Construction unit mounting system

[0001] The invention relates to mounting prefabricated construction units in apertures in building envelopes. The invention has particular application to a system for mounting windows in apertures in a building envelope.

[0002] Today most windows are provided in the form of a unit which includes one or more glass panes mounted in a frame. The glass panes typically comprise sealed double- or triple-glazed panels. The frame is typically made of vinyl or another plastic material which does not conduct heat well although some aluminum-framed window units are still sold. The frame of each window unit typically includes a broad flange which projects in a lateral direction and extends around the periphery of the window unit. Other types of prefabricated construction units such as doors, vents and sunlights may have similar flanges.

[0003] A typical wood frame building has a frame of wooden members which includes apertures for prefabricated construction units such as windows, doors, vents, sunlights and the like. An appropriately-sized construction unit is received in each of the apertures with the flange overlapping with and abutting the outside of the building frame. The construction units are typically secured in place by placing a few screws or nails through the flange into the building frame on each side of the construction units.

[0004] One disadvantage of the way that construction units are currently installed is that a person must be outside of the building to install the construction units. This is especially problematic for window units, since window apertures may be located well above ground level. Windows in such locations are often installed by a person standing on a ladder. This can be dangerous, especially if the weather is windy or during winter conditions.

[0005] Another disadvantage of the way that construction units are currently installed is that many buildings have a waterproofing membrane applied to their exterior. Puncturing the membrane with screws or nails reduces the effectiveness of the membrane.

[0006] There is a need for more efficient ways to install construction units.

[0007] This invention provides prefabricated construction units with tabs which can be used to affix the construction units in place in apertures in a building wall from inside a building. One aspect of the invention provides a clip for use in affixing a construction unit to a building structure. The clip comprises a thin tab having a transverse groove at an exterior end thereof for receiving a flange of a frame of the construction unit and at least one attachment point at an interior end thereof. The at least one attachment point may comprise, for example, one or more of an aperture and a projection projecting substantially perpendicularly to the tab. The clip can be affixed to a frame by inserting a flange of the frame into the groove. The attachment point can be used to affix the clip to a building structure.

[0008] Another aspect of the invention provides a clip for affixing a construction unit to a building structure. The clip comprises an exterior end and an interior end. The exterior end of the clip has means for affixing the clip to a frame of a construction unit. The interior end of the clip comprises means for affixing the interior end of the clip to a building structure. Various means for performing these functions are described below.

[0009] A still further embodiment of the invention provides a construction unit comprising a frame; a flange projecting laterally from the frame around a periphery of the frame; and, a plurality of tabs projecting from the frame in an interior direction. Each of the tabs is attached to the frame at an exterior end thereof and comprises at least one attachment point at an interior end thereof. The at least one attachment point comprises one or more of an aperture and a projection projecting substantially perpendicularly to the tab.

[0010] Yet another aspect of the invention provides methods for installing a construction unit in an aperture in a wall of a building structure. One such method comprises affixing a plurality of tabs to a frame of a construction unit with the tabs projecting interiorly from the frame; placing the construction unit into the aperture; and, affixing an interior end of the tabs to the building structure.

[0011] Further aspects of the invention and features of specific embodiments of the invention are described below.

[0017] Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive, sense.

[0018] FIG. 1 shows a portion of the frame 10 of a typical wood-framed structure. Frame 10 comprises wooden studs 11 covered on the exterior by sheathing 12. Frame 10 includes an aperture 13 surrounded by wooden framing members 14 for receiving a window unit 15. Window unit 15 includes a window frame 16, which may be made from any suitable material, and a glass panel 18.

[0019] Window unit 15 is illustrated as being four-sided. The invention may also be used with construction units having other shapes such as triangular, round, semi-circular, polygonal etc.

[0020] Window frame 16 includes a flange 20 which projects in a lateral direction around the periphery of window frame 16. Aperture 13 is smaller than the outer dimension of flange 20 and is dimensioned to receive window frame 16 while flange 20 bears against the exterior surface of sheathing 12.

[0021] This invention provides clips 30. Each clip 30 has an exterior end 32 adapted to engage window frame 16 and an interior end 34 adapted to be fastened to building frame 10 from the inside of building frame 10. Clips 30 are used by affixing a number of clips 30 to each side of window frame 16. In the example shown in FIG. 1 two clips 30 are affixed to each side of window frame 16. For larger window units three or more clips 30 might be affixed to each side of window frame 16. In most cases two or more clips 30 will be affixed to each side of window frame 16.

[0022] In the illustrated embodiment of the invention clips 30 attach to flange 20. FIG. 2 shows a clip 30 in greater detail. Clip 30 is formed from a strip of any suitable material, such as steel, strong plastic, or the like. The material of clip 30 is preferably resilient. Interior end 34 comprises one or more apertures 36 which can receive fasteners, such as screws or nails, to affix interior end 34 to building structure 10. Apertures 36 constitute one possible means for affixing interior end 34 to a building structure.

[0023] End 32 of clip 30 is bent to define a deep groove 38. As shown in FIG. 3, groove 38 is deep enough to receive flange 20 of window frame 16. The portions 39A and 39B of clip 30 on either side of groove 38 are preferably resiliently biased toward one another so that clip 30 tends to grip flange 20. Inwardly-angled teeth 40 may optionally be provided on one or both sides of groove 38. After flange 20 is received in groove 38, teeth 40 bite into flange 20 and resist any forces which might tend to pull flange 20 out of groove 38.

[0024] An outer side 42 of groove 38 is tapered so that it is easy to guide flange 20 into groove 38. As flange 20 is introduced into side 42 of groove 38, it tends to wedge portions 39A and 39B apart so that flange 20 is held securely in groove 38.

[0025] Clip 30 is preferably bent at a location intermediate ends 32 and 34. The bend defines a fulcrum 44. As shown in FIG. 3, when end 34 is fastened to structure 10, clip tends to pivot about fulcrum 44 so that end 32 is biased onto even firmer engagement with flange 20. Clip 30 is resiliently flexible. As end 34 is fastened to building structure 10 by fasteners, such as nails 46, clip 30 is straightened.

[0026] Providing a bend in clip 30 also facilitates affixing clip 30 to building structure 10 with fasteners (for example nails or screws) which are angled in an inward direction. When such fasteners are tightened, clips 30 are drawn inwardly and pull window frame 16 firmly into the aperture.

[0027] FIGS. 4A, 4B and 4C illustrate alternative configurations for interior end 34. In each of FIGS. 4A, 4B and 4C, end 34 includes a number of projections 48 which extend substantially laterally when clip 30 is affixed to a window frame 16. In the illustrated embodiments, projections 48 are integral with the material of the body of clip 30 and are formed by bending flaps of the material of clip 30. Projections 48 may be triangular, as shown in FIGS. 4A and 4B, rectangular, as shown in FIG. 4C, or otherwise shaped. The embodiments of FIGS. 4A and 4C comprise both apertures 36 and projections 48. In the alternative, projections 48 capable of use for affixing end 34 to building structure 10 could comprise separate elements affixed to end 34 in any suitable manner. For example, suitable projections 48 could be spot-welded to end 34. Projections affixed to end 34 provide an alternative means for affixing end 34 to a building structure 10.

[0028] In the embodiment of FIG. 4C, projections 48 are located near the ends of flexible fingers 49.

[0029] Projections 48 are not necessarily large enough to permanently affix ends 34 to a building structure 10. In some embodiments, projections 48 may be used to temporarily hold ends 34 to the building structure until screws or nails are inserted through apertures 36.

[0030] It can be appreciated that the use of this invention can significantly simplify the installation of prefabricated construction units in a building, especially where one would need a ladder, scaffold, man lift or the like to reach the locations where the construction units will be installed from the exterior of the building. A worker can affix clips 30 according to the invention to a construction unit and then, from inside the structure, orient the construction unit at an angle to the aperture in which the construction unit will be installed and pass the construction unit through the aperture to the outside of the structure. Still working from inside the structure, the worker can then draw the construction unit into place in the aperture and fasten the construction unit in place by affixing interior ends 34 of clips 30 to the structure. If necessary, shims may be installed around the frame of the construction unit to properly align the construction unit in the aperture.

[0031] A further advantage of the invention is realized in situations where a waterproofing membrane or the like is applied to the exterior of building frame 10. Prior art systems for securing construction units to building structures typically require the membrane to be punctured by nails or screws in the area adjacent to aperture 13. In some cases building codes prohibit fastening the lower sides of construction units in ways which result in the membrane being punctured. Sometimes windows are installed with no fasteners on their lower sides for this reason. The result can be that the lower sides of the windows can move, especially in windy weather. The use of clips 30 according to the invention allows the membrane to remain intact and still permits securing the lower side of window units and other construction units by way of one or more clips 30.

[0032] It can be appreciated that clips 30 having an exterior end 32 as described above can be affixed to a construction unit frame with minimal tools and without the need to drill holes in the frame or to modify the window or door frame in other respects.

[0033] Where a component (e.g. a member, tab, fastener etc.) is referred to above, unless otherwise indicated, reference to that component (including a reference to a “means”) should be interpreted as including as equivalents of that component any component which performs the function of the described component (i.e., that is functionally equivalent), including components which are not structurally equivalent to the disclosed structure which performs the function in the illustrated exemplary embodiments of the invention.

[0034] As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. For example, while the above detailed description relates primarily to window units, it is to be understood that clips according to the invention may equally be used to secure other types of construction units, such as door units, vent units, sunlight units and the like, into appropriately sized apertures in a building frame. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims.