WO2012170575A1 - Window installation corner mounting system and flashing membrane - Google Patents

Window installation corner mounting system and flashing membrane Download PDF

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Publication number
WO2012170575A1
WO2012170575A1 PCT/US2012/041155 US2012041155W WO2012170575A1 WO 2012170575 A1 WO2012170575 A1 WO 2012170575A1 US 2012041155 W US2012041155 W US 2012041155W WO 2012170575 A1 WO2012170575 A1 WO 2012170575A1
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WO
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Patent type
Prior art keywords
wall
corner
back
clip
planar
Prior art date
Application number
PCT/US2012/041155
Other languages
French (fr)
Inventor
Mark E. FLOREN
Michael Paul Henry
Original Assignee
2Fl Enterprises, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Publication date

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Classifications

    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/62Tightening or covering joints between the border of openings and the frame or between contiguous frames
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/56Fastening frames to the border of openings or to similar contiguous frames
    • E06B1/60Fastening frames to the border of openings or to similar contiguous frames by mechanical means, e.g. anchoring means
    • E06B1/6015Anchoring means
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/62Tightening or covering joints between the border of openings and the frame or between contiguous frames
    • E06B2001/628Separate flexible joint covering strips; Flashings

Abstract

A corner mounting system having a corner receptacle with a planar bottom wall, a planar side wall extending from the planar bottom wall, and a planar rear wall to form a three-sided interior, a planar bottom face plate depending from a front edge of the bottom wall, a planar side face plate depending from a front edge of the side wall, the back wall having a first leg and second leg extending from the bottom wall; a corner clip having a planar bottom wall, a planar side wall depending from the bottom wall, and a planar back wall attached to the bottom wall and the side wall, the corner clip further including a clip structure extending from the back wall and structured to fit over the rear wall of the corner receptacle to hold the corner clip in a nested relationship inside the three-sided interior of the corner receptacle.

Description

WINDOW INSTALLATION CORNER MOUNTING

SYSTEM AND FLASHING MEMBRANE

BACKGROUND Technical Field

The present disclosure pertains to new and retrofit window installations for through-openings in buildings and, more particularly, to a window corner support structure and to a flexible reinforced flashing membrane.

Description of the Related Art

Windows, skylights, sliding doors, and other through-opening installations in exterior walls, ceilings, doors, and other structural components are exposed to the elements, including moisture, such as rain, sleet, hail, snow, as well as moisture vapor, such as fog, clouds, and steam. Regardless of whether the installation involves a new window in a new building or a retrofit window in an existing building, these installations not only must repel or resist the elements, they must also provide breathability to the structure to allow entrapped or condensed moisture to escape from the area surrounding the installation. Windows and sliding doors are increasingly retrofitted to replace single pane windows with multiple pane windows or to install vinyl windows. Multiple layer windows better insulate building interiors and minimize climate control requirements in the building. Vinyl windows provide improved

insulation, aesthetics, and durability. Windows and sliding doors can, of course, be retrofitted for other reasons, such as to replace worn frames or windows with broken or otherwise damaged window glasses.

Removal of old windows is typically accomplished by removing the glass, followed by collapsing the frame inward by prying the frame away from the sides of the through-opening of the building to which the window frame is installed. This process can damage weather resistant barriers, such as leak preventing papers and flexible polyurethane and polyether membranes, which were installed during original construction of buildings. Moreover, conventional retrofit window installations include a window in a frame that is simply fastened to the structure that forms the through-opening. Therefore, fluid leaks around the new window are a common problem due to the degraded weather resistant barrier.

BRIEF SUMMARY

In accordance with a first aspect of the present disclosure, a window installation corner mounting system is provided. In one embodiment, the corner mounting system includes a corner receptacle having a bottom wall, side wall, and a rear wall formed orthogonal to the bottom wall and side wall. The receptacle further includes a planar bottom face plate depending from the bottom wall, ideally from a front edge of the bottom wall, and further includes a planar side face plate depending from a front edge of the side wall and away from the bottom wall. The bottom wall, side wall, and rear wall form a three- sided interior. The rear wall is preferably L-shaped with a first leg extending upward in a direction opposite from the bottom face plate and from a back edge of the bottom wall, and a second leg extending from a back edge of the side wall in a direction opposite of the side face plate. The corner mounting system further includes a corner clip having a bottom wall, a side wall depending from the bottom wall, and a back wall attached to and orthogonal to the bottom wall and the sidewall and structured to nest inside the three-sided interior of the corner receptacle. Preferably, the back wall is L-shaped with a first leg extending from a back edge of the bottom wall in the same direction as the side wall and a second leg extending from a back edge of the sidewall and in a direction towards the first leg. A clip structure extends from the rear wall, preferably from both the first leg and the second leg, and is structured to fit over the rear wall of the corner receptacle with an interference fit to hold the corner clip in a nested relationship inside the three-sided interior of the corner receptacle.

In accordance with another aspect of the present disclosure, a flashing membrane is provided that includes cured polyether material and a reinforcing layer of flexible material, preferably a netting or mesh-type material in the form of a grid of intersecting elongate flexible filaments that define openings to receive the polyether material.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The foregoing and other features and advantages of the present disclosure will become more readily appreciated as the same become better understood from the following detailed description when taken in conjunction with the accompanying drawings, wherein:

Figure 1 is an isometric view depicting a first step of installing a sill plate membrane flashing in a through-opening formed in a structural wall;

Figure 2 is an isometric view depicting a second step of installing left and right jam membrane flashings in the through-opening of the structural wall of Figure 1 ;

Figure 3 is an isometric view depicting a third step of installing a head membrane flashing in the through-opening of the structural wall of Figure 1 ;

Figure 4 is an isometric view of a completed installation of the membrane flashings of Figures 1 -3;

Figure 5 is an isometric view of a window installation using the membrane formed in Figures 1 -4;

Figures 6A-6B illustrate two versions of supply rolls for the membrane used in the installation of Figures 1 -5;

Figure 7 is an isometric partial cut-away view of a flashing membrane formed in accordance with another aspect of the present disclosure; Figures 8A-8D are an isometric illustration and top, front, and right side plan views, respectively, of a corner receptacle formed in accordance with the present disclosure;

Figures 9A-9D are an isometric illustration and top, front, and right side plan views of a corner clip formed in accordance with the present disclosure;

Figure 10 is an isometric exploded illustration of the corner clip positioned outside of the corner receptacle;

Figures 1 1A-1 1 C are top, front, and right side views, respectively, of the corner mounting system with the corner clip nested and clipped to the corner receptacle;

Figure 12A is a partial cross-sectional illustration of a corner mounting system installation in conjunction with a sill plate and window;

Figure 12B is a partial cross-sectional illustration of an alternative embodiment of a corner mounting system installation in conjunction with a sill plate and window.

DETAILED DESCRIPTION

In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed embodiments. However, one skilled in the relevant art will recognize that embodiments may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other instances, well-known structures or components or both associated with rough opening installations, including but not limited to windows, skylights, and doors, have not been shown or described in order to avoid unnecessarily obscuring descriptions of the embodiments.

Unless the context requires otherwise, throughout the specification and claims that follow, the word "comprise" and variations thereof, such as "comprises" and "comprising" are to be construed in an open inclusive sense, that is, as "including, but not limited to." The foregoing applies equally to the words "including" and "having."

Reference throughout this description to "one embodiment" or "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, the appearance of the phrases "in one embodiment" or "in an embodiment" in various places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

Although the present disclosure is described in the context of a rough through-opening or rough opening for a window, it is to be understood that the present disclosure can be applied to other installations, such as skylights, doors, and the like. Thus, the present disclosure is not limited to window installations.

Figures 1 -4 illustrate one aspect of a window installation process in which a fully continuous barrier membrane 10 (shown completely assembled in Figure 4) is installed in a rough through-opening or rough opening 12 formed in a structural membrane 14. The structural membrane can be an exterior wall, ceiling, or other structural feature that is exposed to the environment. Here, the rough opening 12 is of rectangular or square shape, although it can have other shapes, such as circular, oval, a polygon, or any other geometric shape.

In this installation, the rough opening 12 is a framed opening designed to receive a window. Generally, two vertical king studs 1 1 define the space in which the rough opening 12 is formed. The rough opening frame includes a sill plate 16, sidewalls formed by a jam plate or trimmer stud 18, and a head plate or head 20 that rests on the trimmer studs or sidewalls 18.

Because the construction of a window rough opening is well known, it will not be described in greater detail. Preferably, the membrane 10 is formed of high-vapor permeable pre-cured polyether-based material composition. For most applications, the polyether has a thickness of 1/8 inch or less and, more preferably, has a thickness in the range of 40 mil to and including 60 mil. An improved polyether type membrane flashing is described below in conjunction with Figure 7.

The first step in forming the membrane 10 is to form a sill plate flashing 22. This sill plate flashing 22 is shaped by taking a sheet of polyether material and cutting and bending it to have the shape shown in Figure 1 . More particularly, the sill plate membrane flashing 22 will be shaped to have a flat base panel 24 that will be applied to the sill 16, an upright rear wall 26 formed by bending a portion of the base panel 24 upward to be essentially orthogonal to the base panel 24. In addition, left and right upright sides 28 are formed by bending side portions of the base panel 24 upward to be orthogonal to the base panel and project in the same direction as the rear wall 26. Thus, when the sill plate membrane flashing 22 is installed in the rough opening 12, the rear wall 26 and left and right upright sidewalls 28 will project upwards towards the head 20.

In addition, a front panel 30 is formed by bending a long strip depending off the base panel 24 to be orthogonal to the base panel 24 and in a direction opposite that of the rear wall 26. It is to be understood that the left and right upright sides 28 and the rear wall 26 are optional. In other words, in an alternative configuration these optional walls are omitted.

As shown in Figure 1 , the sill plate membrane flashing 22 is sized to be received within the rough opening 12 so that the left and right upright sidewalls 28 are flush against the left and right sidewalls 18, and the rear wall 26 projects far enough into the opening 20 to butt against the back of the window to be installed.

As shown in Figure 1 , the combination of the base panel 24, rear wall 26, and left and right upright sidewalls 28 form a tray or receiver that has an open front to facilitate collection and drainage of moisture. In most installations, the front panel 30 will have left and right extensions 32 that project approximately 4-6 inches beyond the length of the base panel 24 to provide additional sealing and enable overlapping with other flashing membranes, as described more fully below.

Prior to installing the sill plate membrane flashing 22 in the rough opening 12, an adhesive, preferably viscous polyether, is applied to the structural membrane 14. More particularly, a bead of the viscous polyether is applied along the sill 16 and a portion of the exterior face 34 in an area under the sill 16 where the front panel 30 and extensions 32 will be applied.

Alternatively, the viscous polyether could be applied to the flexible polyether membrane 22 that forms the sill plate membrane flashing, although this could make it slightly more difficult to handle the flashing 22 during installation. The viscous polyether emulsifies or integrates itself with the polyether membrane during the curing process.

Figure 2 shows the sill plate membrane flashing 22 placed inside the rough opening 12 to bear against the structural membrane 14 and the sill 16.

Also shown in Figure 2 are the left and right jamb membrane flashings 36 formed of the polyether material to have a shape similar to that of the sill plate membrane flashing 22. In other words, each jamb membrane flashing 36 has a base panel 38 with a rear wall 40 extending orthogonally therefrom and a sidewall 42 extending from one side of the base panel 38, preferably the side that will be adjacent the head 20. There is no sidewall formed on the base panel to be adjacent the sill 16. Rather, the base panel 38 has a length that overlaps with the upright sidewall 28 so that moisture runs down the base panel 38 of the left and right jamb membrane flashing 36 into the base panel 24 without getting behind the sill plate membrane flashing 22. The rear wall 40 is optional, depending on the installation requirements.

In addition, each of the left and right jamb membrane flashings 36 has a front panel 44 projecting orthogonally from the base panel 38 in a direction opposite to the rear wall 40 and sidewall 42. The front panel 44 also has extensions 46 that extend beyond the length of the base panel 38.

When installed, as shown in Figure 3, the left and right jamb membrane flashings 36 will have the extensions 46 overlapping the extensions 32 on the front panel 30 of the sill plate membrane flashing 22. In addition, the base panel 38 will overlap the left and right upright sidewalls 28 of the sill plate membrane flashing 22. When installed in this order, the overlapping of the flashings will direct moisture downward and prevent entry of moisture at the intersection of the flashings.

Also shown in Figure 3 is a head plate membrane flashing 48 formed to have a similar configuration to the other flashings in that it has a base panel 50 with a rear wall 52 depending orthogonally therefrom and a front panel 54 also depending orthogonally therefrom in a direction opposite to that of the rear wall 52. The front panel 54 also has extensions 56 on each side that extend beyond the length of the base panel 50. No sidewalls are formed on the head plate membrane flashing 48, although sidewalls could be formed to provide additional overlap with the left and right jamb membrane flashings 36. The rear wall 52 is also optional, again depending on the requirements of the installation.

As described previously with respect to the sill plate membrane flashing 22, a bead of viscous polyether is applied to the rough opening framing membranes and to the exterior surface 34 adjacent the rough opening 12 of the structural membrane 14 prior to applying the left and right jamb membrane flashings 36 and the head plate membrane flashing 48.

The head plate membrane flashing 48 is then positioned inside the rough opening 12 so that the extensions 56 of the front panel 54 overlap the extensions 46 of the front panel 44 of each of the left and right jamb membrane flashings 36.

Figure 4 illustrates the completed rough opening penetration surround wrap membrane 10 installed in the rough opening 12 of the structural membrane 14. As can be seen from Figure 4, the membrane 14 provides a perimeter lining around the faces of the rough opening 12 as well as around the perimeter on the face 34 of the structural membrane 14. The order of installation of the four flashings provides overlap of the flashings such that moisture will run downward without seeping between the flashing intersections.

It is to be understood that the order of the various steps in the method of forming the window installation can be varied. For example, all of the flashings can be preformed prior to installation. Alternatively, the flashings can each be formed just prior to installation. Each of the flashings may be formed in the field or preformed in the shop prior to installation in the field.

Figure 5 illustrates a window installation using the membrane 10 formed in Figures 1 -4. Here, the window 72 is placed in the prepared rough opening 12 so that the back edges of the top, bottom, and sides of the window 72 butt up against the rear walls 26, 40, and 52 of the flashings 22, 36, and 48. Hence, the depth of the base panels 24, 38, 50 is selected to match the depth of the window 72 so that there is contact around the inside perimeter of the window and the membrane 10.

An optional metal or plastic angle piece may be used as a backing for the window to correctly position the window in the through-opening. In one form, the angle piece will have an L-shaped cross sectional configuration in which the bottom leg is attached to the framed opening and the upright leg acts as a stop for the window frame. Preferable the bottom leg faces the interior side of the through opening when installed. The angle piece may have the legs reversed when installed so that the longer leg is on the bottom and attached to the sill, header, or jam plates. Alternative, the legs of the angle piece may be of the same length, and the angle between the legs may vary from the standard right angle as necessary.

Figures 6A and 6B illustrate two optional forms for providing the polyether material from which the flashings are constructed. In Figure 6A, a roll 60 of pre-cured polyether without adhesive backing is provided with a preformed back wall 62. The polyether material can be extruded so that the back wall 62 is already formed in place when removed from the roll 60. In Figure 6B, the roll 62 has an adhesive backing 64 that is protected by a cover sheet 66.

Figure 7 is an isometric illustration in partial cut-away of the construction of a reinforced flashing membrane 74 formed in accordance with the present disclosure. As shown therein, the membrane 74 is formed of a cured polyether 76 that is reinforced with a sheet of reinforcing material 78. In one aspect of the present disclosure, the reinforcing material 78 is embedded in or impregnated with the polyether material 76. Alternatively, the reinforcing material can form a backing for the flashing membrane 74. In other words, the reinforcing material is positioned on one side of the membrane 74 so as to be partially visible and structured as a backing for the flashing membrane 74.

As shown in Figure 7, the reinforcing material 78 is constructed as a sheet of mesh or grid material formed of intersecting elongate flexible filaments 80, 82 that intersect at substantially right angles to each other to define square- or rectangular-shaped openings 84 that the polyether fills. It is to be understood that the elongate flexible filaments 80, 82 can meet at angles other than a right angle, and the openings 84 that form therein would be a diamond, rhombus, or other four-side geometric shape.

In one embodiment, the elongate filaments 80, 82 are formed of strands or filaments of fiberglass or similar material. When the polyether 76 and the reinforcing material 78 are integrated together, the resulting flashing membrane 74 is flexible and can bend but has a very high tensile strength and very high resistance to tearing and ripping. As such, it is an ideal material for window flashing. It can be formed in a range of thicknesses to suit an installation.

In some installations an air barrier is provided around the through opening. In accordance with another aspect of the present disclosure, a layer of polyether is applied to the sill, head, and jam plates using spray equipment. The polyether then cures in place. Because such sprayed on layers are easily subject to ripping when windows are installed or removed, a flashing membrane 74 described above is applied on to the cured polyether to provide a tear resistant surface on which to mount the window. When the flashing membrane is applied to the sprayed-on polyether layer, the two emulsify together.

It has been noted that due to increased strength and thickness, the membrane 74 can be more difficult to bend and retain its shape. In addition, windows need to be positioned at the correct depth in the through- opening. Because the flashing membrane 74 described above is sometimes difficult to retain in a bent shape, and because correct placement of the window in the through-opening with respect to its depth of installation it is important, a novel corner mounting system for window installations has been designed.

Figures 8-12 illustrate a window corner mounting system 86 formed in accordance with the present disclosure. Shown therein is a corner receptacle 88 and corner clip 90 structured to be received in the corners of the through opening to hold the flashing membrane in place and to correctly locate and position the window in the through opening.

Figures 8A-8D illustrate a corner receptacle 80 having a substantially planar bottom wall 92 and a substantially planar side wall 94 extending from one end of the bottom wall 92. An opening 96 is formed at a corner intersection 98 of the bottom and side walls 92, 94 to facilitate the use of a fastener to secure the corner receptacle 88 in the through-opening. For example, a screw (not shown) can be used to hold the corner receptacle 88 in position in the through-opening by attaching it to the intersection of the jam plate and either the sill plate or the head plate.

A bottom face plate 100 extends from a front edge 102 of the bottom wall 92 in a direction that is opposite the direction the side wall 94 extends from the bottom wall. In addition, the side wall 94 has a side face plate 104 extending from a front edge 106 of the side wall 94 in a direction that is substantially opposite the direction that the bottom wall 92 extends from the side wall 94. Ideally the bottom face plate 100 and side face plate 104 are co- planar and are formed as an integral L-shaped unit when viewed from the front plan form view of Figure 8C. Moreover, the bottom wall 92 and the side wall 94 are coupled to a planar rear wall 108. Ideally the rear wall 108 is integrally formed on a back edge 1 10 of the bottom wall 92 and a back edge 1 12 of the side wall 94. As shown, the rear wall 108 has a first leg 1 14 that depends from the back edge 1 10 of the bottom wall 92 in a direction that is opposite the direction the front face plate 100 extends from the bottom wall 92. In addition, the rear wall 108 has a second leg 1 16 that extends from the back edge 1 12 of the side wall 94 in a direction that is opposite the direction the side face plate extends from the side plate 104.

As can be seen in Figure 8A, the rear wall 108 has the first and second legs 1 14, 1 16 integrally formed as a single piece. Moreover, the rear wall 108 is integral with the bottom wall 92 and side wall 94 along with the front, bottom, and side face plates 100, 104 and together define a 3-sided interior.

Preferably the corner receptacle 88 is a molded product made as a single piece. As can be seen in Figure 8A, an optional shim member 1 18 is formed down the bottom wall 92 and along the side wall 94 in the shape of a rectangular ridge. The distance the ridge 1 18 extends from the bottom wall 1 19 or the side wall 94 is determined by the amount of shim the corner receptacle 88 needs to have with respect to the particular window being installed. Thus, the corner receptacle 88 can be made with shim members 1 18 of varying dimensional distances to accommodate different installations.

Turning next to Figures 9A-9D, shown therein is the corner clip 90 having a configuration that is similar to the corner receptacle 88. However, the corner clip 90 is sized and shaped to be nested within the three-sided interior of the corner receptacle 88.

Thus, the corner clip 90 includes a planar bottom wall 120 and a planar side wall 122 extending from a first side of the planar bottom wall 120. A back wall 124 is attached to back edges 126, 128 of the bottom wall 120 and side wall 122, respectively. The back wall 124 is also planar and has an L- shaped configuration with a first leg 130 depending from the bottom wall 120 in a direction that is the same direction the side wall 122 depends from the bottom wall 120, and a second leg 132 depending from the side wall 122 in a same direction that the bottom wall 120 extends from the side wall 122.

The corner clip further includes a clip structure 134 extending from the back wall 124, preferably from both the first and second legs 130, 132 of the back wall 124. It is to be understood that the clip structure 134 could depend from only one leg of the back wall 124, depending on the application. The clip structure 134 is designed to hold the corner clip in a nested

relationship with the corner receptacle, as will be described more fully below in conjunction with Figures 1 1A-1 1 C.

As shown in Figures 9A-9D, the clip structure 124 is shaped as a channel 144 designed to receive the rear wall 108 of the corner receptacle 88 with an interference fit with substantially frictional engagement to retain the two pieces in the nested relationship. The clip structure 134 thus includes a first channel section 136 depending from the first leg 130 of the back wall 124, and further includes a second channel section 138 depending from the second leg 132 of the back wall 124. Thus, the clip structure 134 will have an L-shape by virtue of its dependency from the L-shaped back wall 124. The clip structure 134 depends from an exterior or rear surface of the back wall 124 so as to fit over the rear wall 108 of the corner receptacle 88 when the corner clip 90 is nested inside the three-sided interior of the corner receptacle 88.

The first and second channel sections 136, 138 each include a first side that is formed by the back wall 124, more particularly the first and second legs 130, 132 respectively of the back wall 124. The first and second channel sections 136, 138 further include a second wall 140 that forms the channel floor, and a third wall 142 that extends from the second wall 140 in a direction towards the respective bottom wall 120 and side wall 122. Because the second wall 140 is L-shaped, it will be seen in both an end view and plan form view in Figures 9B and 9D. The back wall 124, second wall 140, and third wall 142 thus define an opening or channel 144 that receives the rear wall 108 of the corner receptacle 88.

In one aspect of the present disclosure, the third wall 142 is formed to angle slightly towards the back wall 124 create a narrow portion of the channel 144 to facilitate an interference fit or frictional engagement with the rear wall 108 of the corner receptacle 88. Other designs include a thickened extended end of the third wall 142 such that the third wall 142 in an end view has an increased thickness at the end 146 as compared to its thickness at the intersection with the second wall 140.

Figure 10 is an exploded view that illustrates the relative

positioning of the corner receptacle 88 and corner clip 90 to form the corner mounting system 86 of the present disclosure. When the corner clip 90 is nested inside the corner receptacle 88, the clip structure 134 on the corner clip 90 will engage the rear wall 108 of the corner receptacle 88, as shown in Figures 1 1A-1 1 C. Thus, the third wall 142 of the respective first and second channel sections 136, 138 will engage with and extend over and down the outside of the respective first and second legs 1 14, 1 16 of the rear wall 108 of the corner receptacle 88. Thus, the corner clip 90 will be retained in a nested relationship inside the three-sided interior of the corner receptacle 88. As shown in Figures 1 1A and 1 1 C, a slight gap 148 is shown between the side wall 122 of the corner clip 90 and the side wall 94 of the corner receptacle 88

(Figure 1 1A) and between the bottom wall 120 of the corner clip 90 and the bottom wall 92 of the corner receptacle 88 (Figure 1 1 C). This gap 148 can be removed by appropriate sizing of the corner clip 90, as shown in Figure 1 1 B where no gap exists between the bottom wall 92 of the corner receptacle 88 and the bottom wall 120 of the corner clip 90.

Referring next to Figure 12A, shown therein is the corner mounting system 86 used in conjunction with a window 150 in which a portion of the window frame 152 is shown to be installed in a through-opening having a sill plate 154. A corresponding jam plate would be behind the corner

installation system 86, i.e., in the background, but the jam plate is not shown for ease of illustration. The sill plate 154 is prepared by having a mounting "L" bracket or setting angle bracket 156 attached to the sill plate 154. A first leg 160 bears against and is attached to the sill plate 154 by a suitable fastener (not shown), and a second leg 162 extends upward from the first leg 160. The upright leg 162 is structured to act as a stop or backing plate for the window 150 and the corner mounting system 86 to ensure the window 150 is installed at the correct depth and position in the through-opening. In a new installation the first leg 160 faces towards the interior of the structure, whereas in a retrofit installation, the first leg 160 must face towards the exterior of the structure and the second upright leg 162 backs up against an existing window casement.

After the setting angle pieces are installed in the through opening, the corner installation system 86 is installed by placing the corner receptacle 88 into a corner between a jam plate and one of the sill plate 154 on the bottom or the header (not shown) on the top. In this illustration, the corner receptacle 88 is placed on the sill plate 154. It would also be backed up so the side wall bears against the corresponding jam plate that would also have a

corresponding setting angle "L" bracket in place. The optional shim member 1 18 in Figure 12A acts to hold the corner receptacle 88 above the sill plate 154 a predetermined distance in order to correctly locate or position the window 150 at the right height in the through-opening. It is to be understood that the shim member 1 18 can be manufactured of different dimensions in order to

accommodate windows 150 of different sizes and through-openings of different sizes. In the installation in Figure 12B, the shim member 1 18 is not present.

The corner receptacle 88 is thus pushed into place against the second leg 162 of the bracket 156 and a fastener (not shown) is then placed through the opening 96 in the corner receptacle into the joint formed by the sill plate 154 and jam plate, preferably at the intersection of these two pieces of wood. The fastener thus holds the corner receptacle 88 in the desired location in the through-opening. When installing a window, it is to be understood that a corner receptacle 88 would be placed at each corner in the through-opening.

At this point, an optional air barrier can be used by applying a spray-on polyether layer described above over corner receptacles and the sill plate 154 up to the top of the upright leg of the setting angle bracket 156. The sprayed on layer of polyether is allowed to cure. In a retrofit installation, the polyether layer could be applied with an industrial laproscope to aid in visualizing the installation and in providing a recorded video of the process. In this situation, the paper barrier or bonding paper between the siding and the building is coated on both sides using the laproscopic sprayer. Ideally a camera is positioned ahead of the sprayer to allow a user to visually confirm the paper barrier is adequately coated, and the camera can be used to create a visual recording of the process. The polyether spray is applied on the paper and around the edge of the paper on to the sill plate, head plate, and the two jam plates up to the top of the upright leg of the setting angle bracket.

Next, the reinforced flashing membrane 74 is applied in the corner receptacles 88 and across the sill plate 154, and corresponding jam plates, and header plate to the other corner receptacles 88. The flashing membrane extends around the outside edges of the corner receptacle and onto the front face 100 and side face 104 where the cured polyether layer helps hold it in place. This forms a surrounding tear- resistant flashing membrane on which to mount the window.

The corner clip 90 is then positioned in a nested relationship inside the corner receptacle 88 such that the back wall 124 of the corner clip 90 bears against the flashing membrane 74 and the rear wall 108 of the corner receptacle 88 which in the embodiment shown in Figure 12A bears against the outside surface (interior surface with respect to the building) of the upright first leg 162 of the mounting L-bracket 156. The first channel section 136 on the corner clip 90 is then slid down over the upright leg 162 and rear wall 108 of the corner receptacle 88, and then the corner clip 88 is slid towards the jam plate so that the second channel section 138 is received over the second leg 1 16 of the rear wall 108 of the corner receptacle 88. Because of frictional engagement between the first and second channel sections 136, 138 and the corresponding first and second legs 1 14, 1 16 of the rear wall 108 of the corner receptacle 88, no fastener is used to hold the corner clip 90 in position. Finally, the window 150 is slid into the corner mounting system 86 by having the frame 152 pushed into contact with the side wall 122 and back wall 124 of the corner clip 90 and retained in place using conventional fastening methods.

It is to be understood that various aspects of window installation have not been described herein in order to focus on the unique aspects of the corner mounting system 86. For example, non-cured polyether can be used in forming a barrier in conjunction with the membrane 158, and sill plate 154 and jam plate.

In accordance with another aspect of the present disclosure, the bottom walls and side walls of the corner receptacles 88 can have a ridge formed at their free ends or free edges or both to enhance sealing of the barrier. When the flashing membrane 74 is placed over the corner receptacle 88, the membrane 74 passes over the ridge, forming a seal between the ridge and the membrane. For example, in Figure 12B the free edge 102 of the of the receptacle 88 shown in has an upturned ridge 164 formed thereon. The membrane 74 seals against the ridge 164 as it is bent over the ridge 164 and down the front face 100. Similarly, the terminal end 103 of the bottom wall 92 would have an upturned ridge (not shown) formed along its length, either partially or completely. The side wall 94 could also have the same

configuration.

The various embodiments described above can be combined to provide further embodiments. All of the U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent

applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet are incorporated herein by reference, in their entirety. Aspects of the embodiments can be modified, if necessary to employ concepts of the various patents, applications and publications to provide yet further embodiments.

These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.

Claims

1 . A corner mounting system, comprising:
a corner receptacle having a planar bottom wall, a planar side wall extending from one side of the planar bottom wall, and a planar back wall formed orthogonal to the bottom wall and the sidewall to form a three-sided interior, a planar bottom face plate depending from a front edge of the bottom wall, a planar side face plate depending from a front edge of the side wall, the back wall structured to have a first leg extending upward from a back edge of the bottom wall in a direction opposite the bottom face plate, and a second leg extending from the back edge of the side wall in a direction opposite the side face plate;
a corner clip having a planar bottom wall, a planar side wall depending from a first side of the bottom wall, and a planar back wall formed orthogonal to the bottom wall and the side wall and attached to a back edge of the bottom wall and the side wall, the corner clip structured to nest inside the three-sided interior of the corner receptacle, the back wall of the corner clip structured to have a first leg extending from a back edge of the bottom wall, and a second leg extending from a back edge of the side wall, the corner clip further including a clip structure extending from the back wall and structured to fit over the back wall of the corner receptacle to hold the corner clip in a nested relationship inside the three-sided interior of the corner receptacle.
2. The corner mounting system of claim 1 wherein the clip structure extends from the first and second legs of the back wall of the corner clip to engage the first and second legs of the back wall with the back wall of the corner receptacle.
3. The system of claim 2 wherein the clip structure comprises a first channel section extending from the first leg of the back wall and a second channel section extending from the second leg of the back wall.
4. The system of claim 3 wherein the first and second channel sections each comprise the first wall formed by the first and second legs of the back wall, the second wall forming a channel floor and extending from the respective first and second legs of the back wall at substantially the right angle to be orthogonal thereto, and a third wall extending from the second wall.
5. The system of claim 4 wherein the first and second channel sections each comprise a channel structured to receive the respective first and second legs of the back wall in frictional engagement.
6. The system of claim 1 wherein the corner receptacle includes a shim structure extending from the bottom wall in a same direction as the bottom face plate to form a shim.
7. A flashing membrane comprising cured polyether material and a reinforcing layer of flexible material.
8. The flashing membrane of claim 7 wherein the reinforcing layer comprises a grid sheet formed of intersecting elongate flexible filaments that define openings to receive polyether material therein.
9. The flashing membrane of claim 8 wherein the reinforcing layer is impregnated with cured polyether material to form an integral membrane structure
10. The flashing membrane of claim 7 wherein the reinforcing layer comprises a backing of the flashing membrane.
1 1 . A corner mounting device for installing a flexible reinforced flashing membrane in new and retrofit window installations for through-openings in buildings having a three-sided interior corner having a rear wall, the device comprising:
a corner clip having a planar bottom wall, a planar side wall depending from a first side of the bottom wall, and a planar back wall formed orthogonal to the bottom wall and the side wall and attached to a back edge of the bottom wall and the side wall, the corner clip structured to nest inside the three-sided interior corner, the back wall of the corner clip structured to have a first leg extending from a back edge of the bottom wall, and a second leg extending from a back edge of the side wall, the corner clip further including a clip structure extending from the back wall and structured to fit over the rear wall of the corner to hold the corner clip in a nested relationship inside the three-sided interior of the corner.
12. The corner mounting system of claim 1 1 wherein the clip structure extends from the first and second legs of the back wall of the corner clip to engage the first and second legs of the back wall with the rear wall of the corner receptacle.
13. The system of claim 12 wherein the clip structure comprises a first channel section extending from the first leg of the back wall and a second channel section extending from the second leg of the back wall.
14. The system of claim 13 wherein the first and second channel sections each comprise the first wall formed by the first and second legs of the back wall, the second wall forming a channel floor and extending from the respective first and second legs of the back wall at substantially the right angle to be orthogonal thereto, and a third wall extending from the second wall.
15. The system of claim 14 wherein the first and second channel sections each comprise a channel structured to receive the respective first and second legs of the back wall in frictional engagement.
16. A flashing membrane comprising cured polyether material and a reinforcing layer of flexible material.
17. The flashing membrane of claim 16 wherein the reinforcing layer comprises a grid sheet formed of intersecting elongate flexible filaments that define openings to receive polyether material therein.
18. The flashing membrane of claim 17 wherein the reinforcing layer is impregnated with cured polyether material to form an integral membrane structure.
19. The flashing membrane of claim 18 wherein the reinforcing layer comprises a backing of the flashing membrane.
PCT/US2012/041155 2011-06-06 2012-06-06 Window installation corner mounting system and flashing membrane WO2012170575A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
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US61/493,666 2011-06-06

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CN106103877A (en) * 2015-03-03 2016-11-09 日章工业株式会社 Door frame structure and method for mounting door frame structure

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US6119416A (en) * 1999-01-30 2000-09-19 Plastic Components, Inc. Flashing system
US6401402B1 (en) * 2001-02-07 2002-06-11 Mark F. Williams Pre-folded flashing systems and method
WO2004048719A1 (en) * 2002-11-27 2004-06-10 W.L. Gore & Associates Gmbh Covering device
US7222462B2 (en) * 2003-12-17 2007-05-29 Astro Plastics, Inc. Sill pan system
US20100058683A1 (en) * 2008-09-11 2010-03-11 Weather-Max LLC Adjustable sill pan assembly and system

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Publication number Priority date Publication date Assignee Title
US6119416A (en) * 1999-01-30 2000-09-19 Plastic Components, Inc. Flashing system
US6401402B1 (en) * 2001-02-07 2002-06-11 Mark F. Williams Pre-folded flashing systems and method
WO2004048719A1 (en) * 2002-11-27 2004-06-10 W.L. Gore & Associates Gmbh Covering device
US7222462B2 (en) * 2003-12-17 2007-05-29 Astro Plastics, Inc. Sill pan system
US20100058683A1 (en) * 2008-09-11 2010-03-11 Weather-Max LLC Adjustable sill pan assembly and system

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN106103877A (en) * 2015-03-03 2016-11-09 日章工业株式会社 Door frame structure and method for mounting door frame structure
CN106103877B (en) * 2015-03-03 2017-10-31 日章工业株式会社 The method of mounting the door frame structure and the door frame structure

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