Patent Application
20190309521
The present disclosure relates generally to systems and methods for protecting openings in roofs from weather effects.
Many structures include roofs with openings to facilitate venting and the like. For example, a roof may include an opening such that a venting pipe for a heater can pass through the opening. Weather effects, such as rain, can leak into these openings. For example, a gap between an edge of an opening and a vent pipe passing therethrough may allow water to leak through a roof in which the opening is disposed. In the roofing industry, it is traditional to utilize flashings installed about such openings to protect them from such leaks. A flashing generally includes a strip of metal that protects a gap between an edge of an opening in a roof and another object, such as a vent or chimney. It is now recognized that use of traditional flashings can be inefficient for certain roof types.
This section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.
A summary of certain embodiments disclosed herein is set forth below. It should be understood that these aspects are presented merely to provide the reader with a brief summary of these certain embodiments and that these aspects are not intended to limit the scope of this disclosure. Indeed, this disclosure may encompass a variety of aspects that may not be set forth below.
In accordance with a first embodiment, a roof curb is used in association with a roof flashing installed on a roof with an incline and corrugated ribs, the roof flashing having a base member that may be mounted over a substantially vertical chimney in the roof and a hollow member having a first end and a second end, the first end being larger than the second end and the first end being attached to the base member of the roof flashing. The roof curb includes a first skid and a second skid that may be mounted upon the roof substantially in a direction of the incline and substantially parallel to each other. The first skid and the second skid each have a length that terminates in a top end and a bottom end, each of the first skid and the second skid being tapered such that the bottom end of each of the first and the second skids has a height greater than the top end, the first and the second skids being selectively attached to the roof to bridge the corrugated ribs and the taper being of a gradation to permit attachment of the roof flashing to the roof curb and passage of the substantially vertical chimney therethrough, the roof curb being discrete from the roof flashing.
In accordance with a second embodiment, a roof flashing assembly is provided for attachment to an inclined roof having corrugated ribs. The roof flashing assembly includes a roof flashing having a base member adapted to be mounted over a substantially vertical chimney in the inclined roof and a hollow member, having a first end and a second end, the first end being larger than the second end and the first end being attached to the base member of the roof flashing, and a roof curb having a first skid and a second skid that may each be mounted upon the inclined roof substantially in a direction of the incline and substantially parallel to each other. The first skid and the second skid each have a length that terminates in a top end and a bottom end, each of the skids being tapered such that the bottom end of each of the skids has a height greater than the top end, the skids being selectively attached to the inclined roof to bridge the corrugated ribs and the taper being of a gradation to permit the attachment of the roof flashing to the roof curb and passage of the substantially vertical chimney therethrough, the roof curb being discrete from the roof flashing.
In accordance with a third embodiment, method for installing a roof flashing on a roof with an incline and ribs is provided, the roof flashing having a base member adapted to be mounted over a substantially vertical chimney in the roof and a hollow member having a first end and a second end, the first end being larger than the second end and the first end being attached to the base member of the roof flashing. The method includes the steps of: attaching a first skid and a second skid upon the roof substantially in a direction of the incline and substantially parallel to each other, cutting a slot in the roof above the substantially vertical chimney, the slot sized to receive a top edge of the base member; inserting the top edge of the base member into the slot cut in the roof, and attaching the base member of the roof flashing to the first skid and the second skid.
In accordance with a fourth embodiment, a roof curb includes a generally U-shaped ledge that may engage a flashing, a base wall extending in a first direction from a base portion of the generally U-shaped ledge, a first side wall extending in the first direction from a first arm portion of the generally U-shaped ledge, and a second side wall extending in the first direction from a second arm portion of the generally U-shaped ledge. The first side wall and the second side wall taper in height along a second direction transverse to the first direction and extending from the base portion of the generally U-shaped ledge toward distal ends of the first and second arm portions of the generally U-shaped ledge.
Present embodiments are directed to an intermediate system or feature that engages a flashing and a rooftop to facilitate a desired orientation of the flashing relative to the rooftop. Flashings are commonly used to protect certain portions of a roof and/or exterior wall of a structure that may be prone to leaks and water damage. For example, flashings may be applied at a base of a chimney, around skylights, drip edges of a roof, and vent pipes. Certain flashings are positioned over a desired area of the rooftop by techniques such as hammering, bending, or the like to conform the flashing to the shape of the desired area. These technique may be tedious and may result in flashings having an unaesthetic appearance. It is presently recognized that the disclosed intermediate system or feature may facilitate positioning and coupling of the flashing to the rooftop in a manner that improves the esthetics of the flashing on the rooftop as well as improving some functionality. This intermediate system or feature, which may be referred to as a roof curb, coordinates with the flashing to protect a corresponding opening in a roof, such as a gap between a vent pipe and an edge of the opening through the roof, from leaks.
As discussed in further detail below, the roof curb includes a set of separable roof curb components or skids that engage with each other to form the roof curb. When multiple roof curb components are utilized to form the roof curb in this manner, the collective components may be referred to as a roof curb system. In other embodiments, the roof curb is a single unit that may be referred to as a roof curb feature. That is, the roof curb may not have any separable parts. The roof curb, which may include multiple configurable skids, includes features that enable coupling with an angled or inclined roof that includes ridges, such as corrugated ribs found on a corrugated roof. In addition, the components of the roof curb may move relative to one another to adjust and customize one or more dimensions of the roof curb to fit dimensions of the flashing and/or the opening on the rooftop.
Turning now to the drawings,
The roof curb system 10 includes a first roof curb component 24 (or first skid 24) and a second roof curb component 26 (or second skid 26) that may engage with one another to form a curb around a perimeter 28 of the base 18 of the flashing 16. The roof curb components 24, 26 may include one or more features that facilitate coupling of the roof curb system 10 to the flashing 16 and the corrugated roof 14. As illustrated in
As discussed in further detail below, portions of the roof curb components 24, 26 may include engagement features such as one or more recesses 32, or gaps/notches, along a lower edge 34 of the roof curb system 10 that may engage with the corrugations of the corrugated roof 14. In one embodiment, the recesses 32 are preformed on the lower edge 34. In other embodiments, the recesses 32 are trimmed along the lower edge 34 of the roof curb system 10 such that a user can customize the roof curb system 10 to fit corrugation patterns of the corrugated roof 14. For example, a user may trim the roof curb components 24, 26 by using tin snips, a blade, a saw, or the like. The recesses 32 are trimmed and shaped in a manner that accommodates corrugations in the corrugated roof 14. Accordingly, to facilitate customization of the roof curb components 24, 26, the roof curb components 24, 26 may be manufactured from materials that may be readily and easily trimmed on site. The materials may include, but are not limited to, metals, plastics, resins, or the like. By way of non-limiting example, in certain embodiments, the roof curb components 24, 26 are manufactured from galvanized metals, stainless steel, aluminum, and metal alloys. In some embodiments, for certain roofing patterns, for example standard corrugation geometries, templates corresponding to such patterns may be pre-formed in the roof curb components 24, 26. This may facilitate configuration of the roof curb components 24, 26 for engagement with the roof.
In the illustrated embodiment, the roof curb system 10 includes a geometry that coordinates with a slanted or sloping, e.g., the incline 30, of the corrugated roof 14 in a generally complementary manner. The positioning of the roof curb system 10 in this manner may facilitate a desired orientation of the flashing 16. For example, the roof curb system 10 may generally form a U-shape when viewed from overhead. In one embodiment, the U-shape may include three sides of a square or rectangle. In other embodiments, more rounded features may be employed, including a semi-circle or partial oval. Thus, reference to a general U-shape includes a broad range of geometric configurations. When the roof curb system 10 is installed on the corrugated roof 14, a base wall 38 of the U-shape is positioned on a lower portion 40 of the corrugated roof 14 and an open end 42 of the U-shape is positioned on a higher portion 46 of the corrugated roof 14. In some embodiments, a bracket, border or wall, such as a thin metal bar, extends between the distal ends of the U-shape and couples to each end.
The first and second roof curb components 24, 26 are each generally L-shaped and are designed to combine to form a generally U-shaped roof curb 50. The use of two roof curb components or skids 24, 26 may facilitate sizing of the roof curb 50 to fit with an existing flashing, such as the flashing 16. In the illustrated embodiment, the U-shape and corresponding L-shapes are formed with angled engagement points. However, in other embodiments, curves may be employed. In some embodiments, the roof curb 50 is a single unit having a U-shape. That is, the roof curb components 24, 26 are inseparable. In some embodiments, the roof curb components 24, 26 are pre-attached and are adjustably engaged, for example, slidably engaged. The roof curb components 24, 26 have lengths that correspond to the arms of the general U-shape in the illustrated embodiment. For example, each roof curb component 24, 26 includes a first arm 74a, 74b and a second arm 76a, 76b, respectively. To facilitate discussion of the roof curb components 24, 26, reference will only be made to the roof curb component 24. The roof curb component 26 is substantially a mirror image of the roof curb component 24 and includes similar features arranged in a similar manner as those of the roof curb component 24. The first arm 74 of the roof curb component 24 is arranged crosswise or transverse relative to the second arm 76 of the roof curb component 24. As such, the first arm 74 and the second arm 76 of the roof curb component 24 form an angle 80 (a right, acute or obtuse angle) at a junction 82, thereby forming the L-shape configuration of the roof curb component 24. As used herein, the term “crosswise” is intended to denote a non-parallel orientation.
The second arm 76 terminates at a terminal end 84 and is tapered such that an end 86 adjacent to the base, such as the base wall 38, of the U-shape has a greater height than that of the respective terminal end 84. The skids or roof curb components 24, 26 are configurable to be selectively attached to a roof in a manner than bridges reinforcing ribs of a corrugated surface of the corrugated roof 14. That is, the roof components 24, 26 may be attached to the corrugated roof 14 at any desirable location configured to include a flashing, such as the flashing 16. The angle of the taper may be such that a gradation or incline 30 is achieved when attached to the roof 14 that allows passage of a chimney or the like through the flashing 16 mounted to the roof curb 50 in the installed configuration shown in
Each of the first and second roof components 24, 26 includes an upper ledge 88, a base length 90 and a side length 92. In some embodiments, the lengths 90, 92 of the roof curb 50 may be curved instead of generally linear, as illustrated. For example, the first arm 74 includes the base length 90, and the second arm 76 includes the side length 92 extending away from and crosswise to the base length 90. The upper ledge 88 is oriented crosswise relative to the lengths 90, 92, and extends away from an upper perimeter 94 of the respective roof component 24, 26. Accordingly, the base length 90 extends downward from the upper ledge 88, thereby forming the base of the U-shape. Similarly, the side length 92 extends downward from the upper ledge 88 along the second arms 76. The side length 92 tapers in height as it extends away from the base length 90 of the U-shape to the open end 42 of the U-shape in the illustrated embodiment. The taper may correlate to the slope of the corrugated roof 14. In some embodiments, the side length 92 couples to the base length 90, for example, at the junction 82. Further, the base length 90 and the side length 92 may extend substantially perpendicularly or crosswise to the respective upper ledge 88. The components of the upper ledge 88 form a U-shaped ledge that facilitates engagement with the flashing 16. In some embodiments, the U-shaped ledge is formed from the combination of two L-shaped ledges corresponding to each roof curb component 24, 26.
Each roof curb component 24, 26 includes a portion of the base wall 38. For example, when assembled, the lengths 90, 92 each form a portion of the base wall 38 of the U-shaped roof curb 50 and the side lengths 92 form sidewalls 98 of the U-shaped roof curb 50. The base wall 38 may be considered a cross-beam member that couples the sidewalls 98 in some embodiments. The sidewalls 98 may taper in height as they extend away from the base wall 38. Thus, when coupled to a sloping roof, such as the corrugated roof 14, the base wall 38 may be positioned such that the sidewalls 98 extend away from the base wall 38 in a direction of increasing height along the slope of the corrugated roof 14 and complement the corrugated roof 14. This may facilitate arrangement of the flashing 16 in an inclined configuration on a sloping roof and mitigate gaps between the base 18 and non-corrugated portions (portions in between corrugated ridges) of the corrugated roof 14. It should also be noted that portions of the roof curb 50 designed to be positioned adjacent to a roof may include flanges 104, which may also be referred to as lower ledges 104, to facilitate coupling the roof curb 10 with the corrugated roof 14. In some embodiments, the flanges 104 or lower ledges 104 extend from the base wall 38 and sidewalls 98.
In one embodiment, during assembly of the roof curb system 10 on the corrugated roof 14, the roof curb components 24, 26 are positioned such that the arms 76 are on a non-corrugated or flat portion of the roof 14 and along a portion of the edge 114 of the opening 110. For example, each roof curb component 24, 26 is placed on the flat portion (non-corrugated portions) of the corrugated roof 14 adjacent to the opening 110. Each roof curb component 24, 26 is oriented in a manner that places the terminal ends 84 of the respective roof curb components 24, 26 toward the higher portion 46 of the corrugated roof 14 and adjacent to or directly below the slot 118. The arms 76 of the roof curb components 24, 26 may have a predetermined length between the end 86 and the terminal end 84 of each respective arm 76. A user of the roof curb system 10 may select from roof curb component 24, 26 having arms 76 of different lengths based on a dimension of the base 18 of the flashing 16. In certain embodiments, the arms 76 of each respective roof curb component 24, 26 may be trimmed to a desired length. For example, one or both arms 76 may be trimmed such that the terminal end 84 of the respective arm 76 is below the edge 116 and the slots 118.
When properly positioned, the arms 76 of each respective roof curb component 24, 26 are oriented substantially parallel with the edge 116 of the opening 110 or the edge of the flashing 16 to be employed. Positioning based on the flashing 16 may be advantageous for non-linear or non-uniform openings. The dimension 70 of the roof curb system 10 is adjusted by pushing the roof curb components 24, 26 toward one another such that each arm 76 is positioned along the respective edge 114 of the opening 110. In certain embodiments, each respective arm 76 may be positioned at least a distance 124 away from the edge 114 to facilitate securing the roof curb system 10 to the corrugated roof 14. The flashing 16 may also be incorporated during this process. For example, the roof curb system 10 may be formed over the flashing 16. In one embodiment, each respective arm 76 may include a recess or rail along its length from the end 86 to the terminal end 86. Edges of the base 18 of the flashing may be inserted into the rail such that the rail may guide and facilitate positioning of the flashing 16 onto the roof curb system 10. In other embodiments, the flashing 16 may be subsequently attached to the roof curb system 10 once it is installed.
Once positioned on the corrugated roof 14, the roof curb components 24, 26 are affixed to one another and to the roof via fasteners 112 spaced apart along and coupled to the respective flange 104. Various fasteners may be employed, such as screws, nails, adhesive, sealant and the like. In certain embodiments, a sealant is used instead of, or in addition to, the fasteners 112 to further engage or otherwise secure the roof curb 50 to the corrugated roof 14.
As discussed above, the roof curb system 10 may be customized to include the recesses 32 that coordinate with features, such as corrugated ridges or ribs, of the corrugated roof 14 to facilitate coupling of the roof curb 50 to the corrugated roof 14 and formation of a sealing engagement that blocks moisture and other debris from leaking into the opening 110. In some embodiments, the recesses 32 may be formed in the first and second roof curb components 24, 26 such that sliding engagement of these components 24, 26 adjusts the size of the recesses 32.
Following positioning and securing the roof curb system 10 around the opening 110, the flashing 16 is inserted in and/or coupled to the roof curb system 10, thereby covering the opening 110.
In certain embodiments, an adhesive or sealant may be disposed between a bottom facing surface of the flashing 16, such as a surface facing the corrugated roof 14 in the illustrated embodiment, and the corrugated roof 14 or an upper side of the upper ledge 88. In other embodiments, the adhesive or sealant may be employed between a lower surface of the upper ledge 88 and an upper surface of the flashing 16.
In certain embodiments, the roof curb system 10 may be part of a flashing adapter kit. The flashing adapter kit may include one or more of the roof components 24, 26, the sealant, fasteners, and cutting instrument (tin snips, blade, or the like). In certain embodiments, the flashing adapter kit may include one or more flashings that are compatible with a shape of the one or more flashings. The roof components 24, 26 may be field shaped to the desired contour of the corrugated roof 14 to facilitate installation of the flashing 16 onto the corrugated roof 14.
Only certain features and embodiments of the disclosure have been illustrated and described, many modifications and changes may occur to those skilled in the art without materially departing from the novel teachings and advantages of the subject matter recited in the claims. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the disclosure. Furthermore, in an effort to provide a concise description of the exemplary embodiments, all features of an actual implementation may not have been described, such as those unrelated to the presently contemplated best mode of carrying out the disclosure, or those unrelated to enabling the claimed subject matter. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation specific decisions may be made. Such a development effort might be complex and time consuming, but would be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure, without undue experimentation.
This application claims priority from and the benefit of U.S. Provisional Application Ser. No. 62/653,944, entitled “CURB FOR USE WITH ROOF FLASHING,” filed Apr. 6, 2018, which is hereby incorporated by reference in its entirety for all purposes.
| Number | Date | Country | |
|---|---|---|---|
| 62653944 | Apr 2018 | US |
