Patent Publication Number: US-8109052-B2

Title: Monolithic fenestration construction member and wall and fenestration assembly using the same

Description:
FILED OF THE INVENTION 
     The present invention relates generally to building fenestrations, and more particularly, relating to a monolithic fenestration construction member. 
     BACKGROUND OF THE INVENTION 
     Water penetration is one of the most significant factors leading to premature failures of structures. One of the most common failure points where water enters a building&#39;s envelope is around exterior windows and doors. In conventional constructions, the ability to prevent water intrusion around window and door fenestrations is highly dependent upon the skill of the carpenter constructing the fenestration and the durability and reliability of the various materials used. 
     In a conventional fenestration construction, there are several separate assemblies that, if not constructed properly, will lead to failure and water intrusion. One area prone to failure, resulting in water intrusion, is the rough opening that is framed into the frame of the exterior wall into which the window is to be installed. The rough opening is essentially comprised of a header, a sill, and a pair of spaced trim studs extending vertically between the header and sill. The rough opening can be considered the base from which the remaining fenestration is built. If the rough opening is not constructed to be perfectly square (for rectangular windows) with an equal sized opening and with the correct opening dimensions for a particular window, the remaining construction becomes more difficult and more likely to fail. Another area prone to failure is the waterproof membrane that is installed around the rough opening on top of the wall&#39;s exterior sheeting, and in some applications installed over the nail fin of the window. The waterproof membrane is typically cut into long strips and is layered around the rough opening such that adjacent strips are overlapped with the vertical most layer being on top. The waterproof membrane must be carefully installed to ensure proper alignment with the rough opening and to overlay adjacent waterproof membrane layers. Another area prone to failure is the flashing that is installed along the top of the window once the window has been installed, and in some applications, the sill pan flashing that is installed along the sill of the rough opening before the window is installed. 
     In addition to the above, another potential problem area includes the surround trim and the sill. If the surround trim and sill is not properly sized and installed correctly, water can be directed to failure prone areas of the fenestration construction. Further, improperly sized and/or installed surround trim and sill assemblies result in a less than desirable appearance. Further, it requires a skilled carpenter to install surround trim and sills on multiple similar fenestrations while maintaining consistency between each fenestration such that each fenestration has the same visual appearance. 
     Accordingly, it is desirable to have a fenestration construction member which overcomes the disadvantages of the prior art, and provides increased waterproofing by integrating fenestration construction into a unitary, monolithic member that is easily installed by less skilled laborers. 
     SUMMARY OF THE INVENTION 
     The preferred embodiments of the present invention address this need by providing a fenestration construction member that is factory built and is easily installed onsite. The preferred embodiments further provide a monolithic fenestration construction member having a window assembly receiving opening into which the window assembly will fit properly with close tolerance. The preferred embodiments further provide a monolithic fenestration construction member having integrated therewith a decorative, architecturally correct, maintenance free, pre-assembled window surround trim and sill assembly. The preferred embodiments further provide a monolithic fenestration construction member which reduces the time and number of materials required to construct a fenestration. The preferred embodiments further provide a monolithic construction member that is installed and attached to the framing of a wall prior to the attachment of exterior sheeting, and thereby provides a shiplap construction increasing the waterproofing of the through wall opening. The preferred embodiments further provide a monolithic construction member where the surround trim and sill assemblies are installed prior to installation of the window assembly. 
     To achieve these and other advantages, in general, in one aspect, a fenestration construction member for preventing intrusion of water and air around through wall penetrations is provided. The construction member includes a monolithic frame having a front surface, a rear surface, and peripheral wall extending between the front and rear surfaces. The peripheral wall having an inward facing surface and an outward facing surface. The inward facing surface of the peripheral wall defining a through opening into which is positionable a window assembly in sealing contact with the inward facing surface. The monolithic frame further having a sill pan flange extending continuously around the interior facing surface in a direction inwardly therefrom. The monolithic frame further having a fastening flange extending in a direction outwardly from the outward facing surface. The monolithic frame being positionable in a wall frame having a rough opening defined by a sill, a header and a pair vertical jambs extending therebetween with the peripheral wall extending into the rough opening and with the fastening flange abutting an exterior surface of the wall frame. 
     In general, in another aspect, wall and fenestration assembly is provided. The wall and fenestration assembly includes a framed wall having an interior facing surface, an exterior facing surface, and a wall opening defined by a sill, a header and a pair vertical jambs extending between the sill and header, and exterior sheeting attached to and covering the exterior facing surface of the framed wall. The exterior sheeting having an opening corresponding to the wall opening. The assembly further includes a monolithic frame having a front surface, a rear surface, and peripheral wall extending between the front and rear surfaces. The peripheral wall having an inward facing surface and an outward facing surface. The inward facing surface of the peripheral wall defining a through opening into which is positionable a window assembly in sealing contact with the inward facing surface. The monolithic frame further having a sill pan flange extending continuously around the interior facing surface in a direction inwardly therefrom. The monolithic frame further having a fastening flange extending in a direction outwardly from the outward facing surface at an offset distance from the front surface in a direction towards the back surface. The monolithic frame further having a peripheral outward facing sealing surface between the front surface and the fastening flange. The monolithic frame is positioned with the peripheral wall extending into the wall opening, with the fastening flange fastened to the framed wall, with the exterior sheeting sandwiching the fastening flange between the exterior surface and the exterior sheeting, and with the exterior sheeting sealed against at least the sealing surface of the monolithic frame. 
     There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be better appreciated. 
     Numerous objects, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art upon a reading of the following detailed description of presently preferred, but nonetheless illustrative, embodiments of the present invention when taken in conjunction with the accompanying drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting. 
     As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
     For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are included to provide further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate preferred embodiments of the invention and together with the description serve to explain the principles of the invention, in which: 
         FIG. 1  is a front perspective view of a monolithic fenestration construction member in accordance with the principles of the present invention; 
         FIG. 2  is a rear perspective view of the monolithic fenestration construction member of  FIG. 1 ; 
         FIG. 3  is an exterior partial perspective view of a typical exterior building wall frame having a rough opening for a window; 
         FIG. 4  is the perspective view of  FIG. 3  with a fenestration construction member and exterior sheeting attached to the wall frame, and with the exterior sheeting partially removed to expose underlying portions of the fenestration construction member; 
         FIG. 5  is a transverse cross sectional view taken along line  5 - 5  in  FIG. 4  through the wall, the fenestration construction member and the exterior sheeting; 
         FIG. 6  is a perspective view of a fenestration construction member and wall in an alternate installed configuration; 
         FIG. 7  is a transverse cross sectional view taken along line  7 - 7  in  FIG. 6  through the wall and fenestration construction member; 
         FIG. 8  is front elevation view of a fenestration construction member having an alternative surround trim and sill; and 
         FIG. 9  is front elevation view of a fenestration construction member having an alternative surround trim and sill. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In  FIGS. 1 and 2 , there is depicted a monolithic fenestration construction member  10  in accordance with the principals of the present invention, and hereinafter referred to as a construction member.  FIG. 1  is a front perspective view of the construction member  10 , and  FIG. 2  is a rear perspective view of the construction member of  FIG. 1 . The intended use of the construction member  10  is in providing a factory built fenestration opening in a building where a window or door will properly fit according specified requirements, and thereby providing the highest possible sound and heat insulation attainable with the respective window or door. Further, the construction member  10  integrates into a single, monolithic member the fenestration opening, waterproofing flashing, the surround trim and the sill, which heretofore required skilled carpenters to install each separately during different phases of construction. 
     The construction member  10  includes a frame  12  that is molded or otherwise fabricated to be unitary and monolithic. The term monolithic, as used herein, has the meaning of formed or composed of a material without joints or seams. The frame  12  is constructed of a material non-porous to both water and air. In one aspect, the frame  12  is molded from a composite fabric sheet material bonded by a resin. The fabric sheet material can be of a fiber glass material. The frame  12  includes a front surface  14 , a rear surface  16 , and a peripheral wall  18  generally extending between the front and rear surfaces. The front and rear surfaces  14  and  16  are longitudinally spaced and are substantially parallel to each other. The peripheral wall  18  has an outward facing surface  20  and an oppositely-facing inward facing surface  22 . The outward facing surface  20  and inward facing surface  22  are laterally spaced the thickness of the peripheral wall  18 . The inward facing surface  22  defines a through opening  24 , which extends longitudinally through the frame  12  from the front surface  14  to the rear surface  16 . 
     The frame  12  further includes a sill pan flange  26 . The sill pan flange  26  extends in a inwardly direction from the inward facing surface  22  continuously around the through opening  24 . The sill pan flange  26  has oppositely facing sill pan flange surfaces  28  and  30 , and a peripheral sill pan flange edge  32 . The sill pan flange surface  28  and  30  are generally parallel to each other. The sill pan flange edge  32  defines a sill pan flange opening  35  that is narrower than the through opening  24 . As shown, the sill pan flange  26  has a zero offset distance as measured from the rear surface  16  of the peripheral wall  18  with sill pan flange surface  30  flush with the rear surface. However, the sill pan flange  26  could be longitudinally offset in an inwardly direction a distance from the rear surface  16  of the peripheral wall according to desired specifications. In one aspect, the sill pan flange  26  extends from the inward facing surface  22  at a right angle thereto, and the sill pan flange edge  32  is parallel to the inward facing surface. 
     The through opening  24  is dimensioned to receive therein a window assembly (not shown) to be in sealing contact with the inward facing surface  22  and the sill pan flange  26  to provide a watertight and airtight installation between the through opening and the window assembly. 
     The frame  12  further includes a fastening flange  34 . The fastening flange  34  extends in a direction outwardly from the outward facing surface  20  of the peripheral wall  18  continuously around the peripheral wall and terminates at fastening flange edge  36 . The fastening flange  34  has oppositely facing fastening flange surfaces  38  and  40 . In one aspect, the fastening flange  28  is planar and lies in a plane parallel to the front surface  14  of the frame  12 . The fastening flange  34  serves as the attachment point between the frame  12  of the construction member  10  and the frame of the wall to which the construction member is to be used in connection with. In one aspect, the fastening flange  34  is offset a distance from the front surface  14  in a direction towards the back surface  16 . The distance the fastening flange  34  is offset from the font surface  14  is at least equal to the thickness of exterior sheeting of the building wall, as will be described in further detail below. 
     The frame  12  can further include a peripheral sealing surface  46  located between the peripheral outward edge  48  of the front surface  14  and surface  38  of the fastening flange  34 , and continuously around the peripheral outward edge  48  of the front surface  14 . The sealing surface  46  is generally normal to surface  38  of the fastening flange  34 , and the fastening flange edge  36  extends outwardly beyond the sealing surface  46 . 
     In an aspect, the frame  12  can further include decorative molding which may include surround trim  50  and optionally a sill  52 . The surround trim  50  and the sill  52 , when provided, frame the through opening  24 , and can at least partially form the front surface  14 . As illustrated in  FIGS. 1 and 2 , The through opening  24  is rectangular shaped and includes two spaced vertical sides extending between an upper and a lower horizontal side. The surround trim  50  is provided along the two vertical sides, and the upper horizontal side, while the sill  52  is provided along the lower horizontal side. With the surround trim  50  and sill  52  molded integral and monolithic with the frame  12 , there are no seams or joints that need to be sealed or flashed to prevent water or air intrusion. 
     In  FIG. 3 , there is illustrated a typical building exterior wall frame  54  having a top plate  56 , a sole plate  58  and a plurality of spaced studs  60  extending vertically between the top plate and the sole plate. The wall frame  54  further includes a wall opening  62  for receiving a window. The rough opening  62  is defined by a header  64 , a sill  66  and a pair of spaced trim studs  68  extending vertically between the header and the sill. The wall frame  54 , as shown in  FIG. 3 , is prior to the attachment of exterior sheeting, such as ply wood, to the exterior surface  70  of the wall frame. 
     In  FIG. 4 , there is illustrated the wall frame  54  with the construction member  10  and exterior sheeting  72 . The exterior sheeting  72  is shown in partial section to illustrate portions of the underlying wall frame  54  and the frame  12  of the construction member  10 . In  FIG. 5 , there is illustrated a transverse cross-section through the wall frame  54 , construction member  10 , and exterior sheeting taken along line  5 - 5  as depicted in  FIG. 4 . 
     With further reference to  FIGS. 4 and 5 , initially the peripheral wall  18  of frame  12  is inserted through the rough opening  62  with the fastening flange  34  abutted against the exterior surface  70  of the wall frame  54 . The frame  12  is secured to the wall frame  54  by a plurality of penetrating fasteners  74  driven through the fastening flange  34  and into the wall frame  54 . With the frame  12  secured to the wall frame  54 , the front surface  14  and sealing surface  46  is spaced outwardly from the exterior surface  70  of the wall frame. Exterior sheeting  72  cut to conform to the sealing surface  46  is secured to the wall frame  54  sandwiching the fastening flange  34  between the exterior sheeting and the wall frame, with sheeting edge  76  sealed against sealing surface  46 . A bead of adhesive sealant  78  can be applied to the sealing surface  46  prior to attachment of the exterior sheeting  72  to the wall frame  54  to provide a sealing contact between sheeting edge  76  and sealing surface  46 . Alternatively, a bead of adhesive sealant could be applied to the interface edge between the sheeting edge  76  and the sealing surface  46  after attaching the exterior sheeting to the wall frame  54  with the sheeting edge abutted against the sealing surface. 
     Alternatively, with reference to  FIGS. 6 and 7 , the construction member  10  can be installed subsequent to the attachment of the exterior sheeting  72  to the wall frame  54 . In this arrangement, the exterior sheeting  72  is initially attached to the wall frame  54  to include an opening  80  corresponding to the rough opening  62  of the wall frame. At this point, a vapor barrier could be installed on the exterior sheeting. The peripheral wall  18  of frame  12  is inserted through opening  80  and rough opening  62  with the fastening flange  34  abutted against the exterior surface  82  of the exterior sheeting  72 . The frame  12  is secured to the exterior sheeting  72  and wall frame  54  by a plurality of penetrating fasteners  74  driven through the fastening flange  34  and into the exterior sheeting and wall frame. Optionally, a bead of an adhesive sealant  84  could be applied to the interface surfaces between the fastening flange and the exterior sheeting. 
     Once attached to the exterior sheeting  72  and wall frame  54  a vapor barrier  86  is applied to the exterior sheeting  72  and frame  12  overlapping at least the fastening flange  34  and the exterior surface  82  of the exterior sheeting. In  FIG. 6 , the vapor barrier  86  is partially cut-away to illustrate the fastening flange  34 . The vapor barrier  86  can be of many different products used in the industry to water-proof adjoining surfaces, such as for example, adhesive flashing (peel-and-stick flashing) or liquid membrane. 
     Once installed, as depicted and discussed, the construction member  10  provides a wall and a fenestration assembly that is in “shiplap” fashion so that water cannot penetrate the wall about the construction member. 
     In an aspect, the peripheral wall  18  may extend through the rough opening  62  and beyond the interior surface of the wall frame  54  such that the back surface  16  of the frame is spaced inwardly from the wall frame. In this manner, the back surface  16  can be made to be flush with or to extend beyond interior wall finishing, such as drywall or plaster. 
     In  FIGS. 8 and 9 , there is depicted a construction member  10  having alternative decorative surround trim  50  and sill  52 , respectively as an illustration of possible variations from the construction member depicted in  FIGS. 1-7 . 
     A number of variations are possible, for example, while the construction member as depicted and described herein includes a peripheral wall  18  and through opening being generally rectangular shaped, the through opening  24  and/or the peripheral wall  18  can take various other shapes. For example, the peripheral wall  18  could be rectangular shaped for installation in combination with wall frame having a corresponding rectangular shaped rough opening, while the through opening  24  could be circular shaped to receive a circular window assembly therein. Moreover, while the description herein is primarily directed towards window fenestrations, the construction member  10  is equally suitable for door fenestrations. Another possible variation include angling of the fastening flange  36  with respect to the front surface  14  to permit installation and attachment of the construction member to an angled wall surface while permitting a window or door to be vertically orientated. Other variations are also possible. 
     A number of embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, while the description made herein is directed towards creating window openings in walls, the window buck of the present invention could easily be used to form other openings in walls, such as door openings. Accordingly, other embodiments are within the scope of the following claims.