Search

US-12618283-B1 - Fenestration unit with interior installation features and associated systems and methods

US12618283B1US 12618283 B1US12618283 B1US 12618283B1US-12618283-B1

Abstract

Installation systems and methods for fenestration units configured to be set into a rough opening (RO) from interior side of a building structure or wall. The fenestration units may include a retention system coupled to the frame and operable to exert a retention force on the fenestration unit to maintain positive engagement of the fenestration unit with the rough opening framing and resist extraction of the fenestration unit from the rough opening upon insertion of the fenestration unit in the rough opening from the interior side of the rough opening.

Inventors

  • Todd A. Bernhagen
  • Ted L. Hansen
  • Jaime P. Ogbourne
  • William R. Parcells
  • Justin McAninch
  • Jake Baier
  • Gabriela Lockaby

Assignees

  • PELLA CORPORATION

Dates

Publication Date
20260505
Application Date
20240513

Claims (17)

  1. 1 . A method of installing a fenestration unit, the method comprising: performing an interior installation phase from an interior of a building structure having an exterior opposite the interior of the building structure, the building structure including a rough opening having a rough opening frame, the rough opening frame having a center, a perimeter extending around the center, and a support surface facing toward the center and substantially orthogonal to an interior surface of the building structure that faces toward the interior of the building structure, the interior installation phase including, arranging a fenestration unit in the rough opening from the interior of the building structure, adjusting a position of the fenestration unit within the rough opening, securing the fenestration unit to the rough opening frame with a plurality of fasteners such that an anchoring clip coupled to a perimeter of the fenestration unit contacts the interior surface of the building structure, and insulating a gap between the rough opening frame and the fenestration unit; and performing an exterior installation phase from an exterior side of the building structure independently from the interior installation phase, the exterior installation phase including, engaging a pop-up fin with the exterior surface of the building structure, the pop-up fin being pre-biased toward engagement with the exterior surface of the building structure, and weather sealing the fenestration unit to an exterior surface of the building structure using the pop-up fin.
  2. 2 . The method of claim 1 , wherein the interior installation phase is carried out by at least one installer and is characterized by an average labor time of 5 minutes or less for the at least one installer.
  3. 3 . The method of claim 1 , wherein at least one of the interior installation phase and the exterior installation phase is carried out by a single installer.
  4. 4 . The method of claim 1 , wherein the exterior installation phase is carried out by at least one installer and is characterized by an average labor time of 3 minutes or less for the at least one installer.
  5. 5 . The method of claim 1 , wherein the exterior installation phase is carried out by an installer on a ladder, and further wherein a percentage of time the installer is on the ladder is 50% or less of a total labor time of the interior and exterior installation phases.
  6. 6 . The method of claim 1 , wherein a total labor time with an installer on an exterior side of the rough opening is 50% or less of a total labor time for the interior and exterior installation phases.
  7. 7 . The method of claim 1 , wherein a total labor time with an installer on an exterior side of the rough opening is 40% or less of a total labor time for the interior and exterior installation phases.
  8. 8 . The method of claim 1 , wherein an average time for the exterior installation phase of the fenestration unit is at least 80% less than an installation of a fenestration unit that includes a nailing fin.
  9. 9 . The method of claim 1 , wherein an average time for the exterior installation phase of the fenestration unit is at least 70% less than an installation of a fenestration unit that includes a nailing fin.
  10. 10 . The method of claim 1 , wherein the exterior installation phase is carried out by an installer on a ladder, and an average labor time with the installer on the ladder is at least 75% less than an exterior installation phase of a fenestration unit that includes a nailing fin.
  11. 11 . The method of claim 1 , wherein weather sealing the fenestration unit to the exterior surface of the building structure includes securing a weather seal system including the pop-up fin to the exterior side of the building structure using a flashing, wherein the weather seal system is configured is such that the fenestration unit meets an ASTM E2112-23 installation sealing standard.
  12. 12 . The method of claim 1 , wherein the interior installation phase is at least 60% of a total labor time for the interior and exterior installation phases.
  13. 13 . The method of claim 1 , wherein adjusting the position of the fenestration unit within the rough opening further includes measuring a level, squareness, and a plumbness of the fenestration unit, and adjusting the position is completed prior to securing the fenestration unit to the rough opening frame with a plurality of fasteners.
  14. 14 . The method of claim 1 , wherein the anchoring clip includes a plurality of anchoring clips secured to the perimeter of the fenestration unit, and wherein securing the fenestration unit to the rough opening frame with a plurality of fasteners further includes securing the plurality of fasteners through the plurality of anchoring clips.
  15. 15 . The method of claim 1 , wherein the fenestration unit includes a frame and a retention system including a spring retainer secured to the frame, and wherein arranging a fenestration unit in the rough opening further includes engaging the retention system with the rough opening such that the retention system exerts a retention force on the rough opening to self-retain the fenestration unit in the rough opening and resists movement out from the rough opening framing against an exterior-to-interior force.
  16. 16 . The method of claim 1 , wherein the fenestration unit includes a frame defining a perimeter and a weather seal system secured to the frame, the weather seal system including the pop-up fin positioned at a top of the frame and configured to transition from a first, folded configuration in which the pop-up fin projects along the top of the frame and a second, projecting configuration in which the pop-up fin assembly projects outward relative to the top of the frame, and a retaining assembly including a clip releasably securing the pop-up fin at the head with the pop-up fin in the first, folded configuration, and wherein the method further includes removing the retaining assembly as a single piece.
  17. 17 . A method of installing a fenestration unit, the method comprising: performing an interior installation phase from an interior of a building structure having an exterior opposite the interior of the building structure, the building structure including a rough opening having a rough opening frame, the rough opening frame having a center, a perimeter extending around the center, and a support surface facing toward the center and substantially orthogonal to an interior surface of the building structure that faces toward the interior of the building structure, the interior installation phase including, arranging a fenestration unit in the rough opening from the interior of the building structure using an insertion force such that the fenestration unit exerts a retention force on the rough opening frame that is greater than the insertion force to maintain positive engagement of the fenestration unit with the rough opening frame and resist extraction of the fenestration unit from the rough opening after insertion of the fenestration unit in the rough opening such that the fenestration unit remains stationary in the rough opening without use of fasteners, adjusting a position of the fenestration unit within the rough opening, securing the fenestration unit to the rough opening frame with a plurality of fasteners such that an anchoring clip coupled to a perimeter of the fenestration unit contacts the interior surface of the building structure, and insulating a gap between the rough opening frame and the fenestration unit; and performing an exterior installation phase from an exterior side of the building structure independently from the interior installation phase, the exterior installation phase including, weather sealing the fenestration unit to an exterior surface of the building structure.

Description

CROSS REFERENCE TO RELATED APPLICATIONS This application claims priority to U.S. Provisional Patent Application No. 63/557,067, entitled “Fenestration Unit with Interior Installation Features and Associated Systems and Methods”, filed Feb. 23, 2024; this application is a continuation-in-part of PCT Application No. PCT/US23/75692, entitled “Fenestration Unit with Interior Installation Features and Associated Systems and Methods”, filed Oct. 2, 2023 which claims priority to U.S. patent application Ser. No. 18/478,189, entitled “Fenestration Unit with Interior Installation Features and Associated Systems and Methods”, filed Sep. 29, 2023, and granted as U.S. Pat. No. 11,933,098, where each of PCT Application No. PCT/US23/75692 and U.S. patent application Ser. No. 18/478,189 claim priority to U.S. Provisional Patent Application No. 63/581,834, entitled “Fenestration Unit with Interior Installation Features and Associated Systems and Methods”, filed Sep. 11, 2023; U.S. Provisional Patent Application No. 63/520,276, entitled “Fenestration Unit with Interior Installation Features and Associated Systems and Methods”, filed Aug. 17, 2023; U.S. Provisional Patent Application No. 63/463,103 entitled “Fenestration Unit with Interior Installation Features and Associated Systems and Methods”, filed May 1, 2023; and U.S. Provisional Patent Application No. 63/453,344, entitled “Interior Installation Features, Systems and Methods”, filed Mar. 20, 2023. The contents of each application are hereby incorporated by reference in their entirety. BACKGROUND Window designs typically have an exterior nailing flange and are installed from the exterior side of the building envelope. Two installers work together, one on the interior and the other on the exterior. Some installation crews have determined it is easier to unpackage the window inside the building where it is relatively clean and flat. Then they pass the window through the rough opening (RO) to a person on the exterior side. In some instances, the person on the exterior side is on a ladder which can substantially complicate installation. The installer on the interior side centers the window in the RO and inserts shims to level, plumb and square all while the exterior installer is holding the window. After the window is correctly set, the interior installer holds the window in place while the exterior installer drives nails or screws through the exterior nailing flange to anchor it. If it is a venting window, the sash is then opened to check functional operation. The interior installer proceeds to inject expansion foam around the perimeter of the window in the gap between the frame and RO to create the interior air seal. At the same time, the exterior installer applies 3 to 4 inches wide flashing tape on the jambs and across the head of the window. Background PatentsPatent NumberTitleFiling DateU.S. Pat. No.Fenestration frame with bonded 2011 Apr. 208,621,795support brackets . . .U.S. Pat. No.Monolithic fenestration construction2009 May 218,109,052member . . .U.S. Pat. No.Spring clip and method of window2004 Feb. 137,162,841installationDE 2020 Supporting and fastening2016 Mar. 1116101375window . . . to . . . wall openingWO 2015/Mounting, sealing and thermal 2014 Sep. 05142201insulation of windows . . .U.S. Pat. No.System and method for installing 1999 Sep. 306,293,061a jambU.S. Pat. No.Apparatus and method for leveling1996 Feb. 025,692,350closuresU.S. Pat. No.Installation features for fenestration2019 Jul. 2511,332,946units . . .U.S. Pat. No.Self-sealing window installation and2008 Jan. 158,006,445methodU.S. 2008/Pre-hung door assembly and 2008 Jan. 180127564method of installationU.S. Pat. No.Support bracket for window2016 Aug. 2310,895,099installation . . .U.S. 2005/Self-Flashing Assembly2004 Jun. 010262782U.S. 2020/Fenestration assembly and installation2020 Apr. 020318418system for the sameU.S. Pat. No.Centering clips for window frames1980 Dec. 174,488,391U.S. 2011/Fenestration frame with bonded 2011 Apr. 200258947support brackets and methods of making sameU.S. Pat. No.Fenestration units with spacer 2015 Dec. 189,790,731blocks and methods of manufacturing the sameU.S. Pat. No.Water intrusion prevention method 2006 Oct. 188,302,353and apparatus Background Products Innotech Windows & Doors, Strap Anchors https://www.innotech-windows.com/blog/in-depth-benefits-of-anchoring-method-window-installationFrontLine Tru-Loc™ Brackets https://frontlinebldg.com/all-products/accessories/tru-loc-window-door-installation-anchor/Amesbury Hinged Fin https://www.amesburytruth.com/products/extrusions/nailing-fin/hinged/hinged-pp 1219 SUMMARY Various advantages may be achieved according to the example systems and methods described herein. The various examples may be one or more of: more efficient (e.g., cycle time reduced by 50% or more); easier to learn; easier to remember; easier to train; may be less physically demanding (e.g., window is not set from the exterior side which could be on uneve