Patent Application
20240209677
The presently disclosed subject matter is generally directed to a sill pan system for use with doors. The presently disclosed subject matter also includes methods of making and using the disclosed sill pan system.
In modern construction, window and door systems generally are provided as integral pre-hung units that include door or window panels pre-mounted in a frame. The frame is typically formed by vertical jambs, a top header, and a bottom sill or threshold assembly that spans the bottom ends of the jambs. The pre-hung units are fitted and secured within appropriately sized framed-in openings in the walls of a building. Specifically, framed-in openings for pre-hung door units include vertical studs and a header, but the bottom sill plate of the door opening usually is formed by the sub-floor of the building. The pre-hung unit is positioned with its threshold resting on the bottom sill plate of the framed-in opening and the unit is leveled, plumed, and secured within the opening with nails or screws.
Over time, rainwater can leak beneath the sill or threshold of the door, causing the underlying framing studs and sub-floor components to rot. Since the rot generally is hidden from view, it often is not discovered until it is so severe that major renovation to replace rotted members is required. In response, water-proof sill pans have been developed. Prior art sill pans generally are made of plastic and include a central web that rests on and spans the framing plate, upwardly projecting end walls that extend partially up the vertical studs of a framed-in opening, an up-turned flange extending along the inside edge of the web, and flashing strips that wrap around onto the outside of the framed-in opening. While prior art sill pans have been somewhat successful, they are not compliant with the American Disabilities Act (ADA). Specifically, adjustable door thresholds for single family houses are much taller than ADA thresholds found on multi-family projects. Sill pans currently in use include an extended back dam/interior that sits above the threshold and causes an obstruction that could impede a resident from crossing with a wheelchair. It would therefore be desirable to provide an ADA-compliant sill pan system that overcomes the shortcomings of the prior art.
In some embodiments, the presently disclosed subject matter is directed to a sill pan system for installation on a framed in door opening extending between bottom end portions of two vertical studs of the framed in door opening. Specifically, the system comprises a left end segment configured to be fitted at one end of the door opening adjacent to the bottom end portion of the first vertical stud. The system also includes a right end segment configured to be fitted at an opposite end of the door opening adjacent to the bottom end portion of the second vertical stud. The left end segment comprises a left top panel comprising a left edge, a right edge, a length, and a width; a left vertical wall extending upward from the left edge of the left top panel and extending the width of the left top panel; an L-shaped left flange extending downward from a front edge of the left top panel and upward to contact a side edge of the left vertical wall; and a lip positioned at the right edge of the left top panel. The right end segment comprises a right top panel comprising a left edge, a right edge, a length, and a width; a right vertical wall extending upward from the right edge of the right top panel and extending the width of the top panel; an L-shaped right flange extending downward from a front edge of the right top panel and upward to contact a side edge of the right vertical wall; and a plurality of spacing ribs positioned at the left edge of the right top panel. The lip is configured to overlay the spacing ribs, thereby joining the left end segment to the right end segment at a seam. The left vertical wall and the right vertical wall overlap at a rear edge of the left and right top panels. The left and right panels each include a back dam positioned at a rear edge, extending in an upward direction.
In some embodiments, the left end segment and right end segments each include a bottom face defined by a plurality of grooves.
In some embodiments, a bottom face of the lip lacks grooves.
In some embodiments, the disclosed sill pan system works with American Disabilities Act (ADA) compliant thresholds. In order to be ADA compliant, existing door thresholds are required to have a vertical height of no greater than 0.25 inches. However, a vertical height of up to 0.75 inches is allowed if a transition ramp is applied. If the door threshold is higher than 0.75 inches, an associated level-landing is required. A level-landing is the code-mandated solution for a threshold modification made to existing doorways with door threshold heights greater than 0.75 inches. Traditional solutions have included saw cutting, jackhammering, abrading, and pouring a built up cement landing. A more contemporary, and increasingly popular, solution is the use of modular landing and ramp systems, which are now a recognized product solution for ADA compliance per CSI MasterFormat Division ‘Specialties’ 10 74 49 (incorporated by reference herein).
However, these solutions are costly and time-consuming to implement.
In some embodiments, the left top panel and right top panel are sloped downward about 1-10 degrees below horizontal. For example, the slope can be about 5.4 degrees in some embodiments.
In some embodiments, the left and right vertical end walls have a height of about 1-3 inches. For example, the left and right vertical end walls can have a height of about 2 inches.
In some embodiments, the left and right L-shaped flanges each have a first end with a height that differs from a second end height.
In some embodiments, the first end of the left and right L-shaped flanges has a height of about 2.5-4 inches (e.g., about 3.25 inches) and the second end of the left and right L-shaped flanges has a height of about 1 inch.
In some embodiments, the left top panel and right top panel each have a length of about 19.5 inches.
In some embodiments, the back dam has a height of about 3/16 of an inch (0.1875 inches). Thus, the back dam lip can include a height of about 0.1-0.5 inches (e.g., at least/no more than about 0.1, 0.2, 0.3, 0.4, or 0.5 inches).
In some embodiments, the grooves cover about 100 percent of the bottom face of the left and right end segments.
In some embodiments, the presently disclosed subject matter is directed to a sill pan kit. The kit includes a plurality of left end segments defined by a left top panel comprising a left edge, a right edge, a length, and a width; a left vertical wall extending upward from the left edge of the left top panel and extending the width of the left top panel; an L-shaped left flange extending downward from a front edge of the left top panel and upward to contact a side edge of the left vertical wall; a lip positioned at the right edge of the left top panel. The kit further includes a plurality of right end segments defined by: a right top panel comprising a left edge, a right edge, a length, and a width; a right vertical wall extending upward from the right edge of the right top panel and extending the width of the top panel; an L-shaped right flange extending downward from a front edge of the right top panel and upward to contact a side edge of the right vertical wall; a plurality of spacing ribs positioned at the left edge of the right top panel. The lip is configured to overlay the spacing ribs, thereby joining the left end segment to the right end segment at a seam. The left vertical wall and the right vertical wall overlap at a rear edge of the left and right top panels. A left end segment can be joined to a right end segment to create an assembled sill pan system.
In some embodiments, the presently disclosed subject matter is directed to a method of installing the disclosed sill pan system along a framed in doorway opening. Particularly, the method comprises fitting the left end segment at a lower left corner of the framed doorway opening. The method includes fitting the right end segment at a lower right corner of the framed doorway opening. The method includes adhering the lip to overlay the spacing ribs, thereby joining the left end segment to the right end segment at a seam. The L-shaped flanges extend below the doorway opening and to the left and right of the doorway opening, and the left and right vertical walls extend upward within the framed doorway opening.
The presently disclosed subject matter is introduced with sufficient details to provide an understanding of one or more particular embodiments of broader inventive subject matters. The descriptions expound upon and exemplify features of those embodiments without limiting the inventive subject matters to the explicitly described embodiments and features. Considerations in view of these descriptions will likely give rise to additional and similar embodiments and features without departing from the scope of the presently disclosed subject matter.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the presently disclosed subject matter pertains. Although any methods, devices, and materials similar or equivalent to those described herein can be used in the practice or testing of the presently disclosed subject matter, representative methods, devices, and materials are now described.
Following long-standing patent law convention, the terms “a”, “an”, and “the” refer to “one or more” when used in the subject specification, including the claims. Thus, for example, reference to “a device” can include a plurality of such devices, and so forth. It will be further understood that the terms “comprises,” “comprising,” “includes,” and/or “including” when used herein specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
Unless otherwise indicated, all numbers expressing quantities of components, conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about”. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the instant specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by the presently disclosed subject matter.
As used herein, the term “about”, when referring to a value or to an amount of mass, weight, time, volume, concentration, and/or percentage can encompass variations of, in some embodiments +/−20%, in some embodiments +/−10%, in some embodiments +/−5%, in some embodiments +/−1%, in some embodiments +/−0.5%, and in some embodiments +/−0.1%, from the specified amount, as such variations are appropriate in the disclosed packages and methods.
As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
Relative terms such as “below” or “above” or “upper” or “lower” or “horizontal” or “vertical” may be used herein to describe a relationship of one element, layer, or region to another element, layer, or region as illustrated in the drawing figures. It will be understood that these terms and those discussed above are intended to encompass different orientations of the device in addition to the orientation depicted in the drawing figures.
The embodiments set forth below represent the necessary information to enable those skilled in the art to practice the embodiments and illustrate the best mode of practicing the embodiments. Upon reading the following description in light of the accompanying drawing figures, those skilled in the art will understand the concepts of the disclosure and will recognize applications of these concepts not particularly addressed herein. It should be understood that these concepts and applications fall within the scope of the disclosure and the accompanying claims.
The presently disclosed subject matter is directed to a door sill pan system that is configured to be used with American Disabilities Act (ADA) compliant door thresholds. The term “sill” as used herein refers to the horizontal bottom part of a window or door as defined by ASTM E 2112-07 Standard Practice for Installation of Exterior Windows, Doors, and Skylights, section 3.2.121, the entire content of which is incorporated by reference herein. The term “sill pan” refers to a flashing used at the base of a rough opening to divert incidental water to the exterior or to the exterior surface of a concealed WRB (weather-resistive barrier), as defined by ASTM E 2112-07 section 3.2.91, the entire content of which is incorporated herein. Conventional sill pans typically include a large portion of rigid plastic material that is positioned beneath an exterior door to prevent moisture from intruding into a building (e.g., commercial building, residential building). The sill pan further prevents the bottom of the door from rotting due to moisture exposure over time.
L-shaped flange 30 projects downwardly from the top panel at horizontal edge 31 to overlap the outside left surface of the sill plate. The flange also extends to the left of the vertical stud at edge 32. It will thus be appreciated that the left end segment covers and protects the left end of the sill plate and the bottom left corner portion of the framed-in opening. The vertical portion of flange 30 that extends to the left of the vertical stud has length 40 of about 2 inches (e.g., at least/no more than about 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, or 2.5 inches). The flange includes first height 36 at left end 12 of about 3.25 inches (e.g., at least/no more than about 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4, 4.1, 4.2, 4.3, 4.4, 4.5, or 4.6 inches). The flange includes second height 35 at right end 13 of about 1.5 inches (e.g., at least/no more than about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, or 3.3 inches).
Left top panel 20 can include length 45 of about 19.5 inches (e.g., at least/no more than about 15, 15.5, 16, 16.5, 17, 17.5, 18, 18.5, 19, 19.5, 20, 20.5, 21, 21.5, 22, 22.5, 23, 23.5, 24, 24.5, or 25 inches), as shown in
The left and right panels also include back dam 91, as shown in
About 100 percent of the bottom face of left end segment 10 includes grooves 60. The spaces between the grooves can present regions configured to allow adjustment of the length of the sill pan left and/or right end segments.
As set forth above right end segment 11 cooperates with the left end segment to form the disclosed sill pan system.
As shown, L-shaped right flange 75 projects downwardly from the top panel at horizontal edge 33 to overlap the outside right surface of the sill plate. The flange also extends to the right of the right-hand vertical stud. It will thus be appreciated that the right end segment covers and protects the right end of the sill plate and the bottom right corner portion of the framed-in opening. The vertical portion of flange 75 that extends to the right of the vertical stud has length 81 of about 2 inches (e.g., at least/no more than about 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, or 2.5 inches). The flange includes first height 37 at right end 39 of about 3.25 inches (e.g., at least/no more than about 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, 4, 4.1, 4.2, 4.3, 4.4, 4.5, 4.6, 4.7, 4.8, 4.9, or 5 inches). The flange includes second height 14 at left end 38 of about 1.25 inches (e.g., at least/no more than about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, or 3 inches).
Right top panel 21 can include length 85 of about 19.5 inches (e.g., at least/no more than about 15, 15.5, 16, 16.5, 17, 17.5, 18, 18.5, 19, 19.5, 20, 20.5, 21, 21.5, 22, 22.5, 23, 23.5, 24, 24.5, or 25 inches), as shown in
In some embodiments, about 100 percent of the bottom face of right end segment 11 includes grooves 135. The spaces between the grooves can present regions configured to allow adjustment of the length of the sill pan left and/or right end segments.
To assemble the disclosed sill pan system, left and right end segments 10, 11 are joined together at seam 15. Particularly, the segments are positioned such that lip 51 of the left end segment is overlayed on top of spacing ribs 61 of the right end segment, as shown in
The left and right end segments can be constructed from any suitable material, such as (but not limited to) plastic (polyurethane, nylon, polycarbonate, acetal, polypropylene, ultra-high molecular weight polyethyelene, PTFE) and/or metal (e.g., stainless steel, copper, lead, aluminum, or combinations thereof). It should be appreciated that the materials used are not limited and any suitable material(s) can be used.
The dimensions of 150 can vary to correspond with the width of a single door panel but may also span a length for a French door entryway or an entryway configured to include one or more sidelight panels. Regional building codes, building materials, residential versus commercial construction, and other factors may also result in a variety of possible entryway widths (also called depths) corresponding to varying thicknesses of exterior building walls. The disclosed sill pan system can be sized up or down accordingly.
Once placed in the rough opening 150, adhesive and/or cement can be used to securing system 5 to the sub-floor. As noted in the Figures, the disclosed sill pan system lacks a raised ridge on the top surface as is commonly seen with prior art sill pans. One embodiment of a prior art sill pan 170 comprising rear ridge 171 is illustrated in
The phrase “ADA-compliant” refers to a threshold system that accommodates individuals with disabilities. For example, a sill pan system that works with ADA compliant thresholds lack a wall that connects the rear edges of the sloped top panels 20, 21. In some embodiments, a sill pan system that works with ADA compliant thresholds can include a front flange with a width of about 3/16 inch (compared to conventional sill pans with a front flange width of 1.5 inches). The overall length of a sill pan system that works with ADA compliant thresholds can be about 39.5 inches, compared to prior art systems with a length of about 42.5 inches. The vertically extending walls of an ADA-compliant system can be about 2 inches, compared to conventional systems with a wall length of about 1.5 inches.
After the components of sill pan system 5 are assembled and installed as described and shown herein, a door frame or the like may be inserted into the rough opening 150 with the sill area being sealed against air and water intrusion through the wall.
The disclosed system offers many advantages over prior art sill pan systems. For example, the left and right segments can be each constructed as a single piece. Thus, the system includes a two-piece construction.
In some embodiments, the sill pan is adjustable up to about 2 inches (e.g., at least/no more than about 1, 1.5, 2, 2.5, or 3 inches). By configuring the system to be adjustable in at least one of the width and length dimensions, the total number of necessary product size combinations is expected to decrease relative to the use of fixed dimension sill pans.
Seam 15 beneficially allows installers to properly position the first and second segments and/or the fully assembled sill pan in the center of a doorway opening.
Advantageously, sill pan 5 can work with ADA compliant door thresholds found in a variety of commercial or multi-family applications.
In some embodiments, the disclosed sill pan can be configured as a kit. Specifically, the kit can include a left end segment and a right end segment, sized and shaped to be installed in a particular door opening. Alternatively, the kit can include a plurality of left and right end segments of the same or varying sizes, allowing a user to customize the sill pan system for a particular sized opening.
The present system, in addition to protecting structural components of a building, achieve disposal of moisture on sill pan surfaces that could otherwise be harmful to wood or manufactured building components.
Exemplary embodiments of the methods and components of the presently disclosed subject matter have been described herein. As noted elsewhere, these embodiments have been described for illustrative purposes only, and are not limiting. Other embodiments are possible and are covered by the presently disclosed subject matter. Such embodiments will be apparent to persons skilled in the relevant art(s) based on the teachings contained herein. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments but should be defined only in accordance with the following claims and their equivalents.
