Patent Grant
7490442
This invention relates to poured concrete walls, and more particularly, to a window system and associated method for installing a window in a poured concrete wall.
In pouring walls of concrete such as residential basement walls, window openings are commonly formed in the concrete wall as it is being poured. In the past, it has been common to construct wood frames for window openings as a part of the wood wall forms for the concrete walls. After the poured concrete had set, the wood forms, including the wood window frames, were removed and at least the wood window frames had to be discarded. The cost of the wood window frames which are not reusable, and the labor required in building the frames were distinct disadvantages of this type of construction.
Another general method which has been used is a metal buck frame or surround which is positioned between the wall forms and cast in place in the concrete wall. When the wall forms are removed, the buck frame or surround is in place to form the periphery of the window opening. Unfortunately, these types of systems have been found to be subject to deformation during the pouring of the concrete. Additionally, cast in place buck frames or surrounds significantly increase the cost of a window installation because they are not reusable.
To avoid these disadvantages, various methods and systems have been proposed. For example, a reusable metal pouring window buck, which is positioned between the spaced wall forms, is one alternative. The bucks may be made in two parts and when the concrete which has been poured around the buck has set, the buck is removed from the window opening formed in the resulting concrete wall. Typically, a window frame is detachably secured within the buck such that the window frame is cast in and remains in the window opening when the concrete sets and the buck is removed. Unfortunately, due to the heavy forces delivered by the concrete being poured around the buck, this method has proven, in many instances, to be unreliable to protect the window contained within the buck. In many instances, the window is damaged or broken during the pouring of the concrete requiring additional time, effort and expense in repairing or replacing the window cast in place in the poured concrete wall. Furthermore, vinyl window frames, while providing many advantages acknowledged in the industry are highly susceptible to being damaged during the pouring of the concrete wall in such systems.
Alternatively, the window buck may be constructed of more robust materials to withstand the forces generated by the pouring and curing of the concrete and avoid deformation to the window buck and window. Examples of robust and reusable window buck systems are disclosed in U.S. Pat. Nos. 6,185,884 and 6,550,194, each assigned to the assignee of this invention and hereby incorporated by reference in its entirety. While the systems and methods shown in those patents have proven to be dramatic advancements over prior systems, improvements are still needed to minimize production costs and maximize ease of use of the window system for some applications.
A removable pouring buck allows a window to be installed into the window opening in the concrete wall after the buck has been removed. In the past, one disadvantage to such systems is the need for additional and often complicated or cumbersome fasteners to secure the window frame into the window opening. Typically, the window frame must be screwed, nailed, anchored or otherwise secured into the window opening with an additional fastener thereby requiring additional installation work, materials, tools and labor. Moreover, in many such systems, the window cannot be easily removed for cleaning, repair and/or replacement once installed in the window opening. Additionally, the initial installation is not easily accomplished and the window is not securely mounted in the window opening.
Therefore, there exists a need for an improved system and method for forming a window opening in a poured concrete wall and installing the window in that opening. The system and method should be economical, efficient and robust to withstand the forces of the poured concrete while allowing for the accurate and reliable positioning of the window in the poured concrete wall. Furthermore, the system and method must be applicable for a wide variety of window styles, sizes and materials while providing for easy and secure installation, removal and manipulation.
These and other objectives of the invention have been attained by a system and associated method for forming a window opening in a poured concrete wall and installing the window and associated frame into the opening. The components of the system include a reusable window buck which is adapted for placement between spaced wall forms to divert poured concrete around the window buck to form the window opening in the concrete wall. Advantageously, the window buck is reusable after being removed from the concrete wall.
According to presently preferred embodiments, the window buck is a one-piece component including a generally rectangular frame. The frame in one embodiment is generally rectangular and aluminum with an extension which forms a rim around the window opening in the concrete wall.
The frame is removable in only one direction from the poured concrete wall. The window buck advantageously forms a raised rim along a sill of the window opening proximate an interior side of the poured concrete wall to inhibit water from flowing through the window opening toward the interior side of the poured concrete wall. The raised rim is positioned against a flange projecting around the window frame. Moreover, the window buck forms a protruding rim along each jamb at each side of the window opening against which a flange of the window unit is positioned when installed in the window opening.
A component of the system according to a presently preferred embodiment of this invention is an improved retainer coupled to the window buck while the concrete is being poured so that the retainer is preferably partially embedded in the concrete wall proximate the window opening. The retainer preferably includes two frangible members which couple the retainer to the window buck so that upon removal of the window buck from the window opening the frangible members are broken leaving the remainder of the retainer embedded in the concrete wall. The frangible members in one embodiment are pins seated within holes in the window buck and retained there during installation of the buck between the wall forms and subsequent pouring of the concrete.
The retainer in a presently preferred form includes a socket which is exposed when the retainer is embedded in the concrete wall. Preferably, two such retainers are mounted to the bottom of the window buck and one retainer on each side of the buck. A window or window frame is easily snapped into the window opening and retained therein by spring clips or other devices mounted on the bottom and each side edge of the window frame or window. The spring clip temporarily deflects inwardly while the window or frame is being installed until the clip is seated within the socket of the embedded retainer. The configuration of the clip according to one aspect of this invention provides for secure installation in the window opening even if the retainer is not precisely aligned with the clip. Accordingly, the secure installation of the window or window frame is easily accomplished without tools or additional fasteners such as nails, screws or the like.
With the system and associated method according to this invention, a window opening is reliably formed in the desired location in a poured concrete wall without damaging a reusable, lightweight and robust window buck. Moreover, a window is securely, efficiently and conveniently installed in the window opening without the need for tools or additional fasteners in an easy, efficient and economical manner.
The objectives and features of the invention will become more readily apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
A presently preferred embodiment of a window buck 10 according to this invention is shown in
The buck 10 includes a number of holes 34 on the exterior face of each lateral side 24 and the bottom side 28. The holes 34 are sized and positioned so that a retainer 36 can be coupled to the window buck 10 prior to installation and use of the window buck 10.
The window buck 10 is adapted to be placed between spaced wall form panels and suspended therein as described in U.S. Pat. Nos. 6,185,884 and 6,550,194. Appropriate components may be added to the buck 10 to facilitate such an installation. Concrete is poured between the wall forms (not shown) and allowed to cure thereby forming a poured concrete wall 38. The window buck 10 diverts the poured concrete thereby forming a window opening 40 in the concrete wall 38, as shown particularly in
Referring to
The retainer 36 includes a generally rectangular socket 50 formed in a face of the retainer body 42 opposite from the anchor 44. The retainer 36 also includes a pair of frangible members 52 projecting from tabs 54 on opposite ends of the retainer body 42 adjacent the socket 50 (
Each frangible member is in the form of a pin 52 which is received within one of the holes 34 in the extension 20 of the buck 10. The pin 52 is oriented generally perpendicularly to the retainer body 42. The pin 52 includes a shaft 56 with a number of concentric ribs 58 which assist in secure placement of the retainer 36 in the holes 34 in the extension 20. The pin 52 also includes a conical-shaped distal tip 60.
The pins 52 are aligned with the holes 34 in the window buck 10 and can be then manually or otherwise inserted therein to securely couple the retainer 36 to the buck 10. The ribs 58 increase the frictional interaction between the pin 52 and the hole 34 for securely mounting the retainer 36 to the buck 10.
After the concrete has been poured and allowed to cure and the wall forms removed from the poured concrete wall 38, the shaft 56 of each pin 52 is easily broken or severed from the buck 10 as the buck 10 is removed from the window opening 40. The anchor 44 and adjacent surfaces of the retainer 36 are embedded in the poured concrete wall 38 with the socket 50 and adjacent faces of the tabs 54 exposed along each jamb 62 and sill 64 of the window opening 40, as shown in
One presently preferred method of installing a window unit 100 in the poured concrete wall 38 according to this invention begins with erecting the pair of spaced wall forms. The retainers 36 are then coupled to the window buck 10 with the frangible pins 52 inserted into the corresponding holes 34 in the buck 10 as previously described. The retainers 36 and window buck 10 are then suspended between the spaced wall forms with any one of the known techniques, depending upon the desired position of the window opening 40 in the poured concrete wall 38. Concrete is then poured between the spaced wall forms and around the window buck 10 thereby partially embedding the retainers 36 in the poured concrete.
After the poured concrete is allowed to cure, the wall forms are dismantled and the retainers 36 are uncoupled from the window buck 10 by severing, breaking or otherwise fracturing the frangible pins 52 from the retainer 36. The window buck 10 is then pulled from the window opening 40 in the poured concrete wall 38. While a one-piece window buck 10 is shown and described, other designs are contemplated within this invention.
The bulkhead 22 between the frame 12 of the buck 10 and the extension 20 forms a rim 66 on the sill 64 of the window opening 40 and along the window opening jambs 62. The rim 66 at the sill 64 advantageously prevents the ingress of water or other moisture to the interior of the concrete wall 38 when the window unit 100 is seated on the sill 64 as shown in
The window unit 100 to be installed in the window opening 40 according to a presently preferred embodiment of this invention has a generally tubular and rectangular frame 102 or other shaped configuration. The window unit 100 shown and described herein is but one of many window designs that can be utilized with this invention including glass block or other window designs and materials. The window unit 100 preferably includes the perimeter frame 102; although, other window constructions or types can be used, such as glass blocks or the like, that may not include a perimeter frame. The window unit 100 also includes one or more window elements 104, such as glass, screen or a glazing element. A generally planar flange 106 projects perpendicularly from the frame 102 and around the entire perimeter of the window unit 100. Preferably, the perimeter frame 102 of the window unit 100 includes an insulation or weather strip seal 108 extending on the flange 106 around the periphery of the window unit 100. A metal spring clip 110 or other type of preferably outwardly biased device or the like is mounted by a pair of bolts, screws or other fasteners 112 to each lateral and bottom side of the window frame 102 as shown in
As seen most clearly in
Another advantageous aspect of the window clip 110 according to this invention is that the tangs 114 of each clip 110 are staggered or offset relative to each other as shown in
The window installation according to this invention preferably includes four retainers 36 and associated clips 110 on the window frame 102: two of which are on the sill 64 and corresponding positions on the bottom of the frame 102 and two of which are on the jambs 62 and corresponding sides of the frame 102. Securing the window unit 100 along the sill 64 of the window opening 40 provides a more stable and secure installation of the window unit 100 compared to prior systems. It should be readily appreciated that while four attachment locations are shown in
While the spring clip 110 shown and described herein is a presently preferred embodiment, it should be understood that any of a variety of other devices, whether biased or not, are encompassed within this invention. The spring clip 110 or other device is advantageously mounted on the window unit 100 or window frame 102 prior to installation for easier and simpler installation without the need for additional mechanical fasteners or tools during installation.
The window unit 100 is installed from the exterior of the poured concrete wall 38 by seating a bottom edge of the window unit 100 or frame 102 along the sill 64 of the window opening 40 with the rim 66 juxtaposed to an interior face of the flange 106. The window unit 100 is then pivoted upwardly toward the jambs 62 of the window opening 40 until the flange 106 of the frame 102 seats against the rim 66 on the jambs 62 at the side edges of the window opening 40. The spring clips 110 temporarily deflect inwardly as the window unit 100 is pivoted upwardly and then spring out to extend into the sockets 50 of the retainers 36 and thereby secure the window unit 100 in the window opening 40. The window unit 100 can be selectively removed from the window opening 40 by inserting a hook-shaped tool or other device (not shown) between the window frame 102 and the jamb 62 to deflect the spring clip 110 on the window unit 100 inwardly and unseat it from the socket 50 and retainer 36 and then pivot the window 100 away from the window opening 40.
As a result, the window unit 100 is easily installed in an efficient manner without the need for additional tools or fasteners to secure the window unit 100 into the formed window opening 40 in the concrete wall 38. Moreover, the window buck 10 used in forming the window opening 40 can be cleaned and subsequently reused thereby minimizing the cost for the construction of the poured concrete wall 38 and window opening 40 therein.
From the above disclosure of the general principles of the present invention and the preceding detailed description of at least one preferred embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. For example, numerous other configurations and/or designs for the window buck, retainer and spring clip are possible within the scope of this invention. Therefore, we desire to be limited only by the scope of the following claims and equivalents thereof.
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