Patent Publication Number: US-6907696-B1

Title: Caulk application device

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to the field of construction and specifically to a device and method of applying caulk to a doorframe. 
     Improperly installed exterior doorframes—particularly in residential construction in coastal areas or hurricane zones—are responsible for substantial incursion of water into the interior of the associated buildings, resulting in significant damage. Accordingly, doorframes should properly be secured to the subfloor in a weatherproof manner upon installation. 
     One popular installation method uses a strip of mastic, or adhesive, between the lower edge of the doorframe and the subfloor. One problem with this method is that mastic is a strong and immediate adhesive. Once placed upon the mastic, the doorframe cannot be moved or shimmed to shift its position, level it, or make similar adjustments. 
     An alternative method commonly employed to secure the doorframe to the subfloor involves the use of caulk. Typically, one or two beads of caulk are hand-applied to either the subfloor or the lower edge of the doorframe using a conventional caulking gun, prior to setting the doorframe into place. While this method allows for subsequent adjustment of the doorframe within the rough opening, the amount of caulk dispensed is typically insufficient to properly seal the gap between the doorframe and the subfloor. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a caulk application device. The device includes an adhesive member having an upper and lower face and a longitudinal extent, with at least the lower face thereof (and preferably additionally the upper face) being adhesive and covered with strippable protective covers. The caulk application device also includes at least one receptacle containing caulk affixed to the upper face, which may comprise two caulk-containing chambers separated by a seam of sufficient width to accept nails or staples. The caulk receptacle(s) may include a pull-tab and drawstring along with a perforated or otherwise weakened strip along the exposed surface, to facilitate opening to expose the caulk. Alternatively, they may include a line or other indicia indicating where the receptacle is to be cut. 
     The present invention additionally relates to a method of installing a doorframe in a rough opening. The lower face protective cover is removed from a caulk application device of the present invention, which is laid on the subfloor within the rough opening, with the caulk receptacle aligned with the interior edge. The caulk application device may be secured to the subfloor by fasteners, preferably applied at the seam between caulk chambers of the caulk receptacle. The device ends may be turned up at the corners of the rough opening. A lip opposite the caulk receptacle, protruding to the exterior of the building, may be cut at the corners, and folded down over the exterior, to be covered with siding or the like. The caulk receptacle is opened by actuation of a pull-tab or by cutting open a caulk chamber, exposing the caulk. The doorframe is then set in place, on a bed of caulk that substantially seals all voids between the lower face of the doorframe and the mastic material adhesively bound to the subfloor, and may subsequently be adjusted, shimmed, leveled, and the like. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a perspective view of a section of a caulk application device of the present invention. 
         FIG. 2  is a side section view of the caulk application device of the present invention. 
         FIG. 3  depicts a door assembly, including a rough opening with a doorframe installed therein. 
         FIG. 4  is a sectional view of the lower portion of the doorframe with the caulk application device of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  depicts a caulk application device  10  according to the present invention. The caulk application device  10  comprises a strip of mastic  12 , upon which is disposed at least one receptacle  18  containing caulk. The mastic strip  12  exhibits strong and immediate adhesive characteristics, at least on the lower face thereof, and preferably on both the upper and lower face. The lower face of the mastic strip  12  is covered with a strippable protective cover  16 , such as a thin layer of plastic, wax paper, or the like. The protective strip  16  facilitates the handling of the mastic strip  12 , and protects the adhesive lower face thereof from contamination by dirt and the like. 
     Affixed to the upper face of the mastic strip  12 , positioned adjacent one side thereof, and extending longitudinally substantially the entire length of the mastic strip  12  is at least one receptacle  18  containing caulk  26 . In a preferred embodiment, the receptacle  18  comprises two longitudinal chambers  20  and  22 , spaced apart from each other, and each containing caulk  26 . The chambers  20 ,  22  may be formed, for example, from a single tube or cylinder of plastic, rubber, or similar suitable material, and divided into two chambers  20 ,  22  by a central seam  24 . The seam  24  may be formed by heat sealing, adhesive, or other suitable means. Alternatively, the two chambers  20 ,  22  and intervening seam  24  may be formed as an assembly, such as by extrusion, molding, or other means as are well known in the art. 
     The caulk receptacle  18  is affixed to the upper face of the mastic strip  12 , oriented in a longitudinal direction, and adjacent one edge thereof. In a preferred embodiment, the mastic strip  12  exhibits adhesive qualities on the upper face thereof as well as the lower face, and the caulk receptacle  18  is affixed to the upper face of the mastic strip  12  via the adhesive action of the mastic strip  12 . In this case, a protective cover  14  covers the portion of the mastic strip  12  left exposed. Alternatively, the caulk receptacle  18  may be affixed to the mastic strip  12  by conventional means, such as heat sealing, adhesive, or other suitable means. Upon being affixed to the upper face of the mastic strip  12 , the caulk receptacle chambers  20  and  22  will preferably assume a generally half-cylindrical or half-elliptical cross-section, as depicted in  FIG. 2 . The caulk receptacle chambers  20  and  22  are sealed at either end, to contain the caulk  26 . 
     In a preferred embodiment, the exposed surface of the caulk receptacle  18 , or the caulk-filled chambers that comprise it—and preferably the center or uppermost portion—includes an easy-opening mechanism, such as a pull-tab or drawstring  21 . The pull-tab or drawstring  21  preferably operates in conjunction with a weakened structural zone of the receptacle  18 , such as a perforated or partially perforated strip  23 , a weakened area of plastic, or the like, to facilitate the opening of the receptacle  18  upon actuation of the drawstring  21  or pull-tab. Alternatively, the receptacle  18  may be marked with a line or similar indicia  30  on the exposed surface thereof (and preferably in the center thereof) to indicate where the receptacle  18  may be cut open to expose the caulk  26 . 
     In a preferred embodiment, wherein the mastic strip  12  exhibits adhesive properties on both the lower and upper face thereof, the portion of the upper face of the mastic strip  12  that is not covered by the caulk receptacle  18  is covered with a strippable protective cover  14 . The protective cover  14  is substantially similar to the protective cover  16  applied to the lower face of the mastic strip  12 . The protective cover  14  facilitates the handling and storage of the caulk application device  10 , and protects the exposed adhesive upper face of the mastic strip  12  from the accumulation of dirt and the like. 
     The caulk application device  10  is preferably formed in lengths sufficient to facilitate the installation of standard residential doorframes. The caulk application device  10  may thus be formed in approximately 42-inch lengths for a standard single door, although other lengths are possible within the scope of the present invention. By pre-forming the caulk application device  10  in a length slightly greater than the width of a standard door frame, several inches on either end may be turned up, along the sides of the rough opening, to ensure proper caulking not only across the entire lower extent, but additionally around the lower corners, of the door frame. The mastic strip  12  is preferably approximately 6 inches wide, a dimension that also exceeds the standard residential doorframe. As described below, this excess width additionally facilitates sealing of the doorframe against water incursion. 
     In use, when a doorframe is ready to be installed in a rough opening, the protective cover  16  is removed from the lower face of the mastic strip  12  and discarded. The caulk application device  10  is laid on the subfloor in the rough opening, with the caulk receptacle  18  flush with the interior side of the rough opening, and the opposite edge of the mastic strip  12  protruding to the exterior of the building. The caulk application device  10  is generally centered across the width of the rough opening, with the edges turned up at the corners on either side. The adhesive action of the lower face of the mastic strip  12  secures the caulk application device  10  to the subfloor as soon as it is positioned in the rough opening and pressed into place. Additionally, the caulk application device  10  may be secured to the subfloor by conventional fasteners  28 , such as nails, screws, staples, or the like. The fasteners  28  are preferably applied through the seam  24  between the two caulk-filled chambers  20  and  22  (which are spaced apart to a degree sufficient to facilitate e.g., the hammering of a nail  28  therebetween). 
     The caulk receptacle  18  is then opened, exposing the caulk contained therein. This may comprise pulling a pull-tab or string, if provided, or alternatively may simply comprise cutting along the top of the receptacle  18 , such as with a utility knife, box cutter or similar implement. If the caulk receptacle  18  lacks a perforated seam or pull-tab, it may be marked with a “cut here” line or similar indicia  30 . The doorframe is then set in place in the rough opening. At this point, the doorframe rests on a thick bed of caulk exposed by opening the caulk receptacle  18 . The caulk substantially seals all voids between the mastic strip  12  and the lower edge of the doorframe. In this manner, the paucity of caulk typically employed in sealing the doorframe to the subfloor, due to inexperience or an attempt to reduce cost, is avoided, and a sufficient amount of caulk is necessarily applied. After setting it in place, the doorframe may be freely shifted, adjusted, shimmed, leveled, and the like, and then secured to the subfloor and rough opening jambs in a conventional manner. 
     In a preferred embodiment, the width of the caulk application device  10  of the present invention exceeds the jamb width of the rough opening of a standard residential doorway. As described, the caulk application device  10  is placed in the rough opening with the caulk receptacle  18  aligned with the interior edge. This leaves an edge, or lip, of the mastic strip  12  protruding to the exterior of the building. The protruding lip of the mastic strip  12  may be cut at either corner of the doorframe (where it turns up along the sides), and folded down over the building exterior. When siding or other covering is applied to the exterior of the building, the upper face protective strip  14  is removed, exposing the adhesive upper face of the mastic strip  12 , which facilitates the secure attachment of the siding. The folded-down lip of mastic prevents water from seeping under the mastic strip  12  (i.e., between the subfloor and the lower face of the mastic strip  12 ). The thick bed of caulk exposed by opening the caulk receptacle  18  substantially seals the space between the lower edge of the doorframe and the upper face of the mastic strip  12  against the incursion of water. Thus, the doorframe is completely and properly weather-sealed, curing a major source of water incursion damage. The use of the caulk application device  10  ensures a proper water-tight seal, regardless of the skill, experience, or craftsmanship of the worker installing the door frame. 
       FIG. 3  depicts a representative doorframe  31  installed in a rough opening formed from framing studs  32  and headpiece  34 , which are conventional elements of residential construction, and may for example comprise 2×4&#39;s. The doorframe  31  normally rests on the subfloor  36 , which may for example be formed from plywood. The subfloor  36  in turn rests on framing member  38 , which may for example be a 2×6 or other size board, as appropriate. According to the present invention, the caulk application device  10  is interposed between the lower edge of the doorframe  31  and the subfloor  36 , releasing caulk  26  to substantially fill all voids beneath the lower edge of the doorframe  31 . Note that the edges of the caulk application device  10  are turned up against the jamb of the rough opening on either side, as described above. 
       FIG. 4  is a sectional diagram, taken along the section lines indicated in  FIG. 3 , depicting the relationship between the lower edge of the doorframe  31 , the caulk application device  10 , and the subfloor  36 . The caulk application device  10  is secured to the subfloor  36  by the adhesive action of the mastic strip  12 , and additionally by fasteners  28 . Note that  FIG. 4  depicts the chambers  20 ,  22  of the caulk receptacle  18  prior to opening. In practice, the chambers  20 ,  22  would be opened to expose the caulk  26  prior to setting the doorframe  31  in place over the caulk application device  10 . The portion of the mastic strip  12  protruding to the exterior of the building may be turned down and secured to the subfloor and framing member  38 , as described above, further protecting the building from the incursion of water at the doorway. 
     Although the present invention has been described herein with respect to particular features, aspects and embodiments thereof, it will be apparent that numerous variations, modifications, and other embodiments are possible within the broad scope of the present invention, and accordingly, all variations, modifications and embodiments are to be regarded as being within the scope of the invention. The present embodiments are therefore to be construed in all aspects as illustrative and not restrictive and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.