window casing  403  and  404  includes a dado  412  and  413  to receive a zipper-tie connector  130 - 139  for joining to side and top window jambs  102 - 104 . In one prototype embodiment that provided good results, the L-connectors were about ⅛″ wide, ⅜″ tall, and 1″ long legs. Dados  408 - 411  were machined to match. 
         [0033]      FIG. 5  details a ribbed plastic L-connector  500 , as can be used in  FIG. 4 . Ribbed plastic L-connectors  500  comprise two legs  501  and  502  on which are disposed ribs of feathers  504 - 507  on their sides. The tops and bottoms of legs  501  and  502  are smooth and straight. In  FIG. 5 , ribs of feathers  504 - 507  are shown set 90° to the long edges of legs  501  and  502 . There may be an advantage to setting them in at some more acute angle to help dados  408 - 411  better permanently retain the ribbed plastic L-connectors  500  after assembly and installation. 
         [0034]      FIG. 6  represents a zipper-tie  600  in an embodiment of the present invention. Zipper-tie  600  is used to permanently connect jams and casings together as shown in  FIGS. 1A ,  1 B, and  7 . Zipper-tie  600  comprises a plastic body  602  with four sets  604 - 607  of three molded feathers each sized to fit and lock into corresponding dados. In one prototype embodiment that provided good results, zipper-tie  600  was 2⅞″ long, ⅜″ tall, and ⅛″ thick. Zipper-tie  600  can be extruded from molten thermo-plastics. 
         [0035]      FIG. 7  represents how zipper-ties  600  are used in the window casing kit  100  ( FIG. 1 ). A casing to jamb joint  700  comprises a window casing  701  joined to a window jamb  702  with one or more zipper-ties  704 . these are pressed into corresponding matching dados  706  and  707  respectively cut into the rear face of casing  701  and the long edge of jamb  702 . The dados  706  and  707  are positioned parallel to their respective longitudinal edges such that an attractive molding reveal  708  will result after assembly. 
         [0036]      FIG. 8  represents a window casing method  800 , in an embodiment of the present invention referred to herein by the general reference numeral  800 . An installer  801  and a factory  802  work together to case windows at a particular jobsite. Installer  801  begins with a step  803  in which particular window openings are identified and measured. This data is then transmitted to the factory in a step  804 , e.g., using a fax, or website on the Internet maintained by the factory  801 . A step  806  receives the data and enters a production order. A step  808  cuts and miters the jambs, casings, sills, and aprons needed for each particular window opening. These are packaged and shipped with the materials and necessary fasteners in a step  810  to the installer and the jobsite. The installer assembles the jambs and sills in a step  812  using the supplied ribbed shank fasteners and corner connectors. The casings are connected to each other using the corner connectors and these are attached to the jambs using the zipper-ties in a step  814 . The assembly is then installed in the window opening in a step  816 . A step  816  finishes the installation by nailing or gluing the whole assembly into the window opening. 
         [0037]      FIG. 9  is a cross-section that represents a second type of zipper-tie  900  in an embodiment of the present invention similar to those shown in  FIGS. 1A ,  6 , and  7 . Zipper-tie  900  is molded from a plastic material about 9.700 mm tall, 3.749 mm overall thickness, and 40-50 mm long with four groups  901 - 904  of feather edges  906 - 921  lay back at about 20° from a opposite noses  922  and  923  on a main body  924 . Main body is narrower at the waist, here about 2.184 mm. Feather edges  906 - 921  are about 0.5 mm thick with tip and valley radii of 0.254 mm, and a feather-to-feather pitch of about 1.081 mm. Noses  922  and  923  have a radii of about 2.54 mm. 
         [0038]    The foregoing dimensions, of course, are merely an example of what has proven to be practical. Other sizes too can work well. 
         [0039]    The advantage of zipper-tie  900  over those shown in  FIGS. 1A ,  6 , and  7 , is that they insert easier into their corresponding dados without getting twisted-in wrong. 
         [0040]    Although the present invention has been described in terms of the presently preferred embodiments, it is to be understood that the disclosure is not to be interpreted as limiting. Various alterations and modifications will no doubt become apparent to those skilled in the art after having read the above disclosure. Accordingly, it is intended that the appended claims be interpreted as covering all alterations and modifications as fall within the “true” spirit and scope of the invention.