The present invention relates to a device to modify jamb dimensions to ease carpentry work on windows. More particularly, the present invention relates to a window jamb extender configured to allow installation of new windows, either as replacement windows in an existing home or other structure, or as new windows installed during construction of a home or other structure.
Replacement or retrofit windows are sometimes installed using an “insert” replacement method in which the existing window is removed but the master window frame is left intact and in position. The replacement window is then inserted into and secured in the existing master window frame. This insert method eliminates labor associated with removing and replacing the master frame, including all of the interior and exterior trim work.
Alternately, replacement windows are sometimes installed using a “full frame” replacement method that includes completely removing the existing master window frame down to jack studs, and installing the replacement window including a new window frame.
Existing windows are constructed of a wide variety of materials, for example, wood, or non-wood type such as vinyl or metal. Conventionally, full frame replacements are best practiced when working with non-wood existing windows. This often requires additional labor and materials to complete the installation compared to the insert replacement method.
Vinyl frame windows have been widely used for several decades in new construction. These vinyl frame windows typically include a J-channel that is integral with the frame to provide a space for receiving siding or other exterior facing of the structure, and also typically include an integral nailing flange for being secured to the house or other structure. Such vinyl frame windows have a relative thinness or narrowness between the interior and exterior sides of the window frame. As such, when they are installed in the window frame or jamb of a new structure with their exterior side approximately even or “flush” with the exterior building wall, the interior side of the vinyl window frame is spaced inward only about 2 inches from the exterior wall of the structure, which is about 1-inch to 1¼-inch less than other (non-vinyl) windows. In other words, the interior side of such vinyl frame new construction windows are recessed significantly greater relative to the interior wall of the home or other structure as compared to wood frame windows.
On the other hand, replacement windows having a vinyl frame or other frame are typically thicker as compared to these new construction vinyl frame windows as measured between the interior and exterior faces of the window frame. Attempting to install these replacement windows in the existing master frame or jamb of the structure causes various problems. More particularly, the “jamb mounting depth” (defined as the dimension measured from the interior face of the window frame to the exterior wall of the house or other structure) is typically about 2 inches for structures originally constructed with vinyl frame windows. In contrast, a replacement window frame is normally 3¼-inches thick between the interior and exterior faces of the window frame, so such a replacement window will not fit in the existing jamb mounting depth of the structure.
Currently, there are different methods for installing a replacement window when the existing jamb mounting depth is too small to fit the replacement window. The first method includes increasing the jamb mounting area to the interior of the house. If the jamb mounting area is increased to the interior of the home, additional carpentry and finish work is required for interior casing, drywall work, painting, staining, new interior casing, new or relocated window treatments, and other such interior finish work. Such interior finish work is costly, disruptive to the homeowner or other occupant, and otherwise undesirable.
The second method includes extending the jamb with lumber to increase the jamb mounting area to the exterior of the building. If the jamb mounting area is extended to the exterior in this manner, this also requires additional carpentry to fabricate new wood jamb extensions inside of the existing house framing and reduces the rough opening size for the new replacement window resulting in a smaller window with less visible glass area. On the exterior, extensive trim work is commonly required, including but not limited to, careful removal and reinstallation of existing siding or cladding to remove the existing window and install new J-channel, trim work required to cover exterior stops and jamb extensions if used. As such, this second method is also undesired.
The third method includes selecting a replacement window that is dimensioned and structured in a manner that corresponds closely to the original window being replaced and including an integral nail flange and J-channel, and having a similar jamb depth. Finding or manufacturing such windows that fit an existing jamb mounting depth can increase cost and are commonly less energy efficient. Also, when a replacement window with an integral nail flange is used, there is less interior carpentry work than in other methods since the jamb depth is the same but there is still extensive exterior work that must be done, including but not limited to, careful removal and reinstallation of exterior cladding, and fastening and sealing the new integral nail flange to the building. This cladding removal, frequently vinyl siding, is difficult because if a piece of siding is damaged and needs to be replaced it is difficult to match siding that has faded or may no longer be available from the original manufacturer. Overall, the exterior cladding work required to remove and reinstall the cladding around every window in the home, around existing landscaping, variable exterior grading, working with scaffolding when required, is very time and cost intensive. As such, to efficiently replace these vinyl new construction windows with replacement windows, a full frame replacement has heretofore been the best practice as the existing window master frames cannot be used and must be completely removed for the reasons described. Hence, there is a long felt but unresolved need for an apparatus and method that prevent the need for increasing the jamb mounting area to the interior of the home. Moreover, there is a need for an apparatus and method that prevent the need for increasing the jamb mounting area to the exterior of the home without extensive carpentry and lumber. Furthermore, there is a need for an apparatus and method that prevents the need for extensive exterior work of the home.
A window jamb extender includes a frame including: (i) a first leg including opposite inner and outer ends; and, (ii) a second leg connected to the outer end of the first leg and arranged transversely relative to the first leg. The first leg includes an outer face adapted to be abutted with an associated wall stud that partially defines a periphery of an opening in an associated wall structure. The first leg includes an inner face that is opposite the outer face and that is adapted to lie adjacent an outer peripheral wall of an associated window frame. The second leg includes an inner face adapted to lie adjacent an exterior face of the associated window frame. The window jamb extender further includes a J-channel portion including: (i) a primary flange that projects outwardly from the outer face of said first leg; and, (ii) a secondary flange that projects outwardly from the outer face of said first leg, wherein the secondary flange is spaced-apart from the primary flange.
Referring also to
The window jamb extender 100 in the present embodiment comprises an extruded one piece polymeric body 100B comprising and defining the profile as shown in
The body 100B of the window jamb extender 100 includes an interior side BI that is oriented toward the interior surface IN (
In the embodiment of
In the illustrated embodiment, an inner face JF1N of the primary flange JF1 includes a self-adhesive seal tape or other adhesive A such that the primary flange JF1 is adhesively bonded to the exterior EX of the house/structure wall W when the jamb extender 100 is operatively installed. The adhesive A preferably includes a paper or other release liner RL (shown partially in
In the illustrated embodiment, the body 100B is defined as a one-piece extruded member or “extrusion” using vinyl (polyvinylchloride (PVC)) or another polymeric material. Alternatively, the body 100B can be injection molded, 3-D printed (or manufactured using a similar additive manufacturing method) and/or defined by removing material from a block of polymeric material, wood, foam, cellular PVC, and/or any other suitable material. Alternatively, as described further below, the body 100B comprises a two-piece wood, polymeric and/or other multi-piece structure that is assembled with fasteners, adhesive, a mechanical interfit, and/or any other suitable assembly method from structures that are defined from similar or dissimilar materials relative to each other. In such case, by way of example only, the legs 102A,102B can be separate structures that are connected together, and/or the J-channel portion 100J is a separate extrusion or other structure (or structures) that is (are) defined from the same or different material and adhered, fastened, welded, and/or otherwise connected to the outer face OF of the first leg 102A. In all embodiments, the window jamb extender 100 can be chambered (i.e., include hollow void regions) or be of solid construction. The body 100B is optionally provided in any desired color and/or can be manufactured and or post-processed to include a simulated woodgrain or laminate color coatings, or a matte finish.
As shown in
The replacement window jamb extender 100 produces a clean, efficient and a readymade finished product compared to the other methods or devices available in the market. When installed, the replacement window jamb extender 100 allows a replacement window RW to utilize the same mounting depth JMD of the existing jamb 106, and it does not require extensive finish work as it has an accommodating integral J-channel 100J for the existing siding or other facing/cladding member(s) FM, and comprises a primary flange JF1 including an adhesive A which slides behind existing cladding members FM. To the interior, depending on the existing window and other building materials, minimal to no interior work is required as the same jamb mounting depth JMD of the jamb 106 is used and no drywall or wood trim work is necessary.
In the illustrated embodiment, the inner end 102AT of the L-shaped frame 102 is configured to be abutted with the end of a drywall section 114 extending from the inner side IN of the wall W. The wall W terminates at a nominal 2 inches×4 inches stud member 116 and the drywall section 114 extends over the stud member 116 to define the jamb mounting area 106.
In the illustrated embodiment, the replacement window jamb extender 100 further comprises a counter sunk screw fastener 120 configured to attach the L-shaped frame 102 to the wall stud member 116, where the counter sunk screw/fastener 120 is inserted from the inner side of the L-shaped frame 102 through the inner face IF into the stud 116 such that a head 120h thereof is countersunk into the first leg 102A so that the head 120h of the screw 120 does not contact or obstruct the window frame FR. The counter sunk screw 120 is screwed to the stud member 116 to increase the stability of the replacement window jamb extender 100 in the opening O of the wall W.
The installation of the replacement window jamb extender 100 comprises different steps. Primarily, the user needs to remove the old window unit ensuring all nails and debris is removed from the space surrounding the window slot opening O. The remaining siding nails are recommended to be removed using a reciprocating saw to obtain a clean surface for the installation of the replacement window jamb extender 100. The previous J-channel attached to the old window unit must be removed, and a sealant is applied to the interior jamb 106 and drywall exterior edge 114. Now, the replacement window jamb extender 100 is cut as per the required dimension.
In other words, the distance between the jambs 106 is measured for the top header and the replacement window jamb extender 100 is cut at an angle of 45 degrees on each side. Then the sealant is applied to the jamb 106 and the drywall exterior edge 114. The sealant can be further applied on a shim if necessary. Pre-drilling of the outside corners is performed and the sealant is applied to the holes and the screws, for example, counter sunk screw 120. Now the liner for the self-adhering seal tape is removed and the replacement window jamb extender 100 is secured with the counter sunk screw 120. Now, the side pieces are measured, as well as top header to sill portion, and then the replacement window jamb extender 100 is cut at 45 degree angles in preparation for a miter joint. Now the other liners for the self-adhering tapes are removed, and the assembly of the replacement window jamb extender 100 is leveled and secured, where a gasket seal or sealant is applied to the corners at the miter joints.
The bottom piece of the replacement window jamb extender 100 is measured, and this bottom sill piece is of similar length as that of the top header piece. The bottom piece of the replacement window jamb extender 100 is slid into place and secured with screws. However, the siding below the window opening may have to be removed and re-applied to properly fit. Finally, the 4 pre-drilled outside corners are filled with decorative plugs or sealant as desired to finish the installation of the replacement window jamb extender 100. As shown in
The window jamb extender 200 comprises a two-piece assembled body 200B in which the L-shaped frame 202 and the J-channel 200J are manufactured as separate members or pieces that are assembled together to define the window jamb extender 200. In particular, the J-channel 200J includes a connecting wall JW that extends between and interconnects the primary and secondary flanges JF1,JF2, and this connecting wall is adhered, fastened, and/or otherwise connected to the outer face OF of the first leg 202A to define this embodiment of the window jamb extender 200 as shown in
As shown herein, both the L-shaped frame 202 and the J-channel 200J are extruded polymeric structures, but any other suitable material and/or manufacturing techniques can be used to manufacture the L-shaped frame 202 and J-channel 200J, such as extruded aluminum, formed aluminum, wood and the like, and the L-shaped frame 202 and J-channel can be manufactured from different materials, and either can be a one-piece or multi-piece structure. As shown herein, the frame 202 and J-channel 200J are each vinyl (polyvinylchloride (PVC)) extrusions.
The L-shaped frame 202 is shown as a one extruded polymeric structure in which the first leg 202A comprises inner and outer spaced-apart walls IW,OW between which are located a plurality of voids or hollow regions V. The first leg 202A comprises opposite inner and outer ends 202Ai,202Ao, and the second leg 202B is connected to the first leg 202A at the outer end 202Ao of the first leg 202A, The first leg 202A includes opposite inner and outer faces IF,OF, and the second leg includes opposite inner and outer faces 202Bi,202Bx. The second leg 202B is connected to the first leg 202A adjacent the outer end 202Ao of the first leg 202A and is oriented transversely, preferably perpendicularly, relative to the first leg 202A.
Adjacent the intersection of the first leg 202A and the second leg 202B, the L-shaped frame 202 comprises a screw boss region SR that comprises a hollow void including a plurality of ribs or other projections SP that extend or project inwardly to provide structures to be engaged by the threads of the corner fastener 121 (
The first leg 202A is defined to include an outer face channel or outer face recess OFR that provides a location where the connecting wall JW of the J-channel 200J is adhered or otherwise connected to the outer face OF of the L-shaped frame 202. The outer face recess OFR is recessed, depressed, or offset inwardly relative to an adjacent portion of the outer surface OF includes or defines a width CW that can exactly match the corresponding width of the J-channel connecting wall JW, but preferably the width CW of the outer face recess OFR is larger than the corresponding width of the J-channel connecting wall JW to allow for customization with respect to the exact location of the J-channel 200J on the outer surface OF within an acceptable range as defined by the width CW of the outer face recess ODR. In the illustrated embodiment, the J-channel connecting wall JW is secured to the outer face OF in the outer face recess OFR using double-sided tape, but any other adhesive or other connecting means or structure can be used such as a mechanical engagement, fasteners, welding, and/or other connection techniques. As with the embodiment 100 of the window jamb extender described above, the window jamb extender 200 can be a one-piece structure including both the L-shaped frame 202 and the J-channel 200J in a monolithic structure such as a one-piece extrusion or injection molded structure.
The L-shaped frame 202 also includes an inner face channel or inner face recess IFR defined in the inner face IF of the first leg 202A in a region where the stud fastener 120 is located. The inner face recess IFR is recessed, depressed, or offset inwardly relative to the adjacent portions of the inner face to provide a location for the stud fastener 120 such that the head 120h of the fastener 120 is countersunk relative to the adjacent portions of the inner face IF and does not interfere with a window frame FR located adjacent the inner face IF as shown in
It can be seen in
The L-shaped frame 302 of the window jamb extender 300 is molded or extruded from a cellular polymeric material such as cellular polyvinylchloride (PVC). The illustrated frame 302 is a monolithic, one-piece structure, but the frame 302 can alternatively be assembled or constructed from multiple substructures of the same or other material. Alternatively, the frame 302 is constructed from one or more pieces of wood, vinyl (PVC) or other materials. The first leg 302A comprises opposite inner and outer ends 302Ai,302Ao, and the second leg 302B is connected to the first leg 302A at the outer end 302Ao of the first leg 302A, The first leg 302A includes opposite inner and outer faces IF,OF, and the second leg includes opposite inner and outer faces 302Bi,302Bx. The second leg 302B is connected to the first leg 302A adjacent the outer end 302Ao of the first leg 302A and is oriented transversely, preferably perpendicularly (at least for its inner face 302Bi), relative to the first leg 302A. The J-channel 300J is separated constructed from a rigid PVC or other material and the connecting wall JW thereof comprises a projecting tongue JT. The outer face OF of the first leg 302A of the L-shaped frame includes a groove JG that is adapted to receive and retain the tongue JT to operatively connect the J-channel to the L-shaped frame 302. Alternatively, the outer face OF of the L-shaped frame 302 comprises an optional outer face recess OFR as used in the L-shaped frame 202 of the embodiment 200 of
As shown in
The outer or exterior faces 102Bx,202Bx,302Bx of the respective window jamb extenders 100,200,300 optionally include decorative features DF such as paint, film, veneer, or another covering or coating, texturing, faux brick structures such as projections or grooves, and the like to improve the exterior aesthetics of an installed window jamb extender 100,200,300.
The foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present development disclosed herein. While the development has been described with reference to various embodiments, it is understood that the words used herein are words of description and illustration, rather than words of limitation. Further, although the development has been described herein with reference to particular means, materials, and embodiments, the development is not intended to be limited to the particulars disclosed herein; rather, the development extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. Those skilled in the art, having the benefit of the teachings of this specification, may affect numerous modifications thereto and changes may be made without departing from the scope and spirit of the development in its aspects.
This application is a continuation-in-part of U.S. application Ser. No. 15/356,409 filed Nov. 18, 2016, which claims priority from and benefit of the filing date of U.S. provisional application Ser. No. 62/392,878 filed Jun. 13, 2016. This application also claims priority from and benefit of the filing date of U.S. provisional application Ser. No. 62/392,878 filed Jun. 13, 2016. The entire disclosures of both U.S. application Ser. No. 15/356,409 filed Nov. 18, 2016 and U.S. provisional application Ser. No. 62/392,878 filed Jun. 13, 2016 are hereby expressly incorporated by reference into the present specification.
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Number | Date | Country | |
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20170356236 A1 | Dec 2017 | US |
Number | Date | Country | |
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62392878 | Jun 2016 | US |
Number | Date | Country | |
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Parent | 15356409 | Nov 2016 | US |
Child | 15621700 | US |