Patent Application
20250075556
The field of this disclosure relates generally to fenestration units and, more particularly, to a fenestration unit with a sill arrangement fluid management system for limiting water intrusion into a building or dwelling interior.
Fenestration units, may provide a degree of protection against water intrusion into the building. The unit may include certain features that help serve as a weather-proofing barrier for the fenestration unit. These features may block and/or divert water away from the fenestration unit and from the interior of the building to avoid mildew, rot, or other water damage.
However, these systems may disadvantageously add complexity and/or cost to the fenestration unit. There may be manufacturing inefficiency, increased assembly time, and/or other disadvantages. These problems may be particular to fenestration units with moveable panels (e.g., a sliding door unit with a horizontally-sliding door panel or a window unit with a horizontally-sliding sash).
Accordingly, there is a need for a sill arrangement for a fenestration unit that incorporates an improved water management system for providing drainage and/or diversion of water away from the sill arrangement and the fenestration unit. There is also a need for such a sill arrangement having a streamlined and simple design that reduces manufacturing costs and assembly time and that simplifies installation. Additionally, there is a need for a sill arrangement that is strong and robust for supporting the panel(s) and other components of the fenestration unit. Additional aspects and advantages will be apparent from the following detailed description of example embodiments, which proceeds with reference to the accompanying drawings.
A sill arrangement for a fenestration frame configured for supporting a panel is disclosed. The sill arrangement includes a sill that is elongate and that includes a first longitudinal end and a second longitudinal end. The sill includes a first chamber, a second chamber, a third chamber, and a fourth chamber. The sill includes a first internal wall that separates the first chamber from the second chamber. The sill arrangement also includes a corner key having a sill-facing surface, and the corner key is coupled to the first longitudinal end of the sill along the sill-facing surface. The corner key includes a first port included on the sill-facing surface. The first port defines a first fluid passage between the first and second chambers of the sill. The first port defines a second fluid passage between the second and third chambers of the sill. Moreover, a second port is included on the sill-facing surface and offset from the first port. The second port defines a third fluid passage between the third and fourth chambers. The corner key further includes a drain in fluid communication with the fourth chamber and configured to direct fluid from the fourth chamber and out of the corner key.
Additionally, a fenestration unit is disclosed, which includes a first panel, a second panel, and a frame that supports the first panel and the second panel. The frame includes a sill arrangement having a sill that is elongate and that includes a first longitudinal end and a second longitudinal end. The sill includes a first chamber, a second chamber, a third chamber, and a fourth chamber. The sill includes a first internal wall that separates the first chamber from the second chamber. The sill includes a slider rail configured to support the first panel for sliding movement on the slider rail within the frame. The slider rail is aligned with the first internal wall. The sill arrangement further includes a corner key having a sill-facing surface. The corner key is coupled to the first longitudinal end of the sill along the sill-facing surface. The corner key includes a first port included on the sill-facing surface. The first port defines a first fluid passage between the first and second chambers of the sill. The first port defines a second fluid passage between the second and third chambers of the sill. The corner key also includes a second port included on the sill-facing surface and offset from the first port. The second port defines a third fluid passage between the third and fourth chambers. Additionally, the corner key includes a drain in fluid communication with the fourth chamber and configured to direct fluid from the fourth chamber and out of the corner key.
Furthermore, a method of assembling a sill arrangement for a fenestration frame configured for supporting a panel is disclosed. The method includes providing a sill that is elongate and that includes a first longitudinal end and a second longitudinal end. The sill includes a first chamber, a second chamber, a third chamber, and a fourth chamber. The sill includes a first internal wall that separates the first chamber from the second chamber. Additionally, the method includes attaching sill-facing surface of a corner key to the first longitudinal end of the sill. The corner key includes a first port included on the sill-facing surface, the first port defining a first fluid passage between the first and second chambers of the sill, the first port defining a second fluid passage between the second and third chambers of the sill. The corner key also includes a second port included on the sill-facing surface and offset from the first port. The second port defines a third fluid passage between the third and fourth chambers. The corner key also includes a drain in communication with the fourth chamber and configured to direct fluid from the fourth chamber and out of the corner key.
The present disclosure will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:
With reference to the drawings, this section describes embodiments of a sill arrangement for a fenestration unit and its detailed construction and operation. Throughout the specification, reference to “one embodiment,” “an embodiment,” or “some embodiments” means that a particular described feature, structure, or characteristic may be included in at least one embodiment of the sill arrangement. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” or “in some embodiments” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the described features, structures, and characteristics may be combined in any suitable manner in one or more embodiments. In view of the disclosure herein, those skilled in the art will recognize that the various embodiments can be practiced without one or more of the specific details or with other methods, components, materials, or the like. In some instances, well-known structures, materials, or operations are not shown or not described in detail to avoid obscuring aspects of the embodiments.
Generally, embodiments of the present disclosure include a sill arrangement for a fenestration unit that is configured with features of a water management system. In some embodiments, the sill arrangement may be configured for supporting a sliding panel, such as a horizontally-sliding door or window.
During extreme weather events, the exterior of the fenestration unit may be subjected to elevated air pressure and/or intensive precipitation. As these conditions continue for prolonged periods of time, a substantial pressure differential may be created between the exterior environment (high pressure region) and interior environment (low pressure region). This pressure differential may result in water being forced through the sill arrangement, such as through small openings or seams at various adjoining surfaces, and toward the interior of the building or dwelling. Thus, the sill arrangement includes a fluid management system (also referred to as “water management system”) that handles, directs, channels, pushes, or otherwise moves water or other liquids that have entered the sill arrangement and allow it to drain away and back to the exterior environment. The sill arrangement may also manage percolation, bubble, and/or other airflow therethrough for additional performance advantages.
These embodiments may be used for any suitable fenestration system. In some embodiments, the fenestration system of the present disclosure may be a patio door system for a building, dwelling, or other structure. The sill arrangement may include a sill and a pair of corner keys at each end. In a completed fenestration frame assembly, each corner key may couple to and support an upright jamb member. In some embodiments, the sill arrangement and the other components of the frame may support a moveable or active panel, such as a sliding door panel. In other embodiments, the sill arrangement may support another door panel or window sash configuration. The water management system may include features that bolster support of an active panel (i.e., a panel moveably supported within the frame) while also allowing fluid flow through the sill arrangement.
During use, water may move through channels, openings, ports, apertures, etc. that are defined by the sill, the corner key(s), and/or other components of the sill arrangement for diverting water away from the sill arrangement and from an interior of the dwelling. Thus, the water management system may limit, impede, or otherwise reduce water intrusion into the structure. The sill assembly may also direct air, bubbles, etc. for improved performance. Furthermore, the sill assembly may avoid negative effects caused by pressure differences between the interior and exterior of the dwelling.
The fenestration unit 102 may include a rectangular frame 104 that defines a first axis 103, a second axis 105, and a third axis 107, which are orthogonal to each other. The second axis 105 may be a vertical axis that is generally aligned with the direction of gravity, the first axis 103 may be a horizontal axis extending across the frame 104, and the third axis 107 may be a horizontal axis extending in an interior-exterior direction through the frame 104.
The fenestration unit 102 may also include a first panel 106, and a second panel 108. The first and second panels 106, 108 may be supported within the frame 104. In some embodiments, the second panel 108 may be fixed within the frame 104, and the first panel 106 may be supported for movement within the frame 104 between a closed position and an open position. The first panel 106 may be supported for sliding movement along the first axis 103 as the first panel 106 moves within the frame between the closed and open positions. The first panel 106 is shown in a closed position in solid lines in
The frame 104 may include a sill arrangement 110 and a header 111 that are spaced apart along the second axis 105. The frame 104 may also include a first jamb 113 and a second jamb 115 that are attached to the sill arrangement 110 and the header 111 and that are spaced apart along the first axis 103.
In some embodiments, the sill arrangement 110 may generally include at least one elongate sill 112 (i.e., sill member) and at least one corner key 118. In some embodiments, there may be a single elongate sill 112 with opposing corner keys 118 at each longitudinal end. One corner key 118 may attach to a first longitudinal end 121 of the sill 112 and may also attach to the first jamb 113. The other corner key 118 may attach to the other, second longitudinal end 123 of the sill 112 and may also attach to the second jamb 115. Stated differently, at least one end 121 of the sill 112 is attached to a corner key 118 as described below.
The sill 112 may be a straight, lineal, elongate, thin-walled, and hollow member. The sill 112 may be a single, unitary, one-piece part. In additional embodiments, the sill 112 may include multiple parts that are assembled together, for example, to form the profile shape shown in
The sill 112 is shown in further detail in
As shown in
The outer wall 69 may also define the first end 121 of the sill 112. At the first end 121, the sill 112 may be planar. In other words, the first end 121 may lie within a common plane 39 (
The sill 112 may have a height dimension 89 (
The sill 112 may also include a slider rail 202 that projects upward from the top side 84. The slider rail 202 may be disposed between the middle lip 73 and the interior lip 71 and offset from each along the third axis 107. The slider rail 202 may extend longitudinally along the first axis 103. The first panel 106 may slide along the slider rail 202 as it slides between its open and closed positions along the first axis 103. As shown in phantom in
As shown in
The outer wall 69 and the internal walls 24, 26, 28 are arranged to define four distinct and hollow chambers 32, 34, 36, 38 of the sill 112. The chambers 32, 34, 36, 38 may each extend along the length of the sill 112 between the first and second longitudinal ends 121, 123. Specifically, the sill 112 may include a first chamber 32, a second chamber 34, a third chamber 36, and a fourth chamber 38.
The first chamber 32 may be disposed proximate the interior side 88. The first chamber 32 may be defined by the outer wall 69 at the interior side 88 and the first internal wall 24, and the first chamber 32 may be defined by the outer wall 69 at the top side 84 and bottom side 86 of the sill 112.
The second chamber 34 may be disposed closer to the interior side 88 than the exterior side 90 as measured along the third axis 107, but the first chamber 32 may be disposed closer to the interior side 88 than the second chamber 34. The second chamber 34 may be disposed between the third chamber 36 and the first chamber 32 along the third axis 107. The second chamber 34 may be defined by the first internal wall 24 and the second internal wall 26 along the third axis 107. Thus, the first internal wall 24 may separate the first chamber 32 from the second chamber 34, and the second internal wall 26 may separate the second chamber 34 from the third chamber 36. The second chamber 34 may also be defined by the outer wall 69 at the top side 84 and bottom side 86 of the sill 112 along the second axis 105.
The third chamber 36 may be disposed closer to the exterior side 90 than the interior side 88 as measured along the third axis 107, but the fourth chamber 38 may be disposed closer to the exterior side 90 than the third chamber 36. The third chamber 36 may be disposed between the second chamber 34 and the fourth chamber 38 along the third axis 107. The third chamber 36 may be defined by the second internal wall 26 and the third internal wall 28 along the third axis 107. The third chamber 36 may also be defined by the outer wall 69 at the top side 84 and bottom side 86 of the sill 112 along the second axis 105. Additionally, the third chamber 36 may have an L-shaped cross section with a portion of the third chamber 36 extending into the middle lip 73.
Moreover, the fourth chamber 38 may be disposed proximate the exterior side 90. The fourth chamber may be defined (along the third axis 107) by the third internal wall 28 and the outer wall 69 at the exterior side 90. Furthermore, the fourth chamber 38 may be defined along the second axis 105 by the outer wall 69 at the top side 84 and bottom side 86 of the sill.
The bottom side 86 of the sill 112 may include a plurality of support rails projecting therefrom. For example, the outer wall 69 may include a first support rail 161, a second support rail 163, and a third support rail 165, which project therefrom in a downward direction from the bottom side 86. The first, second, and third rails 161, 163, 165 may extend in a longitudinal direction along the first axis 103 and may extend continuously from the first longitudinal end 121 to the second longitudinal end 123. The first support rail 161 may be substantially aligned along the second axis 105 with the first internal wall 24. The second support rail 163 may be substantially aligned along the second axis 105 with the second internal wall 26 and may increase stiffness and strength of the sill 112. The third support rail 165 may be substantially aligned along the second axis 105 with the third internal wall 28 and may increase stiffness and strength of the sill 112.
Moreover, the slider rail 202 may be substantially aligned along the second axis 105 with the first internal wall 24 and the first support rail 161. Thus, there may be an aligned vertical path for weight and other loads from the first panel 106 to distribute from the slider rail 202, through the first internal wall 24, and to the first support rail 161. Accordingly, the sill 112 may provide robust support for the first panel 106, for example, as the first panel 106 slides along the slider rail 202.
The sill 112 may be tilted downward slightly from the interior side 88 to the exterior side 90. In some embodiments, the first support rail 161 may be taller than the second support rail 163, and the second support rail 163 may be taller than the first support rail 165 to pitch and tilt the outer wall 69 toward the exterior.
As shown in
The corner keys 118 of the sill arrangement 110 will now be discussed, initially with reference to
The corner key 118 may be block-like and may be thinner along the first axis 103 as compared to a width of the corner key 118 along the third axis 107. The corner key 118 may generally include a sill-facing surface 44 (
As shown in
As shown in
The corner key 118 may further include a drain 65 (
Also, as shown in
The sill-facing surface 44 may further include a plurality of mount extensions 37, 40, 42. The mount extensions 37, 40, 42 may be projections of the sill-facing surface 44 that extend along the first axis 103 from the base 47. The mount extensions 37, 40, 42 may be formed as integral components of the corner key 118.
As mentioned above and as illustrated in
When the corner key 118 is coupled to the sill 112, the mount extensions 37, 40, 42 may sit against and engage various regions of the sill 112 to help support and stabilize the corner key 118 in position against the sill 112. For example, the mount extension 37 and the mount extension 40 may be received in the first chamber 32 of the sill 112, proximate the interior side 88. Similarly, the mount extension 42 may be received in the fourth chamber 38 of the sill 112, proximate the exterior side 90 of the sill arrangement 110.
Also, a plurality of separate fasteners (screws, etc.) may fixedly attach the corner key 118 to the sill 112 at various attachment points. In some embodiments, the sill 112 may include fastener receiving notches 125 that are aligned with fastener holes 127 of the corner key 118, and screws may be received in respective pairs of notches 125 and holes 127 to fix the corner key 118 to the sill 112.
The jamb 113 may be fixedly attached to the jamb portion 49 of the corner key 118 in a number of ways. For example, as shown in
In addition, adhesives may be used in the attachment of the sill 112 and corner key 118 and/or in the attachment of the jamb 113 and the corner key 118. In some embodiments, gaskets and/or sealant may be included for sealing gaps in the sill arrangement 110 and/or between the jamb 113 and corner key 118.
When attached, the first longitudinal end 121 of the sill 112 may abut against the sill-facing surface 44 of the corner key 118 at the base 47. The first internal wall 24 may be received in the notch 87 with one portion of the flange 68 received in the first chamber 32 and another portion of the flange 68 received in the second chamber 34. In this attached position, the first port 52 may extend across a first wall end 130 of the first internal wall 24 at the first longitudinal end 121 of the sill 112 to fluidly connect the first chamber 32 and the second chamber 34. In other words, the first wall end 130 and the first port 52 may define a first fluid passageway 132 between the first chamber 32 and the second chamber 34. Also, the horizontal flange 68 of the degassing arm 66 may abut against the second internal wall 26 of the sill 112 to block off and/or seal a gap therebetween. Also, the vertical flange 70 of the degassing arm 66 may block off areas of the port 52 proximate the interior side 88. The first fluid passageway 132 may be sufficiently small to minimize water or air intrusion from flowing back into the chamber 32.
Additionally, when attached, the first port 52 may extend across a second wall end 134 of the second internal wall 26 at the first longitudinal end 121 of the sill 112 to fluidly connect the second chamber 34 and the third chamber 36. In other words, the second wall end 134 and the first port 52 may define a second fluid passageway 136 between the second chamber 34 and the third chamber 36.
Moreover, the second port 50 may extend across a third wall end 138 of the third internal wall 28 at the first longitudinal end 121 of the sill 112 to fluidly connect the third chamber 36 and the fourth chamber 38. In other words, the third wall end 138 and the second port 50 may define a third fluid passageway 139 between the third chamber 36 and the fourth chamber 38.
As shown in
The upper jamb-facing surface 45 of the corner key 118 may further include an air channel 60 formed thereon (
The corner key 118 may further include an opening 82 on the sill-facing surface 44. The opening 82 may be a block-shaped or columnar recess included on the jamb portion 49 of the corner key 118. The opening 82 may be disposed proximate the divider ridge 63. The corner key 118 may further include a passageway 62 that fluidly connects the channel 60 to the opening 82. The opening 82 may be fluidly connected at its lower end to the first port 52. Thus, when the corner key 118 is mated with the sill 112, the opening 82 opens into the second chamber 34 of the sill 112 (see
The corner key 118 may additionally include a rear vent 64. The rear vent 64 may be a tubular passage that extends through the jamb portion 49 of the corner key 118, proximate the interior side 88 of the arrangement 110. The rear vent 64 may extend along the second axis 105. The rear vent 64 may include a bottom opening 81 that is open to the first port 52, and the rear vent 64 may include a top opening 83 that is open at the jamb-facing surface 45.
As shown in
The chimney vent 54, air channel 60, passageway 62, opening 82, the aperture 91, and the rear vent 64 may be fluidly connected and arranged in-series in this order in a fluid stream direction (i.e., an upstream direction or a downstream direction). The chimney vent 54, air channel 60, passageway 62, opening 82, aperture 91, and rear vent 64 may be arranged to provide a continuous fluid pathway. This fluid pathway may be configured to reduce the pressure gradient in the third and fourth chambers 36, 38, thereby allowing water to exit the chambers 36, 38 and ultimately exit the sill arrangement 110. The components also work together to create a circuitous path with various walls and boundary surfaces designed to help collect any water droplets from the air flowing through the corner key 118 and sill 112 to minimize water infiltration into the dwelling.
Fluid flow through the sill arrangement 110 will now be discussed with reference to
Generally, the water management system of the sill arrangement 110 is designed to store a column of water in the first and/or second chambers 32, 34 where the water builds static head pressure as it accumulates. The water management system then uses this static head pressure built by the column of water to overcome the pressure differential across the sill arrangement 110 and drive water out of the arrangement 110. Depending on the amount of static head pressure built in the chambers 32, 34 some water may be driven out of the arrangement 110 even as water continues flowing in.
More specifically, as shown in
In some situations, an air pressure differential across the arrangement 110 may occur, with higher air pressure exerted on the exterior of the building than on the interior of the building. This pressure differential may cause water to move from the exterior toward the interior of the building. This water movement may continue until the pressure is equalized between the interior and exterior of the building. During these pressure conditions water may accumulate within the sill 112.
For example, the incoming water may accumulate in the first chamber 32 and the second chamber 34. Over time, the water level in the chambers 32, 34 may rise as water continues moving into the sill 112 due to wind and increasing pressure differentials. As the water column rises in the chambers 32, 34, it may build a head pressure that serves to counter the high-pressure areas building in the third and fourth chambers 36, 38. The chimney vent 54 may serve to temper the high-pressure gradient between the chambers 34, 36 by directing fluid flow upwardly from the second port 50 and into the upper jamb-facing surface 45 of the corner key 118, whereat water may flow through the channel 60, the passageway 62, the opening 82, and the aperture 91. The rear vent 64 may relieve bubbling or percolation in the chamber 32 and prevent water from further intrusion. The sill arrangement 110 may also fluidly connect the higher-pressure regions of the sill 112 (e.g., the exterior of the dwelling) to lower-pressure regions (e.g., the interior of the dwelling), thereby allowing the pressure differential within the sill 112 to quickly stabilize.
If air flows through the pathway, droplets of water therein may be trapped and collected either by the walls of the chimney vent 54 or the walls of the channel 60 (or other sections of the pathway), thereby minimizing droplet infiltration into the interior of the dwelling. To further minimize droplet infiltration, air or water being forced toward the interior of the dwelling (i.e., upstream) through the ports 50, 52 may be initially obstructed by the degassing arm 66 to provide additional time for outgassing of the water/air mixture being driven in an upstream direction through the sill 112.
It will be appreciated that the respective height dimensions of the first and second chambers 32, 34 (measured along the second axis 105) may contribute to the overall performance of the sill arrangement 110, as the heights determine how much head pressure may be accumulated in the sill 112. Accordingly, the heights of the first and second chambers 32, 34 may be selected to allow for water build-up and head pressure to overcome air pressure differentials in a given region. In some embodiments, local weather data may be used to determine anticipated air pressure differentials to calculate an appropriate height for the first and second chambers 32, 34 to ensure that the water will build sufficient head pressure to avoid water intrusion into the interior of the building or dwelling.
Also, the respective width, height, and depth dimensions of the ports 50, 52 may be selected to provide a sufficiently large pathway for promoting adequate flow of water through the ports 50, 52 and allowing water to exit the sill arrangement 110. The first port 52 may have a larger passageway (e.g., a passageway with a larger cross-sectional area) as compared to that of the second port 50.
As described previously, the degassing arm 66 serves to block or impede much of the water and air moving upstream toward the interior of the dwelling from the third chamber 36 toward the second chamber 34 and first chamber 32 through the first port 52, while accommodating the flow of the water downstream toward the exterior of the dwelling from the second chamber 34 when possible. While some water and air may bypass the degassing arm 66 and flow into the first and/or second chambers 32, 34, the degassing arm 66 may define a tortuous path by increasing the distance and time that the incoming water/air mixture must travel as it exits the first port 52 before it can infiltrate the interior of the dwelling. Diverting the water and air also provides additional time for outgassing the water/air mixture while it is contained within the sill 112 and corner key 118. This outgassing process may help prevent or minimize infiltration of water droplets through the sill 112 and into the interior of the building or dwelling.
The length of the degassing arm 66 (i.e., the distance that the arm 66 projects along the first axis 103 from the surrounding areas of the corner key 118) may be chosen based on the features and characteristics of the corner key 118. Generally, the length of the degassing arm 66 may be greater than the height of the shorter of the two ports 50, 52 (as measured from their respective bottom surfaces to their top surfaces).
Thus, the water management system provided in the sill arrangement 110 is effective and efficient and provides a number of benefits. The water management system of the sill arrangement 110 is incorporated using relatively simple features. The water management system may be constructed and assembled in a short amount of time, and the part count is relatively low. Complex weep designs integrated into the sill or stepped joinery at the jamb-sill intersection of the fenestration structure are unnecessary. Accordingly, this versatility allows for easier installation and simplifies jamb and sill-end work.
Moreover, it will be appreciated that the sill arrangement 110 is highly robust even with the water management system incorporated therein. For example, the sill arrangement 110 may firmly support the first panel 110 as it slides open and closed. Thus, the sill arrangement 100 may be useful for a slider door or slider window fenestration unit.
It is intended that subject matter disclosed in particular portions herein can be combined with the subject matter of one or more of other portions herein as long as such combinations are not mutually exclusive or inoperable. In addition, many variations, enhancements and modifications are possible.
The terms and descriptions used above are set forth by way of illustration only and are not meant as limitations. Those skilled in the art will recognize that many variations can be made to the details of the above-described embodiments without departing from the underlying principles of the present disclosure.
