Classifications

• • E—FIXED CONSTRUCTIONS
  • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
  • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
  • E06B1/00—Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
  • E06B1/62—Tightening or covering joints between the border of openings and the frame or between contiguous frames
• • E—FIXED CONSTRUCTIONS
  • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
  • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
  • E06B1/00—Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
  • E06B1/62—Tightening or covering joints between the border of openings and the frame or between contiguous frames
  • E06B2001/628—Separate flexible joint covering strips; Flashings

Definitions

• This invention is directed to materials and methods for sealing windows and other fenestration products from moisture intrusion.
• Flanges or nailing fins on windows, doors and other fenestration products in which the flange is integral to and continuous with the window frame, provide a surface that is fully connected to the window for adhesive flashing materials to adhere to, enabling the flashing product to create a continuous watertight seal at the window-wall interface in structures, such as buildings.
• flanges are not present in all windows or fenestration products (hereinafter referred to as "windows").
• Non-flanged windows and windows with brickmold frames hereinafter referred to as "brickmold windows” are prone to moisture intrusion, due to difficulty in achieving a continuous flashing integration between the window and the wall.
• the typical installation method for these types of windows involves a bead of building sealant between the fenestration product and the wall, which is not a durable, continuously integrated moisture seal and is prone to failure after environmental exposure. This results in a higher tendency for moisture damage to the window and the surrounding wall, including rot and mold growth.
• This invention is a self-adhering flange material for sealing interfaces between fenestration products and walls, comprising at least one top coversheet and at least one bottom coversheet with a pressure- sensitive adhesive layer sandwiched between the two coversheets, wherein the coversheets occupy an appreciable width of the flange but do not extend across the entire width of the flange and thereby are offset with respect to each other thereby providing opposing first and second exposed surfaces of the pressures sensitive adhesive layer.
• This invention is also encompasses various methods for installing fenestration products into walls using the subject flange material.
• flanged windows refers to windows, doors, or other fenestration products that include a flange or nailing fin intended to cover any space between the window frame and the rough opening in the wall.
• the flange or fin may be integral to the fenestration product, or may be applied.
• non-flanged windows refers to windows that do not include a flange intended or nailing fin to cover the space between the window frame and the rough opening in the wall.
• brickmold frame refers to decorative trim attached to or integral to the window frame that covers any space between the window frame and the opening in the wall into which the window is installed.
• brickmold window refers to a window having a brickmold frame.
• window jamb or “jamb” refers to the side of the window frame.
• the window jamb is typically vertical.
• windowsill refers to the bottom portion of the window frame.
• the windowsill is typically horizontal.
• window head refers to the top portion of the window frame.
• the window head is typically horizontal.
• window refers to any window, door, or other fenestration products intended to be installed in an opening in a wall.
• Figure 1 is a perspective cross-sectional view of one embodiment of the flange material of the invention.
• Figure 2 is a cross-sectional view of another embodiment of the flange material of the invention.
• Figure 3 is a cross-sectional view of another embodiment of the flange material of the invention.
• Figures 4 through 6 are perspective views useful in illustrating the method of installing the flange material of the invention on a non-flanged window frame, and subsequently installing the window in an opening in a wall.
• Figure 7 is a cross-sectional view of yet another embodiment of the flange material of the invention.
• Figures 8 through 13 are perspective and side views of a brickmold window frame useful in illustrating the method of installing the window into an opening in a wall in such a way that the flange material of the invention is formed as the window is installed.
• Figures 14 through 17 are perspective and plan views of a brickmold window frame useful in illustrating the method of installing the window into an opening in a wall using the flange material of the invention to seal the window to the wall.
• the flange material of this invention can be applied to all non- flanged windows, brickmold windows, and windows having applied flanges to form a self-adhering flange that provides a means for achieving a continuous moisture seal integration of the window-wall interface.
• the flange additionally prevents moisture from entering around fasteners, such as nails, that penetrate the flange material and the window frame.
• pieces of flange material are positioned at the window wall interface to form the flange.
• the flange typically comprises a headpiece of flange material positioned at the top of the window -wall interface and two jamb pieces of flange material positioned at the sides of the window wall interface.
• flange material 10 is an elongated laminate structure formed from at least one top and one bottom coversheet (12 and 16, respectively) with a pressure-sensitive adhesive layer 14 sandwiched between the two coversheets.
• the coversheets occupy an appreciable width of the flange but do not extend across the entire width of the flange and thereby provide an apparent overlap with respect to each other.
• Release papers 18 that cover the adhesive surfaces are not necessarily required but aid considerably in handling and during installation as will be presented in the various installation methods to be described below.
• the width of one release paper is labeled as 10a and the portion of the second and opposite release paper is designated as 10c.
• a portion 10b can designate the extent of overlap between the first and second coversheets in the width of the flanges.
• the flange material can be fabricated in the field.
• flange material 20 as shown in Fig. 3 can be fabricated by contacting an elongated portion of the adhesive surfaces 22 of two pieces of flexible self-adhering flashing 21 together such that the flashing pieces overlap as represented by portion 20b and an elongated portion of each of the two adhesive surfaces as represented by 20a and 20c remain exposed.
• the flange material of the invention can utilize, for example, flexible self-adhering flashing material that will provide a durable moisture seal to the window-wall interface.
• suitable flashing material are DuPont FlexWrapTM flexible flashing or DuPont StraightFlashTM flashing, available from
• the method described as follows uses the flange material of Fig. 1 and as illustrated in Figs. 4 - 6, however it is recognized that the structure depicted in Fig. 1 is not intended to limit the steps of the method. It is further noted that Fig. 4 includes notation indicating whether the view is from inside or outside of the structure. These notations are used in Fig. 4 and other figures as matter of convenience.
• the steps of the method are as follows: a) adhering a first adhesive surface as represented by 10a of a piece of the flange material (the "headpiece” 111 ) to the outer surface of the head 121 of the window and extending to the outer surface of the upper portion of each jamb of the window; b) adhering a first adhesive surface as represented by portion 10c of a second piece of the flange material (the "jamb piece” 112) to the outer surface of the entire length of each jamb 122 of the window, thereby overlapping the headpiece adhered to each jamb in step (a) as shown in Fig. 4; c) installing and securing the window 114 in the opening of wall 250, per normal procedures, such that the head of the window is located at the top of the wall opening and the remaining unadhered portions, as represented, for example, by portion 10c in
• Fig. 1 of the headpiece and jamb pieces of step (a) and step (b) extend outward from the wall as shown in Fig. 5; d) adhering the remaining unadhered portions of the pieces of flange material of step (a) and step (b) to the wall above the head of the window and adjacent each jamb of the window such that the headpiece covers an upper portion of each of the jamb pieces in a shingled manner as shown in Fig. 6.
• the window is thereby sealed to the surrounding wall and any water that contacts the outer surface of the headpiece will be directed downward below the top of the jamb pieces so that there is virtually no opportunity for the water to penetrate the window-wall interface.
• the flange material 30 is an elongated material having a coversheet 32 on one surface thereof and a pressure sensitive adhesive 34 on the other surface thereof.
• the pressure sensitive adhesive surface is covered with release paper 36 that has perforations 37 extending along substantially parallel lines that are also substantially parallel with the lengthwise edges of the flange.
• release papers are not necessarily required but aid considerably in handling and during installation.
• the release paper covers three elongated portions of the adhesive surface (30a, 30b and 30c), the portions defined by the perforations in the release paper. It is noted that the number of perforations and the resultant defined portions can vary as may be required for proper installation.
• the flange of this embodiment is suitable for the installation of windows having brickmold frames.
• One method for installing a brickmold window into a wall opening whereby the interface between the window and the wall is sealed is described in the following steps as Brickmold Method 1. This method may also be applied to windows having integral and applied flanges.
• the window is sealed by means of a flange material as shown in Fig. 7 having release paper perforated along two length-wise lines.
• the flange is formed as the window is installed.
• This method is illustrated in Figs. 8 -13.
• the presence of the release paper on the remaining width-wise portion of the flashing provides a straight edge, facilitating positioning the flange material in the corner.
• a first adhesive surface exposed by removing portion 30a of release paper 36 of another piece of self- adhering flashing material (the "jamb piece” 212) is adhered to the outer surface 222 of one of the window jambs such that the line formed between portion 30a and the remaining width-wise portion of the jamb piece (represented by 30b and 30c together) is positioned in the corner between the outer surface of the window jamb and the back surface of the brickmold frame.
• the top of the jamb piece 212 should not extend more than about one inch above the window head.
• a second adhesive surface exposed by removing the central portion 30b of release paper 36, of the jamb piece is adhered to the back surface 223 (i.e., the interior-facing side) of the brickmold frame.
• the remaining edge portion 30c of release paper remains adhered to the corresponding adhesive surface.
• a cut is made in the jamb piece directly above the adhered portion 30a along the outside corner between the outer surface of the jamb and the outer surface of the head, and the portion of the jamb piece above the cut is adhered to the top surface 221 of the window head.
• Steps (d)-(f) are repeated on the other window jamb using a separate jamb piece of flange material (i.e., a third piece of flange material).
• a side view of the window frame with the installed pieces of flange material is shown in Fig. 10.
• the window frame is then installed in the opening in the wall 250 per the window manufacturer's recommended procedure.
• the remaining edge portion 30c of release paper 36 is intact on each piece of flange material so that the remaining release paper is facing out away from the wall (on the outside surface of the wall) surrounding the window.
• the remaining, third adhesive surface of one of the jamb pieces is exposed along one side of the window by removing the remaining portion of release paper.
• the remaining release paper is removed from the headpiece and a drip cap is installed over the top of the window frame, and then covered by a piece of covering flashing overlapping the top of the drip cap and the wall.
• a drip cap is not used, the remaining release paper is removed from the headpiece and a covering piece of flashing is adhered overlapping the top of the headpiece and the wall.
• Brickmold Method 2 Another method for installing a brickmold window frame into a wall opening is designated as Brickmold Method 2, whereby the interface between the window and the wall is sealed includes the following steps. Again, this method may be used to install windows having integral and applied flanges. In this method, the flange is prepared first, and then attached to the window before the window is installed.
• the flange material as depicted in Fig. 2 may be used advantageously in this method.
• the width of one release paper is labeled as 18a and 18a' and the portion of the second and opposite release paper is designated as 18c and 18c'.
• a portion 18b can designate the extent of offset or overlap between the first and second coversheets in the width of the flanges. Further, it is recognized that the structure depicted in the figure is not intended to limit the steps of the method.
• a length of the flange material (the "head flange" 311 ), advantageously several inches longer than the width of the brickmold frame, is folded along one of the perforations 19 in the release paper to expose a line of adhesive as between 18a and 18a'.
• the line of adhesive is positioned in the corner along the top of the window frame between the back surface 323 of the brickmold frame and the upper surface 321 of the window head.
• the release paper 18a is removed from the portion of the head flange in contact with the back surface of the brickmold frame and adhered to the back surface of the brickmold frame. As shown in Fig.
• the head flange is cut at the outer corners between the upper surface of the window head and the outer surfaces of the jambs, and folded down on the back surface of the brickmold frame.
• Another length of the flange (the "jamb flange" 312), advantageously a few inches longer than the height of the brickmold frame is folded along one of the perforations 19 in the release paper to expose a line of adhesive as in step (a).
• the line of adhesive on the jamb flange is positioned in the corner along one side of the window frame between the outer surface 322 of the jamb and the back surface 323 of the brickmold frame so that the flange slightly overlaps the head flange 311 and extends below the window frame.
• the release paper 18a is removed from the portion of the jamb flange in contact with the surface 322 of the jamb and adhered thereto.
• the release paper 18a' is removed from the portion of the jamb flange in contact with the back surface 323 of the brickmold frame and adhered to the back surface of the brickmold frame.
• the jamb flange is cut at the outer corners between the lower surface of the window frame and the outer surface of the jamb and folded onto the back surface of the brickmold frame.
• Steps (e) through (h) are repeated to install a separate jamb flange on the other side of the window as shown in Fig. 15.
• the window is installed in a wall opening per the window manufacturer's recommended installation procedure.
• the installed window is shown from the outside in Fig. 16.
• the remaining release paper 18c and 18c' is removed from the head flange and the jamb flanges and the exposed adhesive surfaces are adhered to the outside wall surface, i) Optionally, most of the exposed adhesive on the head flange is cut away, leaving a small amount of adhesive remaining along the edges of the flange.
• Self-adhering flexible flashing material 310 is adhered over the intersection of the head and jamb flanges as shown in Fig. 17. The flange material may De applied to the window during window fabrication.
• the window could be provided as it is at the end of step (i) above, and the remaining steps (j) through (m) would be carried out, for example, by the installers at a building site.
• the pressure sensitive adhesive used in the flange material of the invention can be butyl rubber adhesive, bituminous adhesive, acrylic, or combinations thereof (layers or blends). Additionally, the pressure sensitive adhesive can be neoprene, polymers based on epdm (ethylene propylene diene monomer), or other adhesives generally used in construction applications. The thickness of the pressure sensitive adhesive is between about 15 mils (0.38 mm) and 25 mils (0.64 mm). The pressure sensitive adhesive provides a watertight seal around fasteners that penetrate the flange material.
• the material used as the coversheet material in the flange material of the invention can be any nonwoven sheet, film, coated paper, coated nonwoven sheet, or nonwoven-film laminate suitable for use in a flexible flashing material.
• the coversheets can be polyolefin plexifilamentary film- fibril sheet, available under the trade name Tyvek® from DuPont.
• the coversheet of the flange can be made from a relatively rigid material such as metal or plastic formed into the required shape for the various installations noted above.
• the rigid material would have a pressure-sensitive adhesive layer applied to provide attachment to the windows and building structure.
• the flange material of the invention can be adhered to a wall covered by a weather resistive barrier sheet.
• the flange can likewise include a sill piece appropriately installed to form a total barrier system around the wall-window interface to further preclude moisture intrusion.
• the durability of the selected installations was then evaluated by subjecting the walls first to thermal cycling and re-testing for air leakage and water resistance, and secondly by subjecting the walls to wind load using ASTM E 330 for one hour in the positive direction and one hour in the negative direction, and then re-testing for water resistance.
• the thermal cycling of exterior walls was conducted according to AAMA (American Architectural Manufacturers Association) 501.5. Standard Test Method for Exterior Windows, Curtain Walls, and Doors for Water Penetration using Dynamic Pressure.
• Example 1 Four test walls were constructed for the testing. All four walls were constructed using Spruce-Pine-Fir nominal 2 in x 4 in lumber and covered with oriented strand board sheathing applied to 16 in on center studs. All walls were 5 ft wide by 7 ft 6 in high and contained one brickmold window unit. The window used in each case was a JELD-WEN® wood double hung window with applied brickmold. The windows were each 2 ft 10 in wide x 3 ft 4 in high. Four different flashing installations methods were utilized as described below in Examples 1-4. Example 1
• a wall unit as described above was wrapped with Tyvek® HomeWrap® (available from E. I. du Pont de Nemours and Company, Wilmington, Delaware) prior to installing the window.
• DuPont FlexWrapTM available from E. I. du Pont de Nemours and Company
• StraightFlashTM flashing with similarly perforated release paper was applied over this as follows.
• One of the release papers along the edge of the flashing was removed, and the edge of the exposed butyl was placed flush adjacent the corner between the outer surface of the brickmold frame and the exterior surface of the wall such that the edge of the butyl touched the inside of the corner.
• the rest of the exposed butyl strip was laid down onto the already installed, exposed butyl strip adjacent the window. This created a very strong butyl- to-butyl seal. This seal created the flange material.
• the procedure for installing a covering piece of flashing was repeated on other side of the window.
• the flange material system was completed and integrated into the wall by removing the last two strips of release paper from the covering pieces of flashing and laying the exposed butyl adhesive smoothly onto the exterior wall surface to complete the seal of the window- wall interface.
• a metal drip cap was installed and the DuPont StraightFlashTM was installed over the drip cap followed by a flap of the previously installed Tyvek® HomeWrap®.
• the Tyvek® HomeWrap® was taped over the drip cap and tape was applied in a shingled fashion to avoid leakage.
• Air and water resistance of this window installation are given in Table 1. Air and water resistance after thermal cycling and water resistance after wind loading of this window installation are given in Table 2.
• a wall unit as described above was wrapped with Tyvek® HomeWrap® prior to installing the window.
• DuPont FlexWrapTM was installed on the sill and an aluminum angle was installed under the DuPont FlexWrapTM to serve as a back dam.
• the flange material was prefabricated by attaching two 4 in wide pieces of DuPont StraightFlashTM together. The flange material was installed on the window at the window head and then the jambs.
• the window was installed using Brickmold Method 2 and the final pieces of release papers were removed and adhered to the Tyvek® HomeWrapTM.
• the remaining exposed butyl on the top flange was cut away and the remaining exposed flange area was covered with a 6 in to 8 in long piece of 4 in wide DuPont StraightFlashTM.
• Air and water resistance of this window installation are given in Table 1. Air and water resistance after thermal cycling and water resistance after wind loading of this window installation are given in Table 2.
• DuPont FlexWrapTM was ihstMedlD ⁇ TtheWndbws ⁇ ri and an aluminum angle was installed under the DuPont FlexWrapTM to serve as a back dam.
• the flange material was prefabricated by attaching two 4 in wide pieces of DuPont StraightFlashTM together. The flange material was installed on the window jambs. At the head of the window, a 4 in wide piece of DuPont StraightFlashTM was adhered to the top of the window frame and the back of the decorative brickmold with the final piece of release paper facing out above the decorative brickmold using Brickmold Method 2.
• the window was installed, then the rest of the release paper on the flange material was removed and the flange material was adhered to the wall.
• a drip cap was installed at the head of the window and a piece of DuPont StraightFlashTM was placed over the drip cap. Then the wall was wrapped with Tyvek® HomeWrap® and the joints were taped.
• Air and water resistance of this window installation are given in Table 1. Air and water resistance after thermal cycling and water resistance after wind loading of this window installation are given in Table 2.
• Example 4 The window was installed into a wall unit as in Example 2 (that is using Brickmold Method 2) except that the wall unit was wrapped with Tyvek® HomeWrap® after the window was installed.
• the flange material for the head was fabricated in a "T" configuration by cutting a smaller piece of flashing the width of the window frame and centering it on a relatively larger piece of flashing.
• Air and water resistance of this window installation are given in Table 1. Air and water resistance after thermal cycling and water resistance after wind loading of this window installation are given in Table 2. Table 1

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• Engineering & Computer Science (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Door And Window Frames Mounted To Openings (AREA)
• Building Environments (AREA)
• Specific Sealing Or Ventilating Devices For Doors And Windows (AREA)
• Adhesive Tapes (AREA)
• Adhesives Or Adhesive Processes (AREA)

Applications Claiming Priority (2)

Publications (1)

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• 2004
  • 2004-12-14 US US11/011,669 patent/US20060137262A1/en not_active Abandoned
• 2005
  • 2005-12-14 JP JP2007546908A patent/JP2008523284A/ja active Pending
  • 2005-12-14 EP EP05854246A patent/EP1825092A2/en not_active Withdrawn
  • 2005-12-14 CN CNA2005800429726A patent/CN101080547A/zh active Pending
  • 2005-12-14 CA CA002586917A patent/CA2586917A1/en not_active Abandoned
  • 2005-12-14 WO PCT/US2005/045483 patent/WO2006066034A2/en active Application Filing
• 2006
  • 2006-12-20 US US11/642,070 patent/US20070175107A1/en not_active Abandoned

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