Window designs typically have an exterior nailing flange and are installed from the exterior side of the building envelope. Two installers work together, one on the interior and the other on the exterior. Some installation crews have determined it is easier to unpackage the window inside the building where it is relatively clean and flat. Then they pass the window through the rough opening (RO) to a person on the exterior side. In some instances, the person on the exterior side is on a ladder, which can substantially complicate installation. The person on the ladder may need to support at least part of the window's weight during installation steps.
Various advantages may be achieved according to the example systems and methods described herein. The various examples may be one or more of: more efficient (e.g., cycle time reduced by 50% or more); easier to learn; easier to remember; easier to train; may be less physically demanding (e.g., window is not set from the exterior side which could be on uneven ground or require a ladder); window is unable to fall out toward exterior during installation; can be installed by a single person from the interior of the building structure; interior and exterior installation tasks do not need to be done simultaneously; improved fenestration install quality and fenestration performance following installation; delivers an installation method that is unique to the industry and offers many benefits for the installer; faster cycle times; improved performance (water and air infiltration); adapts to wall depth variation; simplifies casing installation for finish carpenters; separates interior and exterior work so they can be done “independently”.
The fenestration unit includes an anchoring clip system that may be used to hold and stabilize the fenestration unit within a rough opening framing during installation of the fenestration unit. In some embodiments, the anchoring clip system may be adjustable to accommodate a variety of wall construction depths (e.g., accommodating drywall, foam insulation, sheeting, and/or jamb extensions). The anchoring clip system may provide a means to accurately gauge against the rough opening framing during installation of the fenestration unit.
According to one embodiment (“Embodiment 1”), a fenestration unit has an interior side and an exterior side that is configured for installation in an opening in a structure defined by a rough opening framing. The fenestration unit comprises a frame having a perimeter and defining a center and at least one anchoring clip including a first anchoring clip, the first anchoring clip coupled to the perimeter of the frame and transitionable between a stowed configuration and an installation configuration. The first anchoring clip includes a coupling bracket having a first leg and a second leg and a carrier bracket configured to receive a portion of the first leg. In the stowed configuration, the second leg projects inwardly away from the perimeter toward the center of the frame. In the installation configuration, the second leg projects outwardly from perimeter and away from the center of the frame.
According to another embodiment (“Embodiment 2”), further to Embodiment 1, the first leg and the second leg extend orthogonal to one another.
According to another embodiment (“Embodiment 3”), further to Embodiment 1, the second leg includes at least one aperture configured to receive a fastener for securing the second leg to the rough opening framing when the first anchoring clip is in the installation configuration.
According to another embodiment (“Embodiment 4”), further to Embodiment 1, the coupling bracket includes at least one detent defined along a length of the first leg and the carrier bracket includes at least one catch configured to engage with the at least one detent when the anchoring clip is in the installation configuration.
According to another embodiment (“Embodiment 5”), further to Embodiment 4, the at least one detent is positioned at a pre-selected length along the first leg corresponding to a wall depth of the rough opening framing.
According to another embodiment (“Embodiment 6”), further to Embodiment 5, the wall depth is one of a 2×4 wall depth, a 2×6 wall depth, or a 2×8 wall depth.
According to another embodiment (“Embodiment 7”), further to Embodiment 4, the at least one detent includes a plurality of detents positioned at ⅛-inch increments or less along a portion of the length of the first leg.
According to another embodiment (“Embodiment 8”), further to Embodiment 4, the at least one detent includes a plurality of detents positioned at ⅛-inch increments or greater along a portion of the length of the first leg.
According to another embodiment (“Embodiment 9”), further to Embodiment 1, the first anchoring clip is configured to provide an audible cue when the coupling bracket is received by the carrier bracket and positioned in the installation configuration.
According to another embodiment (“Embodiment 10”), further to Embodiment 1, the carrier bracket includes at least one catch defining a ramp edge and the coupling bracket includes an insert guide defined along a leading edge of the coupling bracket, wherein the ramp edge is configured to contact the insert guide upon insertion of the coupling bracket within the carrier bracket in the installation configuration.
According to another embodiment (“Embodiment 11”), further to Embodiment 10, a portion of the carrier bracket is lifted away from the frame when the coupling bracket is received by the carrier bracket in the installation configuration.
According to another embodiment (“Embodiment 12”), further to Embodiment 1, the first anchoring clip is configured to require 8 lbs of force or less to receive the coupling bracket with the carrier bracket in the installation configuration.
According to another embodiment (“Embodiment 13”), further to Embodiment 1, the first anchoring clip has a first orientation feature defined by the coupling bracket and a second orientation feature defined by the carrier bracket, wherein the first orientation feature and the second orientation feature align with one another when the first anchoring clip is in the installation configuration. Optionally, the first orientation feature and the second orientation feature align when the first anchoring clip is gauged to a standard wall depth of the rough opening framing.
According to another embodiment (“Embodiment 14”), further to Embodiment 1, further including at least one gusset positioned at an intersection of the first leg and the second leg, wherein the gusset creates a gap between the coupling bracket and the perimeter of the frame when the first anchoring clip is in the stowed configuration.
According to another embodiment (“Embodiment 15”), further to Embodiment 14, the gussets are configured to create a marking on the perimeter of the frame when the first anchoring clip is in the installation configuration.
According to one embodiment (“Embodiment 16”) a method of installing a fenestration unit having an interior side and an exterior side within a rough opening of a structure defined by rough opening framing comprises transitioning an anchoring system from a first, stowed configuration to a second, installation configuration, the anchoring system including a plurality of anchoring clips coupled to a perimeter of the fenestration unit, the plurality of anchoring clips including a first anchoring clip, wherein the anchoring system gauges the fenestration unit to an interior side of the rough opening framing, placing the fenestration unit within the rough opening framing from an interior side of the rough opening framing, and securing the anchoring system to the rough opening framing using one or more fasteners.
According to another embodiment (“Embodiment 17”), further to Embodiment 16, the first anchoring clip includes a coupling bracket and a carrier bracket configured to receive a portion of the coupling bracket. Transitioning an anchoring system from a first, stowed configuration to a second, installation configuration further includes removing the coupling bracket from the carrier bracket, rotating the coupling bracket, and re-inserting the coupling bracket into the carrier bracket.
According to another embodiment (“Embodiment 18”), further to Embodiment 17, the coupling bracket includes a first leg and a second leg angularly offset from the first leg. The method further includes removing the first leg from the carrier bracket, rotating the coupling bracket 180 degrees, and re-inserting the first leg into the carrier bracket.
According to another embodiment (“Embodiment 19”), further to Embodiment 17, the coupling bracket includes a first leg and a second leg angularly offset from the first leg. The method including removing the second leg from the carrier bracket, rotating the coupling bracket end-to-end, and inserting the first leg into the carrier bracket.
According to another embodiment (“Embodiment 20”), further to Embodiment 17, the method further includes determining the coupling bracket is seated within the carrier bracket through at least one of an audible cue and a visible cue.
According to another embodiment (“Embodiment 21”), further to Embodiment 16, the first anchoring clip includes a coupling bracket and a carrier bracket configured to receive a portion of the coupling bracket. The method further including gauging a wall depth of the rough opening framing to determine a wall depth and adjusting an insertion depth of the coupling bracket within the carrier bracket based on the wall depth.
According to another embodiment (“Embodiment 22”), further to Embodiment 21, the coupling bracket includes a second orientation feature (e.g., a through hole) defined along a length of the coupling bracket and the carrier bracket includes a first orientation feature (e.g., a notch), the method further including determining the insertion depth by aligning the first orientation feature and the second orientation feature.
According to another embodiment (“Embodiment 23”), further to Embodiment 22, the first anchoring clip includes a coupling bracket defining a plurality of detents along a length of the coupling bracket and the carrier bracket includes one or more catches configured to engage the detents. The method further including receiving the coupling bracket with the carrier bracket such that the at least one catch engages at least one of the detents at a desired position selected based upon the wall depth of the rough opening framing.
According to one embodiment (“Embodiment 24”), an anchoring clip comprises a coupling bracket having a first leg and a second leg, the first leg defining a length, at least one detent is defined along a portion of the length, and a leading end defined at one end of the length, the leading end having an insert guide; and a carrier bracket having a receiving pocket configured to receive a portion of the first leg, the carrier bracket including at least one catch configured to be received within the at one detent to releasably lock the first leg within the receiving pocket of the carrier bracket.
According to another embodiment (“Embodiment 25”), further to Embodiment 24, the at least one catch defines a ramp edge, and wherein, upon insertion of the first leg within the carrier bracket, the insert guide contacts the ramp edges and lifts a portion of the carrier bracket to facilitate receiving the coupling bracket with the carrier bracket.
According to another embodiment (“Embodiment 26”), further to Embodiment 24, the first leg is configured to be received within a generally central position of the receiving pocket, and wherein the at least one catch is configured to direct the insert guide to the generally central position of the receiving pocket.
According to another embodiment (“Embodiment 27”), further to Embodiment 24, the carrier bracket includes a backing plate and a receiver, and the receiving pocket is defined between the backing plate and the receiver.
According to another embodiment (“Embodiment 28”), further to Embodiment 24, the anchoring clip is configured to provide audible cue when the coupling bracket is received at a pre-selected depth within the carrier bracket.
According to another embodiment (“Embodiment 29”), further to Embodiment 24, the coupling bracket defines a first orientation feature, and the carrier bracket defines a second orientation feature. The first orientation feature and the second orientation feature are aligned with one another when the coupling bracket is received within the carrier bracket.
According to another embodiment (“Embodiment 30”), further to Embodiment 29, the anchoring clip is configured to be gauged to a wall depth defined by a rough opening framing. The pre-selected depth optionally corresponds to the wall depth.
The foregoing embodiments and additional embodiments described herein should not be read to limit or otherwise narrow the scope of any of the inventive concepts otherwise provided by the instant disclosure. While multiple examples are disclosed, still other embodiments will become apparent to those skilled in the art from this specification and its drawings, which show and describe various illustrative examples. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature rather than restrictive in nature.
The accompanying drawings are included to provide a further understanding of the disclosure and are incorporated in and constitute a part of this specification, illustrate embodiments, and together with the description, serve to explain the principles of the disclosure.
This disclosure is not meant to be read in a restrictive manner. For example, the terminology used in the application should be read broadly in the context of the meaning those in the field would attribute such terminology.
With respect to terminology of inexactitude, the terms “about” and “approximately” may be used, interchangeably, to refer to a measurement that includes the stated measurement and that also includes any measurements that are reasonably close to the stated measurement. Measurements that are reasonably close to the stated measurement may deviate from the stated measurement by a reasonably small amount as understood and readily ascertained by individuals having ordinary skill in the relevant arts. Such deviations may be attributable to measurement error, differences in measurement and/or manufacturing equipment calibration, human error in reading and/or setting measurements, minor adjustments made to optimize performance and/or structural parameters in view of differences in measurements associated with other components, particular implementation scenarios, imprecise adjustment and/or manipulation of objects by a person or machine, and/or the like, for example. In the event it is determined that individuals having ordinary skill in the relevant arts would not readily ascertain values for such reasonably small differences, the terms “about” and “approximately” can be understood to mean plus or minus 10% of the stated value.
Persons skilled in the art will readily appreciate that various aspects of the present disclosure can be realized by any number of methods and apparatuses configured to perform the intended functions. It should also be noted that the accompanying drawing figures referred to herein are not necessarily drawn to scale and may be exaggerated to illustrate various aspects of the present disclosure, and in that regard, the drawing figures should not be construed as limiting.
Various concepts of this patent specification address installation systems and methods for fenestration units, such as windows and doors. Some features of such systems and methods include one or more of the following: the fenestration unit configured to be set into a rough opening (RO) from the interior side of a building structure or wall defined by a rough opening framing; gauging to the interior face of rough opening framing for more accurate finishing (e.g., drywall and/or trim) offsets; the fenestration unit having attached pre-applied (e.g., factory-applied) anchoring clips configured for interior unit installation; and the fenestration unit being configured to be installed by a single person/installer.
In various examples, the fenestration units (e.g., fenestration unit 10) include features that promote installation of the fenestration unit from an interior side of a rough opening (RO) using a methodology that can be readily achieved by a single installer. In particular, a fenestration unit according to various examples includes an engagement system coupled to the frame, the engagement system configured to positively engage the interior face of the rough opening framing upon insertion of the fenestration unit in the rough opening (RO) from the interior side of the rough opening (RO). In this manner, a single individual may insert a fenestration unit into the rough opening (RO) on the interior side thereof and secure the fenestration unit to the interior side of the rough opening framing without needing a second person to hold the fenestration unit against the rough opening framing from an exterior side thereof. The engagement system, also referred to herein as an anchoring clip system, may hold and stabilize the fenestration unit within a framing of the rough opening (RO) such that shims are not required to hold the fenestration unit in place.
In various embodiments, the fenestration unit is anchored to and stabilized against an interior side of the rough opening framing via the anchoring clip system. Anchoring to the exterior side of the rough opening framing is not required, and in some examples, is not possible. In some examples, the exterior side of the rough opening framing includes insulation (e.g., a foam board), which is relatively soft, and does not provide a solid surface to anchor against, or to drive fasteners therethrough. By providing the anchoring clip system that interfaces with the interior side of the framing, challenges due to insulation may be lessened.
As shown in
As shown, the frame 30 may be a wood frame (e.g., aluminum clad wood) design. However, vinyl, fiberglass, or other materials may be implemented for the frame 30. The frame 30 also includes an outer perimeter P and has a front face 42, or interior face 42 (
As shown in
In use, each of the anchoring clips 102 can be set at an intended depth, or gauged, for installation (e.g., to accommodate jamb extensions and/or drywall returns which are not shown). The anchoring clips 102 can help gauge the fenestration unit 10 from an interior face of the rough opening (RO). This gauging capability helps ensure a proper offset for drywall thickness or other wall features and may help eliminate or reduce such problems as jamb extensions of the fenestration unit 10 being “proud” or “recessed” from an interior face of the finished wall surface (e.g., inner drywall face). The resulting installation using the anchoring clips 102 may help ensure flush jamb extensions relative to the interior face of the wall (e.g., inner drywall face) which makes the installation of trim (e.g., casing) of the fenestration unit 10 much more efficient for subsequent detailing steps (e.g., finish carpenters). The anchoring clips 102 may be coupled to the frame 30 either forward of the jamb extensions (e.g., in a more exterior direction, situated on the frame base) or may be coupled to the jamb extensions themselves.
In some implementations, the anchoring clips 102 are initially provided to an installer (e.g., shipped or delivered to the installer) attached to the fenestration unit 10 in a stowed configuration, for example as shown in
Anchoring clips 102 may also have different adjustment settings or features on different portions of the anchoring clips 102 such that the anchoring clips 102 may be flipped to accommodate different (e.g., greater) adjustability. For example, one portion (e.g., one leg) of the anchoring clip 102 may have a first set of adjustment features (e.g., to accommodate ½-inch or ⅝-inch interior drywall thickness offsets) and another portion (e.g., another leg) of the anchoring clip 102 may have a second set of adjustment features (e.g., multiple slots for ⅛-inch or 1/16-inch incremental adjustments over a desired distance).
With the foregoing in mind, as shown in
As shown, the first anchoring clip 102a includes a carrier bracket 110 configured to be coupled to the perimeter P (
The coupling bracket 112 is securable to the carrier bracket 110 such that the coupling bracket 112 can be transitioned between a first stowed configuration (
As shown in
In some embodiments, the first orientation feature 111a and the second orientation feature 111b align with each other when the first anchoring clip 102a is gauged to a standard wall depth of the rough opening (RO) framing. The standard wall depth is defined by both a depth of the wall/framing (e.g., a 2×4, a 2×6, or a 2×8 depth) and an exterior sheeting thickness (e.g., a ½-inch or 7/16-inch exterior sheeting thickness). In embodiments where the first anchoring clip 102a is gauged to a non-standard wall depth (e.g., any depth between the 2×4, 2×6, or 2×8 depths with exterior sheeting thickness), the orientation features 111 may not align with one another. Additionally, as further discussed below, an Installer may listen for an audible and/or tactile “click” between the carrier bracket 110 and the coupling bracket 112 during insertion of the coupling bracket 112 within the carrier bracket 110. The audible and/or tactile “click” indicates to the Installer that the first coupling bracket 102a is correctly gauged to the wall depth, and that the coupling bracket 112 is in a secure state with the carrier bracket 110.
The receiver 122 has a retaining lip 132 and a retention member 134. The retaining lip 132 acts as both a guide and a retainer under which the coupling bracket 112 may be slid. The retaining lip 132 may define a first side portion 132a and a second side portion 132b toward the edges of the retaining pocket 130 for securing corresponding portions of the coupling bracket 112. The first side portion 132a and the second side portion 132b may be raised relative to an outer perimeter, or outer edge portion, of the receiver 122 to receive a portion of the coupling bracket 112. As referenced above, the first orientation feature 111a may be defined on at least one of the first and second side portions 132a, 132b by a curved cutout. The cutout may be the shape of half circle, as shown, or take any of a variety of shapes (e.g., triangular, square, or others). The first orientation feature 111a may additionally or alternatively be a surface feature (e.g., etching, stamping, embossing) or marking (ink, paint, or the like) as desired.
The retention member 134 may be formed by a portion of the retaining lip 132. As shown in
Although insertion force to insert the coupling bracket 112 into the carrier bracket 110 are relatively low, in various examples the coupling bracket 112 and the carrier bracket 110 form a strong mechanical interlock with each other that is generally not susceptible to inadvertent release or decoupling. The strong mechanical interlock helps keep the coupling bracket 112 coupled within carrier bracket 110 (e.g., within the retaining pocket 130). When the anchoring clip 102a is in the second, installation configuration, and anchored to the rough opening framing, the first anchoring clip 102a provides wind-load resistance to the fenestration unit 10.
As shown in
In use, the flex tab 142 may be outwardly deflected to release, or translate, the one or more catches 150 in an outward direction, and once released the flex tab 142 will resiliently flex back into its original position. As shown in
The retention member 134 further includes a release handle 144 that projects relative to the flex tab 142. For example, the release handle 144 may be oriented to project toward the front, or interior side, of the frame 30, the release handle 144 being operable to be lifted away from the frame 30 to actuate, or release, the retention member 134 from one or more of the detents 174 of the coupling bracket 112 (e.g., as shown in
The one or more gussets 160 may also create a space (e.g., an air space or gap) between the frame 16 and the face of the coupling bracket 112. This space or gap may help prevent damage (e.g., abrasion) to the coupling bracket 112 or the frame 30 when shipped in the stowed configuration (
As mentioned, the first anchoring clip 102a is configured to be transitioned from the stowed configuration to the installation configuration. In the first, stowed configuration, the first leg 114 is slidably received by the carrier bracket 110 and the second leg 116 may instead extend along a portion of the fenestration unit 10 (e.g., extend in the opposite direction from the second, installation configuration). In the second, installation configuration, the first leg 114 is slidably received by the carrier bracket 110 such that the second leg 116 is configured to be secured to framing surrounding a rough opening (RO) in a building structure using one or more fasteners (e.g., nails or screws). The fasteners may be received through the one or more fastener apertures 180 defined through a thickness of the second leg 116. In the second, installation configuration, the second leg 116 may be configured to rest flat against the rough opening framing when the fenestration unit 10 is installed within the rough opening (RO). The anchoring clip(s) may thereby be used to ensure proper registration, or depth of installation of the fenestration unit in the rough opening (RO).
The anchoring clip(s) may be reversible by design. For example, the first and second legs 114, 116 may be reversible in function wherein both the first and second legs 114, 116 are configured to be slidably received by the carrier bracket 110 and both are configured to be secured to framing surrounding the rough opening (RO). If desired, the two legs may be gauged to different size wall depths, providing greater overall flexibility to the anchoring clip(s).
In various embodiments, the first anchoring clip 102a may be packaged in the first, stowed configuration for shipping. The first, stowed configuration helps to protect the first anchoring clip 102a during shipping and may require less packaging compared to scenarios in which the first anchoring clip 102a is shipped in the second, installation configuration and/or separately from a remainder of the fenestration unit 10. Upon receipt, and prior to or during installation of the fenestration unit 10, the first anchoring clip 102a may be transitioned from the first, stowed configuration to the second, installation configuration.
The second leg 116 of the coupling bracket 112 optionally includes a release aperture 162 through a thickness of the second leg 116. As can be visualized with reference to
As shown, the first leg 114 has first and second edges 166, 168 that are opposite one another, a length L1, and a leading end 170 at one end of the length L1 including an insert guide 172 in the form of a rounded projection. The insert guide 172 may assist with aligning and inserting the first leg 114 into the carrier bracket 110 as the leading end 170 is inserted into the carrier bracket 110. As shown, the coupling bracket 112 may be received at a generally central position within the retaining pocket 130. Where the coupling bracket 112 is inserted at a lateral angle relative to the generally central position (e.g., off axis-loading) the ramp edge 151 may contact the insert guide 172 and correct alignment between the carrier bracket 110 and the coupling bracket 112. The contact between the ramp edge 151 and insert guide 172 helps guide the coupling bracket 112 to the generally central, axially aligned position within the retaining pocket 130. In some embodiments, upon insertion, the insert guide 172 engages the one or more catches 150 of the carrier bracket 110 to raise the receiver 122 and self-load within the retaining pocket 130. In particular, upon insertion of the coupling bracket 112 within the carrier bracket 110, the insert guide 172 may engage the ramp edge 151 (
The first leg 114 also has one or more detents 174 (a pair of first detents 174a as shown) at one or more longitudinal positions along the length L1 of the first leg 114. The one or more detents 174 may take the form of slots through the thickness of the first leg 114 as shown, but other configurations (e.g., partial depth detents) may also be employed. The one or more detents 174 may receive the one or more catches 150 of the carrier bracket 110 when the first anchoring clip 102a is in the second, installation configuration. The one or more longitudinal positions of the one or more detents 174 are selected according to a desired offset, or pre-selected depth, of the second leg 116 from the front face 42 of the frame 30 when the coupling bracket 112 is in the second, installation configuration. The desired offset, or pre-selected depth may generally correspond to the wall depth of the rough opening (RO) framing and the exterior sheeting thickness, as described above. In the embodiment of
The second leg 116 defines one or more fastener apertures 180 configured to receiver one or more fasteners (not shown), such as screws or nails. The second leg 116 also has a length L2, which may be selected to ensure sufficient overlap with the framing surrounding a rough opening (RO) (not shown) to ensure the fasteners are able to bite into the framing. The fastener apertures 180 may be recessed or countersunk in order to allow screw heads to be mounted flush. In this way, the fasteners will not interfere with drywall or other wall treatments installed over the second leg 116.
The second leg 116 may include a tab 182 on one side of the length L2. The tab 182 may include a center portion 184 and define one or more recessed portions 186 on either side of the center portion 184. In some embodiments, the center portion 184 of the second leg 116 has a different shape than the insert guide 172 of the first leg 114 such that the installer can quickly visualize whether the first anchoring clip 102a is in the first, stowed configuration or the second, installation configuration. The shape of tab 182 may also be used to visually and/or tactilely distinguish between different coupling bracket embodiments, such as coupling bracket 212 (
The coupling bracket 112 may be fastened to the rough opening (RO) and removed from the rough opening (RO) without damaging the components of the coupling bracket 112. The coupling bracket 112 may be removed from the rough opening (RO) using standard tools (e.g., a screwdriver). The one or more fastener apertures 180 may be placed at different lengths along the second leg 116 to account for differences in drywall thickness and lengths of different spaces between the frame 30 and the rough opening (RO).
In
As shown in
In the second, installation configuration as shown in
As shown, the first anchoring clip 102b includes a carrier bracket 110 and a coupling bracket 212. The carrier bracket 110 of the first anchoring clip 102b may be substantially similar to the carrier bracket 110 of the first anchoring clip 102a, as described above. The same carrier bracket 110 may be compatible with a variety of coupling bracket designs, including the coupling bracket 112 of
As shown, the first anchoring clip 102b may include one or more coin lines or indented lines 250 across at least a portion of the width of the first anchoring clip 102b. As shown, the indented line 250 is positioned along the width of the first leg 214, but the indented line 250 may be positioned along either of the first or second legs 214, 216. The indented line 250 may allow an installer to shorten the length of the first anchoring clip 102b. For example, after the installer reinserts the coupling bracket 212 into the carrier bracket 110, the coupling bracket 212 may extend too far away from the frame 30, which may affect the installation of features around the fenestration unit 10 such as additional drywall or paint. To shorten the coupling bracket 212, the installer may bend either the first leg 214 back-and-forth along the indented line 250 such that a first portion 275 of first leg 214 is broken off and removed. When the first portion 275 is removed, a second portion 278 remains for coupling to the carrier bracket 110. Shortening the coupling bracket 212 may increase adjustability of the first anchoring clip 102b to accommodate various wall depths as desired. For example, shorting the coupling bracket 212 may allow the coupling bracket to gauge against a shorter 2×4 wall depth instead of a longer 2×6 wall depth.
Similar to coupling bracket 112, the coupling bracket 212 includes a leading end 270a at one end including an insert guide 272a in the form of a rounded projection. The insert guide 272a may also define a recessed portion 273 on either side of the insert guide 272a that helps reduce friction upon insertion of the coupling bracket 212 within the carrier bracket 110 by helping to ensure the one or more catches 150 of the carrier bracket 110 minimally contact the coupling bracket 112. In examples where the first portion 275 of the first leg 214 is removed at the indented line 250, the first anchoring clip 102b may be configured substantially similar to the first anchoring clip 102a. For instance, removing a portion of the first leg 214 exposes a second leading end 270b positioned at the indented line 250. The second leading end 270b may define a second insert guide 272b, which is substantially similar to the insert guide 172. In some embodiments, the indented line 250 extends across the entire width of the first leg 214 such that the second insert guide 272b may be removed with the first portion 275 of the first leg 214. In other embodiments, the indented line 250 may extend discontinuously across only a portion of the width of the first leg 214 such that the second insert guide 272b remains coupled to the first anchoring clip 102b upon removal of the first portion 275. In such embodiments, the first leg 214 may define a relief portion 276 about the second insert guide 272b. The relief portion 276 may be defined through a thickness of the first leg 214 and may prevent the second insert guide 272b from being bent upon removal of the first portion 275.
As shown, the first anchoring clip 102b includes one or more detents 274, or one or more pairs of detents 274, along a length of the first leg 214. The one or more detents 274 may be substantially similar to the one or more detents 174 of the first anchoring clip 102a as described above. As shown, the first anchoring clip 102b includes a first pair of detents 274a and a second pair of detents 274b. In some embodiments, multiple pairs of detents 274 permit the retention member 134 of the carrier bracket 110 to be releasably locked at first and second offset distances from the front of the frame 30 as desired. For example, as shown in
Similar to the first anchoring clip 102a, the first anchoring clip 102b may include at least one orientation feature 211 that gives the installer visual indication that the coupling bracket 212 is properly engaged and seated within the carrier bracket 110 when the first anchoring clip 102b is in the second, installation configuration, and that the first anchoring clip 102b is gauged to the correct wall depth. The carrier bracket 110 may include a first orientation feature, similar to the first orientation feature 111a described above. The coupling bracket 212 may define a second orientation feature 211b defined by the first portion 275 of the first leg 214 and a third orientation feature 211c defined by the second portion 278 of the first leg 214, both of which are complementary in shape to the first orientation feature 211a. The second and third orientation features 211b and 211c may be defined through a thickness of the first leg 214 and may be rounded, though other shapes are contemplated. In embodiments in which the first anchoring clip 102b is gauged to the 2×6 wall depth, the first orientation feature 111a of the carrier bracket 110 aligns with the second orientation feature 211b of the coupling bracket 212 (e.g., as shown in
As shown in
As shown, the first anchoring clip 102c includes a carrier bracket 110 and a coupling bracket 312. The carrier bracket 110 of the first anchoring clip 102c may be substantially similar to the carrier bracket 110 of the first anchoring clip 102a, as described above. The same carrier bracket 110 may be compatible with a variety of coupling bracket designs, including the coupling bracket 112 of
As shown, the first anchoring clip 102c has a plurality of pairs of detents 374 along the length of the first leg 314. In some examples, the plurality of pairs of detents 374 permit the retention member 134 of the carrier bracket 110 to be releasably locked at first and second offset distances from the front of the frame 30 as desired. For example, the second offset distance may be approximately 0.125 inches greater than the first offset distance, such that the first anchoring clip 102c is configured to accommodate different installation depths, for example to accommodate different thickness wall coverings (e.g., drywall) or fenestration unit features (e.g., jamb extended fenestration units or handles). The pairs of detents 374 may be substantially similar to the detents 174 (
As shown, the first anchoring clip 102c may be adjustable between a 2×8 wall depth, a 2×6 wall depth, a 2×4 wall depth, and non-standard wall depths therebetween. The first anchoring clip 102c may optionally include one or more coin lines, or indented lines 350, similar to the indented lines 250 of the first anchoring clip 102b, described above. As shown, the first anchoring clip 102c includes a first indented line 350a and a second indented line 350b, where both the first and second indented lines 350a and 350b are positioned along a width of the first leg 314. The first indented line 350a may be positioned between a first portion 352 of the first anchoring clip 102c and a second portion 354 of the first anchoring clip 102c. In embodiments where the installer bends the first indented line 350a, the first portion 352 may be removed and the length of the first anchoring clip 102c is shortened. In some embodiments, this allows the first anchoring clip 102c to be shortened to gauge against a 2×6 wall depth instead of a 2×8 wall depth, or a non-standard wall depth less than the 2×6 wall depth. The second indented line 350b may be positioned between the second portion 354 of the first anchoring clip 102c and a third portion 356 of the first anchoring clip 102c. In embodiments where the installer bends the second indented line 350b, the second portion 354 (and the first portion 352 if not previously removed) may be removed and the length of the first anchoring clip 102c is further shortened. In some embodiments, this allows the first anchoring clip 102c to be shortened to gauge against a 2×4 wall depth instead of a 2×6 wall depth, or a non-standard wall depth less than the 2×4 wall depth. Shortening the coupling bracket 312 may further permit the adjustability of the first anchoring clip 102c. The first anchoring clip 102c may further define a notch 390, or a slot 390, along a portion of the length of the first leg 314 to assist with gauging, which is further described below.
Similar to the first anchoring clips 102a, 102b, the first anchoring clip 102c may include at least one orientation feature 311 that gives the installer a visual indication that the coupling bracket 312 is properly engaged and seated within the carrier bracket 110 in the second installation configuration, and that the first anchoring clip 102c is gauged to the correct wall depth. The carrier bracket 110 may include a first orientation feature, similar to the first orientation feature 111a described above. The coupling bracket 312 may define a second orientation feature 311b defined through a thickness of the first portion 352 of the first leg 314, a third orientation feature 311c defined through a thickness of the second portion 354 of the first leg 314, and/or a fourth orientation feature 311d defined through a thickness of the third portion 356 of the first leg 314, all of which are complementary in shape to the first orientation feature of the carrier bracket 110. The second, third, and fourth orientation features 311b, 311c, and 311d may be rounded, though other shapes are contemplated. In embodiments in which the first anchoring clip 102c is gauged to the 2×8 wall depth, the first orientation feature 111a of the carrier bracket 110 aligns with the second orientation feature 311b of the coupling bracket 312 (e.g., as shown in
As shown in
Installation of the fenestration unit 10 can proceed in view of the various concepts described in the foregoing sections. In particular, installation of the fenestration unit 10 in the rough opening (RO) may proceed from the interior side of the rough opening (RO) and may be executed by a single installer on the interior side of the rough opening (RO).
As part of the installation process, the rough opening (RO) in the building structure should be prepared for fenestration unit 10 installation. Generally, the rough opening (RO) is sized to be between ½ inches and ¾ inches larger than the fenestration unit 10 in both width and height, although other setups may also be suitable. Some methods also include forming the rough opening (RO), such as by cutting out the rough opening (RO) (e.g., plywood cladding covering rough opening framing). The sill portion of the framing of the rough opening (RO) (lower framing) may be flashed (e.g., using appropriate flashing tape).
The fenestration unit 10 is then partially deployed from the stowed to the active configuration. In particular, the anchoring clips 102 (including any of first anchoring clips 102a, 102b, or 102c) are transitioned to the installation configuration by removing the coupling brackets 112, 212, or 312 from the carrier brackets 110, rotating them 180 degrees so they no longer extend inward toward the center of the fenestration unit 10, and then re-inserting the coupling brackets 112, 212, or 312 into the carrier brackets 110 such that the coupling brackets 112, 212, or 312 project radially outward from outer perimeter P of the frame 30. In various examples, in both the first, stowed configuration and the second, installation configuration, the first leg 114, 214, or 314 of the respective coupling brackets 112, 212, or 312 is received by the carrier bracket 110, and the respective second legs 116, 216, or 316 project relative to the perimeter P of the frame 30. In the first, stowed configuration, the first leg 114, 214, 314 projects inward relative to the perimeter P of the frame 30 (
In the first, stowed configuration, the carrier bracket 112, 212, and 312 is positioned against the perimeter P of the frame 30 to minimize the profile of the fenestration unit 10 and protect the respective first anchoring clip 102 during shipping. As shown in
As shown in
In some examples, the one or more markings 400 may correspond to a standard wall depth of the rough opening (RO) and indicate a length of the first leg 314 that corresponds with the standard wall depth. As shown, the one or more markings include a first marking 402 (e.g., “2×4”), an optional second marking 404 (e.g., “2×6”), and/or an optional third marking (e.g., “2×8”) that correspond to 2×4, 2×6, and 2×8 wall depths, respectively. For example, the first marking 402 is positioned between the second coin line 350b (
The one or more markings 400 on the first leg 314 may also include one or more arrows 410, where the one or more arrows indicate an insertion direction of the coupling bracket 312 into the carrier bracket 110 in the second, installation configuration (
Advantageously, in various implementations, no tools are needed for the foregoing steps. In other words, the removal, reversal, re-insertion, and coupling/assembly of the anchoring clips 102 can be accomplished by hand. If it is desired to remove the coupling brackets 112 from the carrier brackets 110 after the catches 150 have engaged the detents 174, a user may lift the catches 150 from the detents 174 using the release handle 144 (e.g., using by hand and/or by using a tool such as a screwdriver as previously described) and the coupling brackets 112 may then be withdrawn.
In gauging the anchoring system 100 to a non-standard wall depth using first anchoring clips 102c, the slot 390 may be utilized. In one embodiment, as shown in
The fenestration unit 10 is inserted or pushed into the rough opening (RO) from the interior side of the rough opening (RO), for example by a single installer. The fenestration unit 10 may be passed from the exterior, through the rough opening (RO) and then repositioned or pushed or pulled in an exterior direction to seat the fenestration unit, but this is generally less preferred. The ability and functionality to be installed from an interior side of the unit can be an important feature of the fenestration unit 10, as traditional fenestration installations require at least one installer on the exterior side of the rough opening (RO) and/or at least one installer on the interior side of the rough opening (RO).
The fenestration unit 10 is inserted into the rough opening (RO) until the anchoring clips 102 engage the edges of the rough opening (RO), and specifically the jamb portions of the rough opening framing. The anchoring clips 102 act as an engagement system that is positively engaged with the interior face of the rough opening framing from the interior side of the rough opening (RO) upon insertion therein.
The fenestration unit 10 is then centered in the rough opening (RO). The fenestration unit 10 may be centered side-to-side by inserting a screwdriver having a standard head (e.g., ¼-inch-thick head) and rotating the screwdriver to ensure a minimum desired gap is achieved at the first and second jambs 34, 36. To begin the shimming/levelling processes, a level is used to check the horizontal level of the fenestration unit 10 and one or more shims may be applied as needed to achieve a desired level.
Once a desired levelling and spacing is achieved at the sill portion of the fenestration unit 10, fasteners (e.g., screws or nails) are driven through the anchoring clips 102, corresponding to the two bottom-most clips on the fenestration unit 10, and into the rough opening framing.
The fenestration unit 10 can then continue to be plumbed, squared, and fully coupled to the framing of the rough opening (RO). For example, a user may plumb one of the first jamb 34 and the second jamb 36 to vertical level. In some embodiments, an installer may use an air bag designed for such a purpose that can be inflated to adjust the gap between the first and second jambs 34, 36 and the rough opening framing, and thus vertical level thereof, or other suitable methods may be implemented as desired. Once plumbed to be vertically level, the remaining anchoring clips 102 are fastened to the rough opening framing until all anchoring clips 102 are attached to the rough opening framing using one or more fasteners such that the fenestration unit 10 is structurally secured to the rough opening (RO).
Various advantages may be achieved according to the foregoing example systems and methods. The various examples may be one or more of: more efficient (e.g., cycle time reduced by 50% or more); easier to learn; easier to remember; easier to train; may be less physically demanding (e.g., fenestration unit 10 is not set from the exterior side which could be on uneven ground or require a ladder); fenestration unit 10 is unable to fall out toward exterior during installation; can be installed by a single person from the interior of the building structure; interior and exterior installation tasks do not need to be done simultaneously; improved fenestration unit 10 install quality and fenestration unit 10 performance following installation; delivers an installation method that is unique to the industry and offers many benefits for the installer; faster cycle times; improved performance (water and air infiltration); adapts to wall depth variation; simplifies casing installation for finish carpenters; separates interior and exterior work so they can be done “independently”.
The invention of this application has been described above both generically and with regard to specific embodiments. It will be apparent to those skilled in the art that various modifications and variations can be made in the embodiments without departing from the scope of the disclosure. Thus, it is intended that the embodiments cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
This application claims priority to the following: U.S. Provisional Patent Application No. 63/558,603, entitled “Fenestration Unit Installation Clips and Associated Methods”, filed Feb. 27, 2024; U.S. Provisional Patent Application No. 63/581,834, entitled “Fenestration Unit with Interior Installation Features and Associated Systems and Methods”, filed Sep. 11, 2023; U.S. Provisional Patent Application No. 63/520,276, entitled “Fenestration Unit with Interior Installation Features and Associated Systems and Methods”, filed Aug. 17, 2023; U.S. Provisional Patent Application No., 63/463,103 entitled “Fenestration Unit with Interior Installation Features and Associated Systems and Methods”, filed May 1, 2023. The contents of each application are hereby incorporated by reference in their entirety.
Number | Date | Country | |
---|---|---|---|
63558603 | Feb 2024 | US | |
63581834 | Sep 2023 | US | |
63520276 | Aug 2023 | US | |
63463103 | May 2023 | US |