The present invention relates to trim for exterior window casings in commercial and residential building construction, and more particularly to a trim system that replicates the look of wood trim while functioning to easily attach to and protect an exterior window frame.
Modern window frames and frame members are typically prefabricated members constructed from vinyl, aluminum, or composite materials. The window frames are installed during new construction of a building, such as a house, or during replacement of existing windows. During new construction, a window frame is installed within a rough opening formed within and defined by the frame of a building structure. The window frame may include a nailing flange extending radially from the window frame and around the rough opening, and during installation, nails, staples or other fastening means may be used to secure the nailing flange, and thus the window frame, to the plywood sheathing of the building.
Prefabricated window frame members are often formed from a material such as vinyl or polyvinyl chloride (PVC) using extrusion processes. Molten metal or plastic is forced, drawn or extruded through a die for shaping into window frame members. After extrusion, the extruded window frame member continues to a cooling tank section or calibrator where it is reshaped and cooled in order to harden the member. The member may then be cut into usable or transportable lengths for use as a window frame member.
Trim members, some referred to as “brick mold” may be applied to the exterior periphery of the window frame to provide a finished appearance. Original trim members were made of wooden moldings which were mitered to provide a cover for the rough window frame. These trim members also extended beyond the outer periphery of the window frame to cover a portion of the siding or brick facing of the house structure to which the window frame is attached. The use of wooden trim members required careful sealing of the miter joints and the connections between the trim, the window frame, and the siding/brick facing to prevent moisture accumulation that could lead to premature rotting or other degradation of the trim, window and/or building structure. More modern approaches involve the use of vinyl trim members that are impervious to such moisture-induced rotting. Such vinyl trim members, however, did not completely mimic the look of real wood. Faced with a choice, customers resisted use of such vinyl trim members based on the lack of an aesthetically pleasing design.
Additionally, when vinyl trim members are used, it is still important that the trim members form a desired seal with the window frame to prevent moisture from penetrating between the trim and the window frame. Previous vinyl trim members used a variety of techniques to address this moisture ingress problem, including the use of caulking between the trim and frame, as well as the implementation of drain or “weep” holes in the structure to allow collected water to drain away from the frame, trim and building structure. These approaches, however, can be costly to implement from a manufacturing and/or manpower perspective. Additionally, they may require periodic maintenance, for example, to remove and replace worn or damaged caulk.
Thus, there is presently a need for a highly durable and easy to manufacture trim system for use with new construction and replacement windows. Further, there is a need for an aesthetically pleasing and cost effective trim system that can be attached to a window frame to effectively conceal portions of a siding or sheathing product attached to a building. There is also a need for a trim system that can easily and inexpensively seal the associated window frame to provide long term protection against moisture ingress.
A window trim molding segment is disclosed. The molding segment may comprise a first portion for engaging a window frame member at a first location. The first portion may have a first flexible sealing element for engaging said window frame member to provide a substantially water-tight seal between the molding segment and the window frame member. The molding segment may have a second portion for engaging said window frame at a second location. The second portion may be configured to receive a fastener for fixing the molding segment to the window frame. The molding segment may further have a third portion for engaging a building structure. The third portion may optionally comprise an elongated flange element having sufficient lateral extension to allow a fastener to be received by said flange element to fix the molding segment to an adjacent building structure. The first, second and third portions may comprise a material having a first hardness, flexibility or stiffness and the flexible sealing element may comprise a material having a second hardness, flexibility or stiffness wherein the first hardness or stiffness is greater than the second hardness or stiffness, and the first flexibility is less than the second flexibility.
A molding segment is disclosed for use in window trimming. The molding segment may comprise a first portion for engaging a window frame member at a first location, the first portion having an integral flexible sealing member for engaging the window frame member to provide a water-tight seal between the molding segment and the window frame member. The molding segment may have a second portion for engaging said window frame at a second location, the second portion configured to receive a fastener for fixing the molding segment to the window frame. The molding segment may further have a third portion for engaging a building structure, the third portion comprising an elongated flange element for receiving a fastener to fix the molding segment to an adjacent building structure. The first, second and third portions comprise a material which is relatively inflexible and the integral flexible sealing member comprises a material which is relatively flexible, wherein the integral flexible sealing member is biased against an exterior surface of the window frame member.
A molding segment comprising: a first portion for engaging a window frame member at a first location, the first portion having an integral flexible sealing member for engaging the window frame member to provide a water-tight seal between the molding segment and the window frame member; a second portion for engaging said window frame at a second location, the second portion configured to receive a fastener for fixing the molding segment to the window frame a third portion for engaging a building structure, said third portion comprising an elongated flange element for receiving a fastener to fix the molding segment to an adjacent building structure; wherein the first, second and third portions comprise rigid PVC having a first hardness and the integral flexible sealing member comprises flexible PVC having a second hardness, wherein the first hardness is greater than the second hardness.
The accompanying drawings illustrate preferred embodiments of the invention so far devised for the practical application of the principles thereof, and in which:
A design is disclosed for exterior casing trim for vinyl windows having a wood-like appearance. These exterior casing trim designs replicate the traditionally trimmed look of wood trim on windows and doors, and will be applied to finished widows or doors to provide this look. A four-sided frame of the trim will be assembled, and the window frame then will be installed inside it. The two may be fastened together using sealant, staples, or other fastening methods.
Referring to
Additionally, in the illustrated embodiments disclosed herein, sashes 14 and 16 are shown as having double glazing, i.e., where each glass panel 10, 12, comprises a pair of glass sheets, respectively. However, it will be appreciated that different glazing configurations may also be utilized, and single or triple glazed windows are also within the scope of the present disclosure.
As illustrated in
Referring to
The jamb frame member 8 may have a variety of additional features typical for such frame elements, such as a window seat 42, an interior accessory channel 44 for accepting and securing interior window accessories such as trim (not shown) to the window frame assembly 1, a grid slot 46 for permitting a decorative grid or muntin accessory to be secured over a window that is secured to the window seat 42, a weep channel 48 for draining water away from the window, and glazing bead channel 50 shaped to permit decorative glazing beads (not shown) to be secured to a window frame member. The jamb frame member 8 may further have an exterior surface 52 designed to be exposed to the weather when the window frame assembly 1 is installed. One or more support columns 54 may also be provided within the jamb frame member 8 to add stability to the frame member and to enable the member to maintain its manufactured form throughout the life of the frame. It will be appreciated that although these enumerated frame element features are described in relation to the jamb frame member 8, they may also be incorporated into header frame member 2, sill frame member 4 and jamb frame member 6.
The brick mold casing 34 may have an inner facing portion 56 for engaging the second flange member 40. The inner facing portion 56 may comprise an extending nail fin portion 58 which is positioned to abut the building structure when the window frame assembly 1 is installed. This nail fin portion 58 provides a broad surface for receiving nails, staples or the like to fix the window frame assembly to the building structure in new construction (though it is not always needed in the replacement market). For nailing purposes, one or more openings or grooves (not shown) may be provided in the nailfin portion 58 to make nailing or stapling easier. The inner facing portion 56 of the brick mold casing 34 may comprise a reinforcing, or double, wall 60 for receiving a staple 62 or other appropriate fastener to attach the brick molding casing 34 to the window frame (in this case the jamb frame member 8).
An inner perimeter region 64 may be shaped to conform to a portion of the first flange member 38 of the jamb frame member 8. In the illustrated embodiment, the inner perimeter region may comprise a “z-shaped” surface 66 configured to match a corresponding surface 68 of the first flange member 38 so that a “z-shaped” groove 70 is formed therebetween. Caulk 72 or similar gasket material may be introduced within this groove (by application to one or both of surfaces 66, 68) during fit-up of the brick mold casing 34 to the jamb frame member 8. This caulk 72 or gasket material may prevent the ingress of moisture between the brick mold casing 34 and the jamb frame member 8.
To further minimize the penetration of moisture between the two pieces, a flexible seal 74 may be provided on the brick mold casing 34 directly adjacent to the exterior surface 52 of the jamb frame member 8. As shown in greater detail in
In one embodiment, the flexible seal 74 is co-extruded with the remainder of the casing 34. As such, the casing 34 may be fabricated from a substantially rigid PVC material having a hardness of from about 60 to about 85 Shore D, while the flexible seal 74 may comprise a relatively flexible PVC material having a hardness of from about 45 to about 100 Shore A. In a preferred embodiment, the rigid PVC material may have a hardness of about 65 Shore D, while the flexible PVC material may have a hardness of about 70 Shore A. Alternatively, the flexible seal 74 may be manufactured as a separate piece and applied to the casing 34 by gluing, heat sealing or other appropriate technique. Additionally, it may be possible to manufacture the casing 34 and flexible seal 74 from the same material, where the flexible seal 74 is formed in a reduced thickness sufficient to provide a desired degree of flexibility for sealing purposes.
It is noted that although the embodiment of
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Since the flat trim casing 82 will engage the same window frame members as the brick mold casing 34, the flat trim casing will have substantially the same structural configuration as the brick mold casing 34 with regard to the manner in which it engages the associated window frame member (header 2, sill 4 and jamb 6, 8 frame members). Thus, the flat trim casing 82 may have an inner facing portion 156 for engaging the second flange member 40 of the jamb frame member 8. The inner facing portion 156 may comprise an optional extending nail fin portion 158. The inner facing portion 156 of the flat trim casing 82 may further comprise a reinforcing wall 160 for receiving a staple 162 or other appropriate fastener for attaching the flat trim casing 82 to the window frame. An inner perimeter region 164 may be shaped to conform to a portion of the first flange member 38 of the jamb frame member 8. As with the brick mold casing 34, the inner perimeter region 164 of the flat trim casing 82 may comprise a “z-shaped” surface 166 that forms a “z-shaped” groove 170 with opposing surface 68 of the jamb member 8. Caulk 172 or gasket material may be provided within the groove 170 to prevent the ingress of moisture between the flat trim casing 82 and the jamb frame member 8.
Flexible seal 174 may be provided on the flat trim casing 82 directly adjacent to the exterior surface 52 of the jamb frame member 8. The flexible seal 174 may have all of the characteristics of the seal 74 described previously in relation to
Additionally, the flat trim casing 82 may comprise an exterior cladding pocket 176 into which the cladding (e.g., brick, siding) of the building structure is received during construction. One or more screw ports 178 may be provided adjacent the external surface 84 of the casing 82 to enable attachment of an optional sill nose profile 80 (see
Referring to
To provide an additional degree of vertical stability to the engagement between the sill nose profile 80 and the sill frame member 4, a locking tab 275 may be provided adjacent the inner facing portion 256 of the sill nose profile 80 to engage a corresponding lip 41 on the sill frame member 4. This lip 41 may be located adjacent the intersection of the first flange member 4 and the support column 54 of the sill frame member 4 to provide a stiff surface for supporting the sill nose profile 80. Thus, the interaction between the corresponding horizontal surfaces of the tab 275 and lip 41 enable direct transmission of vertical force (once the window frame assembly has been installed in the building structure) between the profile 80 and frame member 4 so that the profile will not “sag” over the lifetime of the unit. This additional support is highly advantageous because the staples 262, while providing good lateral support to fix the sill nose 80 to the sill frame 4, may not provide the desired degree of long term vertical support between the pieces.
As previously noted, the sill nose profile 80 may be fixed to the adjacent pieces of brick mold casing 34 or flat trim casing 82 to form a desired window trim assembly for covering the perimeter formed by the window frame members 2, 4, 6, 8. Thus, one or more screw cavities 286 may be provided within the profile 80 through which one or more screws (not shown) may be inserted to engage the screw ports 78, 178 (
The external surface 284 of the sill nose profile 80 may be sloped away from the window in a traditional manner so as to allow water to run away from the window frame. The external surface 284 may be embossed or have other surface finishing to provide a desired wood grain appearance, similar to the other trim elements previously described.
A flexible seal 274, similar to those previously described in relation to
The sill nose profile 80 may further comprise an exterior cladding pocket 276, similar for receiving building structure cladding. This exterior cladding pocket 276 may be substantially the same as the cladding pockets 76, 176 described in relation to
Referring now to
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The previous descriptions relate to the discrete interactions between individual trim and window frame structures. To manufacture and install a four-sided assembly of trim members to the respective four elements of a window frame (header 2, sill 4 and jambs 6, 8), four individual pieces of trim must be joined to provide a smooth, aesthetically pleasing frame structure. Thus, where a “picture frame” type trim assembly is desired, four individual pieces of brick mold casing 34 or flat trim casing 82 may be selected, cut, and mitered at each end in a manner typical for joining molding members. The casing pieces are then joined together, and finally fixed as an assembly to an associated window frame. In the embodiment in which the casings 34, 82 are manufactured from PVC, the individual trim elements may be hot plate welded together.
Where a sill nose profile 80 is used (
While this invention has been described with respect to particular embodiments thereof, it is apparent that numerous other forms and modifications of this invention will be obvious to those skilled in the art. The appended claims and this invention generally should be construed to cover all such obvious forms and modifications which are within the true spirit and scope of the present invention.