US2005210824A1PendingUtilityA1

Method for installing a fenestration unit in a composite panel

42
Individually held — no corporate assignee on recordPriority: Mar 29, 2004Filed: Mar 29, 2004Published: Sep 29, 2005
Est. expiryMar 29, 2024(expired)· nominal 20-yr term from priority
Inventors:Cordell R. BurtonJulio Chiarella
E06B 1/58E04F 21/0015
42
PatentIndex Score
0
Cited by
0
References
0
Claims

Abstract

A method of installing a fenestration unit in a composite panel using a foam material, and to a composite panel with the fenestration unit installed using a foam material, where the foam material is the primary attachment structure. A rough opening is created in the composite panel where the rough opening has a perimeter larger than a perimeter of the frame of the fenestration unit. Then the fenestration unit is positioned in the rough opening with a space between the perimeter of the frame of the fenestration unit and the perimeter of the rough opening of the composite panel. A foam material is delivered into at least a portion of the space to fixedly adhere the fenestration unit to the insulating core of the composite panel. The foam material typically provides the primary structural attachment between the fenestration unit and the composite panel.

Claims

exact text as granted — not AI-modified
1 . A method of installing a fenestration unit, the method comprising the steps of: 
 creating a rough opening in a composite panel having an insulating core, the rough opening having a perimeter larger than an outer perimeter of a frame of the fenestration unit;    positioning the fenestration unit inside the rough opening; and    delivering a foam material into at least a portion of a space between the perimeter of the frame of the fenestration unit and the perimeter of the rough opening of the composite panel, the foam material fixedly adhering the fenestration unit to the insulating core of the composite panel.    
   
   
       2 . The method of  claim 1  wherein the foam material provides a sole structural attachment between the fenestration unit and the composite panel when the foam material is substantially cured.  
   
   
       3 . The method of  claim 1  wherein the foam material provides at least 50% of an attachment force that resists separation of the fenestration unit from the composite panel along a direction generally perpendicular to a major surface of the composite panel.  
   
   
       4 . The method of  claim 1  wherein the foam material provides about 80% of an attachment force that resists separation of the fenestration unit from the composite panel along a direction generally perpendicular to a major surface of the composite panel.  
   
   
       5 . The method of  claim 1  wherein the foam material provides about 95% of an attachment force that resists separation of the fenestration unit from the composite panel along a direction generally perpendicular to a major surface of the composite panel.  
   
   
       6 . The method of  claim 1  comprising selecting a foam material that is compatible with a material of the insulating core of the composite panel.  
   
   
       7 . The method of  claim 1  comprising fixedly adhering the foam material to at least one side surface of an outer layer of the composite panel at the rough opening.  
   
   
       8 . The method of  claim 1  comprising selecting a low expansion adhesive foam.  
   
   
       9 . The method of  claim 1  wherein the step of delivering a foam material into a space includes delivering the foam material around at least a portion of the perimeter of the frame of the fenestration unit.  
   
   
       10 . The method of  claim 1  wherein the step of delivering the foam material includes delivering the foam material around the entire perimeter of the frame of the fenestration unit.  
   
   
       11 . The method of  claim 1  comprising attaching a fin on the frame of the fenestration unit to an outer surface of an outer layer of the composite panel.  
   
   
       12 . The method of  claim 11  comprising locating a sealant material between the fin and the outer surface of the outer layer.  
   
   
       13 . The method of  claim 11  comprising attaching the fin to the outer layer using fasteners.  
   
   
       14 . The method of  claim 1  comprising delivering the foam material into recesses located in the perimeter of the frame.  
   
   
       15 . The method of  claim 1  comprising applying an intermediate adhesion promoting material to at least one of the perimeter of the frame and the insulating core exposed by the rough opening.  
   
   
       16 . The method of  claim 1  comprising assembling the composite panel on-site.  
   
   
       17 . The method of  claim 1  comprising prefabricating the composite panel at a remote location.  
   
   
       18 . The method of  claim 1  wherein the step of creating the rough opening in the composite panel occurs on-site.  
   
   
       19 . The method of  claim 1  wherein the step of creating the rough opening in the composite panel occurs at a remote location.  
   
   
       20 . The method of  claim 1  wherein the insulating core comprises a polymeric foam material.  
   
   
       21 . A method of installing a fenestration unit in a composite panel including an insulating core, the method comprising the steps of: 
 creating a rough opening in the panel, the rough opening having a perimeter larger than a perimeter of a frame of the fenestration unit;    positioning the fenestration unit inside the rough opening; and    delivering a low expansion adhesive foam around at least a portion of the perimeter of the frame of the fenestration unit to fixedly adhere the fenestration unit to the insulating core of the composite panel, wherein the foam provides a primary structural attachment between the fenestration unit and the composite panel when the foam material is substantially cured.    
   
   
       22 . A wall structure comprising: 
 a fenestration unit including a frame;    a composite panel comprising an insulating core;    a rough opening created in the composite panel receiving the frame of the fenestration unit, the rough opening having a perimeter larger than a perimeter of the frame of the fenestration unit; and    a foam material deposited between at least a portion of the perimeter of the frame of the fenestration unit and the perimeter of the rough opening of the composite panel to fixedly adhere the fenestration unit to the insulating core of the composite panel.    
   
   
       23 . The wall structure of  claim 22  wherein the foam material provides a sole structural attachment between the fenestration unit and the composite panel when the foam material is substantially cured.  
   
   
       24 . The wall structure of  claim 22  wherein the foam material provides at least 50% of an attachment force that resists separation of the fenestration unit from the composite panel along a direction generally perpendicular to a major surface of the composite panel.  
   
   
       25 . The wall structure of  claim 22  wherein the foam material provides about 80% of an attachment force that resists separation of the fenestration unit from the composite panel along a direction generally perpendicular to a major surface of the composite panel.  
   
   
       26 . The wall structure of  claim 22  wherein the foam material provides about 95% of an attachment force that resists separation of the fenestration unit from the composite panel along a direction generally perpendicular to a major surface of the composite panel.  
   
   
       27 . The wall structure of  claim 22  wherein the foam material is compatible with a material of the insulating core of the composite panel.  
   
   
       28 . The wall structure of  claim 22  wherein the foam material is fixedly adhered to at least one side surface of an outer layer of the composite panel at the rough opening.  
   
   
       29 . The wall structure of  claim 22  wherein the foam material comprises a low expansion adhesive foam.  
   
   
       30 . The wall structure of  claim 22  wherein the foam material is delivered around at least a portion of the perimeter of the frame of the fenestration unit.  
   
   
       31 . The wall structure of  claim 22  wherein the foam material is delivered around the entire perimeter of the frame of the fenestration unit.  
   
   
       32 . The wall structure of  claim 22  comprising a fin on the frame of the fenestration unit attached to an outer surface of an outer layer of the composite panel.  
   
   
       33 . The wall structure of  claim 32  comprising a sealant material located between the fin and the outer surface of the outer layer.  
   
   
       34 . The wall structure of  claim 32  comprising fasteners attaching the fin to one of the outer layers.  
   
   
       35 . The wall structure of  claim 22  comprising recesses located in the perimeter of the frame adapted to receive the foam material.  
   
   
       36 . The wall structure of  claim 22  comprising an intermediate adhesion promoting material applied to at least one of the perimeter of the frame and the perimeter of the rough opening.  
   
   
       37 . The wall structure of  claim 22  wherein the insulating core comprises a polymeric foam material  
   
   
       38 . A wall structure comprising: 
 a fenestration unit including a frame;    a composite panel comprising an insulating core;    a rough opening created in the composite panel receiving the frame of the fenestration unit, the rough opening having a perimeter larger than a perimeter of the frame of the fenestration unit; and    a foam material deposited around at least a portion of the perimeter of the frame of the fenestration unit to fixedly adhere the fenestration unit to the insulating core of the composite panel, wherein the foam material provides the primary structural attachment between the fenestration unit and the composite panel.    
   
   
       39 . A composite panel having an insulating core located between outer layers, the composite panel comprising a fenestration unit having a frame, wherein the frame of the fenestration unit is fixedly adhered to the insulating core of the composite panel by a foam material that is deposited between the frame and side surfaces of a rough opening of the composite panel.  
   
   
       40 . The panel of  claim 39  wherein the foam material provides the sole structural attachment between the fenestration unit and the composite panel.  
   
   
       41 . The panel of  claim 39  wherein the foam material is compatible with a material of the insulating core of the composite panel.  
   
   
       42 . The panel of  claim 39  wherein the foam material provides a primary structural attachment between the fenestration unit and the composite panel when the foam material is substantially cured.  
   
   
       43 . The panel of  claim 39  wherein the foam material provides at least 50% of an attachment force that resists separation of the fenestration unit from the composite panel along a direction generally perpendicular to a major surface of the composite panel.  
   
   
       44 . The panel of  claim 39  wherein the foam material provides about 80% of an attachment force that resists separation of the fenestration unit from the composite panel along a direction generally perpendicular to a major surface of the composite panel.  
   
   
       45 . The panel of  claim 39  comprising an intermediate adhesion promoting material applied to at least one of the frame and the insulating core exposed by the rough opening.  
   
   
       46 . The panel of  claim 39  wherein the insulating core comprises a polymeric foam material.

Join the waitlist — get patent alerts

Track US2005210824A1 — get alerts on status changes and closely related new filings.

We store only your email — no account needed. See our privacy policy.