Patent Grant
7490441
The present invention relates to a high performance fenestration assembly installation system, and in particular, to a drainage system with a siphoning action that expels moisture.
Fenestration assemblies are typically installed in rough openings in structures. A gap is typically maintained between the fenestration assembly and the rough opening to accommodate expansion and contraction of building materials throughout temperature changes, as well as overall shifting and settling of the structure. Water, such as airborne moisture and liquid water in the form of rainwater, ice, snow can penetrate into the building wall interior from in and around building fenestration assemblies.
Attempts have been made to prevent entry of water into the building wall interior by sealing or caulking entry points in and around fenestration assemblies as the primary defense against water intrusion, or by installing flashing around the fenestration assemblies to divert the water. These attempts have not been completely successful. Sealants are not only difficult and costly to properly install, but tend to separate from the fenestration assembly or wall due to climatic conditions, building movement, the surface type, or chemical reactions. Flashing is also difficult to install and may tend to hold the water against the fenestration assembly, accelerating the decay.
The efficiency of such weatherproofing relies largely on the careful installation of both the fenestration assembly and the weatherproofing materials. However, no matter how carefully installed, moisture may enter into gaps between the fenestration assembly and the rough opening. Moisture penetration may be due to shifting or expansion/contraction of materials post-installation.
Such moisture typically collects below the fenestration assembly, where it can cause rot and other undesirable damage to both the fenestration assembly and the structure below the fenestration assembly. In some situations attempts to prevent water penetration around fenestration assemblies may actually trap the water within the structure, exacerbating the problem.
Various drain holes systems for fenestration assemblies have been used to divert water from the structure, such as disclosed in U.S. Pat. Nos. 3,851,420 (Tibbetts); U.S. Pat. No. 4,691,487 (Kessler); and U.S. Pat. No. 5,890,331 (Hope).
Specialized flashing structures have been developed for installation in the gap between the rough opening and the fenestration assembly. Examples of such specialized flashing structures are shown in U.S. Pats. No. 4,555,882 (Moffitt et al.); U.S. Pat. No. 5,542,217 (Larivee); and U.S. Pat. No. 6,098,343 (Brown et al.). U.S. Pat. No. 5,822,933 (Burroughs et al.) and U.S. Pat. No. 5,921,038 (Burroughs et al.) disclose a water drainage system with an angled pan and a plurality of ribs that is located underneath a fenestration assembly.
These specialized flashing structures, however, do not effectively remove water from the interior of the structure. Additionally, the installation of moisture guards often requires changes in the way the fenestration assembly is installed into the rough opening and how the fenestration assembly is finished on the room side so as to accommodate the vertical height of the angled pan. Furthermore, the gap between the fenestration assembly and the rough opening must be sufficient to accommodate the raised end of the angled pan.
The Installation Instructions for New Construction Vinyl Window with Integral Nailing Fin published by Jeld-Wen, Inc. discloses installing a 6″ tall section of screen to the exterior of the structure below the fenestration assembly. The screen extends about the width of the fenestration assembly and is located on top of flashing tape and building wrap. Another layer of flashing tape is applied to the top of the screen. The screen, however, forms one contiguous channel that is too large to permit effective drainage of water.
The present invention is directed to a drainage system for a fenestration assembly located in a rough opening of a structure. The drainage system includes a moisture barrier located between at least a bottom of the fenestration assembly and a bottom inner surface of the rough opening. The moisture barrier includes a vertical portion extending generally vertically downward below the rough opening on an external side of the structure. A channel assembly is located generally below the rough opening. The channel assembly includes at least one channel having a channel entrance proximate the bottom inner surface of the rough opening and a discharge opening direct toward a drainage area. The channel includes an effective cross-sectional area adapted to siphon water located on the moisture barrier to the drainage area.
The channel assembly may be a block of material with a plurality of channels, a plurality of ribs forming a plurality of discrete channels, a carrier having a plurality of ribs forming a plurality of open channels, or a woven or non-woven web of material and a flashing tape sealing a front and at least a portion of side edges of the web of material to the vertical portion of the moisture barrier.
In one embodiment, the channel assembly is located less than four inches from bottom corners of the rough opening, or more preferably be located less than two inches from bottom corners of the rough opening.
The channel preferably has an effective cross-sectional area in the range of about 0.0012 inch2 to about 0.625 inch2, and more preferably about 0.0012 inch2 to about 0.1 inch2 and most preferably about 0.0012 inch2 to about 0.05 inch2. Channels with generally circular cross-sectional areas preferably have a diameter of about 0.040 inches to about 0.4 inches. Channels with non-circular cross-sectional area preferably have a major dimension of about 0.04 inches to about 6 inches and a minor dimension of about 0.040 inches to about 0.4 inches.
The drainage system is installed with a fenestration assembly located in a rough opening of a structure by first locating a moisture barrier between at least a bottom of the fenestration assembly and a bottom inner surface of the rough opening. Then, the moisture barrier is extended generally vertically downward below the rough opening on an external side of the structure to form a vertical portion. A channel assembly is located generally below the rough opening so that a channel entrance is proximate the bottom inner surface of the rough opening and a discharge opening is directed toward a drainage area. Finally, a channel is selected with an effective cross-sectional area adapted to siphon water located on the moisture barrier to the drainage area.
While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
While the invention is amenable to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and are described in detail below. The intention, however, is not to limit the invention to the particular embodiments described. On the contrary, the invention is intended to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.
The present drainage system 32 preferably includes moisture barrier 38 located along at least a portion of inner surface 30D and extending downward below the rough opening 20 along exterior surface 40 of the water resistant barrier 28. In some embodiments, the moisture barrier 38 may extend vertically along a portion of the inner surfaces 30B, 30C.
In the illustrated embodiment, the moisture barrier 38 includes a collection surface 42 located above and parallel to the inner surface 30D and a generally vertical surface 44 located generally on the exterior surface 40 immediately below the rough opening 20 and in front of the sill plate 24A. In the preferred embodiment, the moisture barrier 38 is located on top of the water resistant barrier 28. In an alternate embodiment, the moisture barrier 38 can be located directly on the inner surface 30D of the sill plate 24A.
The moisture barrier 38 can be constructed from a variety of flexible, semi-rigid or rigid materials, such as, for example, metal, plastic, or composites thereof. The moisture barrier 38 can, for example, be a flexible sheet material, a thin metal material that can be bent into the desired shape, or a molded article. In one embodiment, the moisture barrier 38 is metal flashing. In another embodiment, the moisture barrier 38 is a foil-backed flashing tape. The moisture barrier 38 can optionally be a pre-formed sill pan. The moisture barrier 38 can be secured in the rough opening 20 using a variety of conventional methods, such as for example nails, screws, clips, brackets, and/or adhesives.
Channel assembly 46 is located on the generally vertical surface 44 of the moisture barrier 38 generally in front of the sill plate 24A. As will be discussed in detail below, the channel assembly 46 includes one or more channels 48A-48E (referred to collectively as “48”) that are configured to siphon water on the collection surface 42 from the channel entrance 45 in direction 50 and out a discharge opening 47 to a drainage area 40A. As used herein, “siphon” refers to conduit that uses the weight of a liquid to pull the liquid from the higher level to a lower level.
The channels 48 can be located anywhere along the width W of the rough opening 20. Most water penetration, however, occurs between a fenestration assembly 52 and the vertical inner surfaces 30B, 30C of the rough opening 20. Water tends to concentrate on the collection surface 42 near the bottom corners 34, 36 of the rough opening 20. As used herein, the term “bottom corner” also refers to the intersection of a sill plate and a mullion separating adjacent fenestration assemblies, or the intersection of a sill plate and two vertical surfaces of adjacent fenestration assemblies. In the preferred embodiment, the channels 48 are concentrated near the bottom corners 34, 36. In one embodiment the channels 48A, 48B, 48C, 48D and 48E are located within a distance S from the bottom corners 34, 36. The distance S is preferably less than 4 inches, and more preferably less than 2 inches, and most preferably less than 1 inch.
The fenestration assembly 52 includes a frame 54 that is sized to fit into the rough opening 20. As used herein, “fenestration assembly” refers to double-hung, casement, awning and fixed windows, skylights, sliding and hinged doors, and the like. As indicated by the dashed lines 56, the fenestration assembly 52 is inserted into the rough opening 20 above the drainage system 32.
As best illustrated in
In embodiments where the collection surface 42 is generally horizontal, the interior seal 62 is preferably included. Because the gap 60 is open to an exterior side 65 of the fenestration assembly 52 at least where any leaks are occurring, and likely through the channels 48 as well, the air pressure within the gap 60 will tend to be the same as the air pressure at the exterior side 65 of the fenestration assembly 52. The seal 62 isolates the gap 60 from air pressure on the interior side 64. This feature helps to ensure that the air pressure within the gap 60 is never lower than the air pressure on the exterior side 65, which could cause moisture to flow up the channels 48A-48E and into the gap 60.
The drainage system 32 removes moisture from the gap 60 in the following manner. As moisture leaks into the rough opening 20 from any location around the fenestration assembly 52, the moisture flows downwardly into the gap 60 under the force of gravity and collects on the collection surface 42. The collection surface 42 is water impermeable, so the sill plate 24A is protected from water damage.
Eventually, due to random accumulation and flow of moisture across the collection surface 42, or because the collection surface 42 is completely covered, moisture accumulates over the channel entrances 45. Surface tension in the water molecules will for a time prevent the moisture from flowing down the channels 48A-48E. However, as moisture continues to accumulate, the weight of the water causes the water immediately adjacent the channel entrances 45 to flow down the channels 48 and out the discharge openings 47 into the drainage area 40A. As water flows down the channels 48, a vacuum is created above the draining water, which draws more water down from the channel entrances 45, and so on. The negative or vacuum pressure of the descending water is strong enough to cause water on the collection surface 42 to be pulled towards the channel entrances 45. In this manner, moisture collecting on the collection surface 42 is removed to the drainage area 40A.
Because the channels 48 generate sufficient vacuum pressure to pull moisture from across the collection surface 42 towards the channel entrance 45, it is unnecessary for the collection surface 42 to be tilted or angled toward the channel assembly 46. Thus, a drainage system 32 in accordance with the present invention does not require substantial modifications to the fenestration assembly 52 installation procedures, nor to the fenestration assembly 52 or rough opening 20.
In order to generate the optimum siphoning action of the present drainage system, the channels 102 preferably have an effective cross-sectional area within a specific range. If the effective cross-sectional area is too small, the surface tension of the water will likewise prevent proper operation of the present drainage system 32. If the effective cross-sectional area is too large, insufficient liquid is typically available to establish a siphon. In the preferred embodiment, the effective cross-sectional area of the channels 102 does not vary along the height h of the channel assembly 100, although variation is possible for some embodiments.
The major and minor dimensions of the cross-sectional area are also preferably within a specific range. In the embodiment of
In the preferred embodiment, the channels 102 have an effective cross-sectional area of less than about 0.625 inches2 and more preferably less than about 0.1 inch2, and most preferably less than about 0.05 inches2. An effective cross-sectional area of about 0.012 inches2, which corresponds to the effective cross-sectional area of a ⅛ inch inner diameter (ID) tube, is a preferred effective cross-sectional area. An effective cross-sectional area of about 0.0012 inches2, which corresponds to a 0.040 inch inner diameter (ID) tube, is the minimum effective cross-sectional area. As used herein, the “effective cross-sectional area” refers to the cross sectional area of a channel measured perpendicular to an axis of the channel. Alternatively, the effective cross-sectional area can be viewed as the minimum cross-sectional area generally perpendicular to the flow of water through the channel.
For channels 102 with a non-circular cross-sectional area, the maximum dimension along a major dimension is preferably less than about 6 inches, and more preferably less than about 4 inches and most preferably less than about 2 inches. The dimension along the minor dimension is preferably between about 0.04 inches and about 0.4 inches, and more preferably between about 0.04 inches and about 0.2 inches, and most preferably between about 0.04 inches and about 0.1 inches. The major and minor dimensions are selected so that the effective cross-sectional area is within the range of about 0.0012 inches2 to about 0.625 inches2. In the illustrated embodiments, the major dimension is typically parallel to the vertical surface 44 and the minor dimension is perpendicular to the vertical surface 44.
For channels 102 with a generally circular cross-sectional area, major dimension and the minor dimension are both the diameter of the channel 102. The diameter of a generally circular channel 102 is preferably between about 0.04 inches and about 0.4 inches, and more preferably between about 0.04 inches and about 0.2 inches, and most preferably between about 0.04 inches and about 0.1 inches. A tube with an ID of about 0.4 inches has a cross-sectional area of about 0.126 inches2, which is within the range of 0.0012 inches2 to about 0.625 inches2. A tube with an ID of about 0.04 inches has a cross-sectional area of about 0.0012 inches2, which is within the range of 0.0012 inches2 to about 0.625 inches2.
For example, in an embodiment where the minor dimension is about 0.4 inches, the major dimension needs to be less than about 1.56 inches in order to be within the acceptable range of effective cross-sectional areas. Similarly, in an embodiment where the minor dimension is about 0.2 inches, the major dimension needs to be less than about 3.125 inches in order to be within the acceptable range of effective cross-sectional areas.
In an example where the minor dimension is about 0.04 inches, however, the major dimension could be as large as 15.625 inches and still be within the acceptable range of effective cross-sectional areas. This major dimension, however, violates the rule that the major dimension be less than about 6 inches. Consequently, the major dimension would be limited to about 6 inches where the minor dimension is about 0.04 inches.
The channel assembly 100 has a height h that is preferably greater than about 0.5 inches up to about 12 inches. The height h may vary depending upon the effective cross-sectional area of the channels 102.
For example, if the effective cross-sectional area of a channel 102 exceeds the maximum effective cross-sectional area the siphoning action will not be established or the draw will be insufficient to operate the present drainage system 32 as intended. Even if the maximum effective cross-sectional area is not exceeded, the maximum minor dimension can not be exceeded; otherwise the drainage system will not function as intended.
As best illustrated in
Alternatively, the channel assembly 120 (see channel assembly 120B) can optionally be installed below the collection surface 42 with the open channels 126 facing away from the generally vertical surface 44 of the moisture barrier 38. A strip of flashing tape 128 is positioned across the open channels 126. In one embodiment, the flashing tape 128 also serves to attach the channel assembly 120B to the generally vertical surface 44. In the illustrated embodiment, the channel assemblies 120A, 120B are located near the bottom corners 34, 36, respectively.
As best illustrated in
Channel assembly 162 is formed of a plurality of fibers or filaments 170 attached to the generally vertical surface 44 with flashing tape 166. The filaments 170 operate as ribs or spacers, and the gaps between adjacent ribs 170 operate as discrete channels 172.
As best illustrated in
The channel assemblies 206 include a plurality of ribs 214 that form a plurality of discrete channels 216. Water entering the channels 216 is discharged from discharge openings 220. Cover 218 can optionally be molded as part of the channel assembly 200. Alternatively, a flashing tape can be applied to complete the channels 216, and optionally secure the channel assembly 200 to the rough opening 20.
The channel assembly 200 is preferably molded as a unitary structure from a polymeric material. Alternatively, the channel assembly 200 can be constructed from multiple pieces. In one embodiment, the multiple pieces are connected using adhesives, interlocking fasteners or a combination thereof.
Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present invention. For example, while the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that do not include all of the described features. Accordingly, the scope of the present invention is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof.
The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/726,573, entitled High Performance Window and Door Installation, filed Oct. 14, 2005, the disclosure of which is hereby incorporated by reference.
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