Door and window sill pan with drain

Abstract

A window sill pan or door sill pan flashing. The sill pan has an inclined base, window or door supports which can be extruded as part of the base unit, and corner elements which can be snapped or otherwise attached to the base. Sill pan offsets provided in the rear sill pan wall and in the front flange create a flow path for water to drain from the sill. The base may be solid or hollow with window or door supports extending vertically through the base. The sill pan may be manufactured by extrusion, and corner pieces may be injection molded. The base may be fabricated from fiberglass, metal, or plastic. A window support means is provided in a horizontal orientation so that the base can be extruded.

1 . A sill pan for a window or door comprising 
 a base having a length and a width, the base comprising 
 a first end,  
 a second end  
 a sloped upper portion,  
 a rear wall,  
 a front flange,  
 a rear support, and  
 a front support  
   such that the rear support and the front support on the base are lengthwise in order to permit the base to be manufactured by extrusion without requiring subsequent addition of support elements;    a first end piece, attachable to the base in the proximity of the first end of the base, the first end piece comprising 
 a side upward lip, and  
 a downwardly extending front lip; and  
   a second end piece, attachable to the base in the proximity of the second end of the base, the second end piece comprising 
 a side upward lip, and  
 a downwardly extending front lip.  
   
   
   
       2 . The sill pan of  claim 1  further comprising 
 a raised side lip;    and a front lip.    
   
   
       3 . The sill pan of  claim 1  further comprising 
 a first portion of the base, the first portion having a first length;    a second portion of the base; the second portion having a second length; and    at least one connector, such that the connector joins the first portion to the second portion of the base.    
   
   
       4 . The sill pan of  claim 1  wherein 
 the base is constructed of a plastic.    
   
   
       5 . The sill pan of  claim 1  wherein 
 the base is constructed of a metal.    
   
   
       6 . The sill pan of  claim 1  wherein 
 the first end piece snaps onto the first end of the base.    
   
   
       7 . The sill pan of  claim 6  wherein 
 the first end piece includes a least one projecting portion; and    the first end of the base includes a slot which accepts the projecting portion.    
   
   
       8 . The sill pan of  claim 1  wherein 
 the first end piece is glued onto the first end of the base.    
   
   
       9 . A fiberglass sill pan for a window or door comprising 
 a base having a length and a width, the base comprising 
 a first end,  
 a second end  
 a slanted upper portion,  
 a rear wall,  
 a front flange,  
 a rear support, and  
 a front support  
   such that the rear support and the front support on the base are lengthwise;    a first end piece comprising 
 a side upward lip, and  
 a downwardly extending front lip; and  
   a second end piece comprising 
 a side upward lip, and  
 a downwardly extending front lip.  
   
   
   
       10 . A method of manufacturing a sill pan comprising 
 extruding a first base unit, the base unit comprising 
 a first end  
 a second end  
 a slanted upper portion,  
 a rear wall,  
 a front flange,  
 a rear support, and  
 a front support  
   such that the rear support and the front support on the first base unit are lengthwise in order to permit the first base unit to be manufactured by extrusion;    cutting the first base unit to a desired length;    affixing a first end element to the first end of the base unit; and    affixing a second end element to the second end of the base unit.    
   
   
       11 . A method of manufacturing a sill pan comprising 
 extruding a first base unit, the base unit comprising 
 a first end  
 a second end  
 a slanted upper portion,  
 a rear wall,  
 a front flange,  
 a rear support, and  
 a front support  
   such that the rear support and the front support on the first base unit are lengthwise in order to permit the first base unit to be manufactured by extrusion;    extruding a second base unit, the base unit comprising 
 a first end  
 a second end  
 a slanted upper portion,  
 a rear wall,  
 a front flange,  
 a rear support, and  
 a front support  
   such that the rear support and the front support on the second base unit are lengthwise in order to permit the first base unit to be manufactured by extrusion;    joining the first base unit to the second base unit to form a base of a desired length;    affixing a first end element to the first end of the base first base unit; and    affixing a second end element to the second end of the second base unit.    
   
   
       12 . A sill pan for a window or door comprising 
 a central base having a first end, a second end, a rear, a front, and a plurality of support ridges and a plurality of drain channels between the support ridges, such that the drain channels are sloped towards the front of the base, and such that a window or door may be supported upon the ridges;    a rear wall extending perpendicularly upward from the rear of the base portion, such that the rear wall has a plurality of spacers which provide an offset spacing between the rear wall and the window or door;    a front face extending perpendicularly downward from the front of the base portion, such that the support ridges extend beyond the front face and extend downwardly along the front face in order to create an offset spacing from the front face;    a first end integral to the first end of the central base, and a second end integral to the second end of the central base, each end comprising 
 a side face extending perpendicularly upward from the base; and  
 a front face extending perpendicularly upward and downward from the side face.  
   
   
   
       13 . The sill pan of  claim 12  wherein the side face further comprises a plurality of spacers.  
   
   
       14 . An adjustable width sill pan for a port such as a window or door, the sill pan comprising 
 a first base section comprising 
 a first end comprising a first corner element which includes a side face extending perpendicularly upward from the first base section, the first end having a first thickness profile,  
 a second end having a second thickness profile which is shorter than the first thickness profile,  
 a rear wall,  
 a port support means; and  
   a second base section comprising 
 a second end comprising a second corner element which includes a side face extending perpendicularly upward from the second base section, the second end having the first thickness profile,  
 a first end having the first thickness profile with a lower recess in the shape of the second thickness profile,  
 a rear wall,  
 a port support means,  
   such that the first end of the second section may be slid over the second end of the first section in order to adjust the length of the assembled sill.    
   
   
       15 . The adjustable width sill pan of  claim 14  wherein 
 the first base section comprises 
 a bottom part integral to the first corner element, the bottom part comprising 
 a rear wall,  
 an inwardly facing lip along the top of the wall,  
 a front face,  
 a plurality of support ridges, such that the support ridges overhang the front face, such that the support ridges define the second thickness profile,  
 a plurality of sloped channels between the support ridges,  
 
 a top part insertable onto a portion of the bottom part, the top part comprising 
 a rear wall,  
 a rear support,  
 a front support,  
 a front face; and  
 
   the second base section comprises 
 a bottom part integral to the first corner element, the bottom part comprising 
 a rear wall,  
 an inwardly facing lip along the top of the wall,  
 a front face, and  
 
 a top part insertable and overlapping the bottom part, the top part comprising 
 a rear wall,  
 a rear support,  
 a front support,  
 a front face.  
 
   
   
   
       16 . The sill pan of  claim 14  wherein 
 the first end of the second section partially covers the second end of the first section; and    a cover element is placed over substantially all of the exposed second end of the first section.    
   
   
       17 . The sill pan of  claim 14  further comprising 
 at least one middle section comprising 
 a rear wall, and  
 a port support means,  
   such that the middle section is positioned between the first section and the second section in order to increase the length of the assembled sill pan.    
   
   
       18 . A sill pan for a window or door comprising 
 an extrudable base having a length and a width, the base comprising 
 a first end,  
 a second end,  
 a sloped upper portion,  
 a rear wall,  
 a rear support, and  
 a front support, such that the rear support and the front support are oriented lengthwise on the base;  
   a first end piece, attachable to the base in the proximity of the first end of the base, the first end piece comprising 
 a horizontal tab which may be inserted between the rear support and the front support, the horizontal tab having a top surface aligned with the top surfaces of the rear support and the front support,  
 a recess for receiving and overlapping the first end of the rear wall,  
 a recess for receiving the first end of the rear support, and  
 a recess for receiving the first end of the front support; and  
   a second end piece, attachable to the base in the proximity of the second end of the base, the first end piece comprising 
 a horizontal tab which may be inserted between the rear support and the front support, the horizontal tab having a top surface aligned with the top surfaces of the rear support and the front support,  
 a recess for receiving and overlapping the second end of the rear wall,  
 a recess for receiving the second end of the rear support,  
 a recess for receiving the second end of the front support.  
   
   
   
       19 . The sill pan of  claim 18  wherein the horizontal tab of the first end piece is tapered.  
   
   
       20 . The sill pan of  claim 18  further comprising 
 a front flange projecting downwardly from the front edge of the extrudable base;    a recess in the first end piece for receiving a first end of the front flange; and    a recess in the second end piece for receiving a second end of the front flange.