Patent Grant
11692353
The invention relates roofing, and, more particularly, to flashing and drip edges used in roof applications.
It is commonplace to install metal flashing where a wall intersects the roof plane and at edges of a roof and metal drip edges adjacent the eaves and rakes of a roof. In sloped roofing applications, it is typical for the roof to encounter a wall, such as a dormer. In flat roof installations, many roof systems terminate at a parapet, roof protrusion, or wall.
The roofing industry has typically frowned on second layer roof applications, due to the inability of the next cover roofing system to tie into existing flashing or drip edges when encountering a wall or eave/rake, respectively. The problem is further exacerbated when a cover material, such as stucco, siding, or other cover, extends over the top edge of the existing flashing or drip edge. To replace the existing flashing or drip edge, the cover material needs to be removed and reinstalled or replaced. These steps add time and expense to roof replacement.
Despite the roofing industry's reservations regarding second layer roofing applications, the use and encouragement of second layer roof applications remains desirable, primarily due to cost and environmental impact benefits. Moreover, there is a substantial movement towards shingle recycling and keeping the existing shingles on the roof through another roofing cycle, as more communities come on board with shingle recycling efforts. Suffice it to say that, second layer applications are cleaner, while saving the owner money and the roofing contractor time.
Regarding flashing installed at the edges of a roof (i.e. drip edges), such flashing is often subjected to high wind that can result in shingle removal or damage and also is subject to damage, such as nail blow-through during installation, especially where installation is performed in cold weather.
What is needed, therefore, is flashing that can be used in second layer roofing applications that is able to tie into existing flashings when encountering a wall, without removal and/or replacement of the existing flashing and flashing for use at the edges of a roof that can improve the resilience of shingles mounted thereon to wind uplift and moisture intrusion while lessening the chances of damage thereto during cold weather installation.
A roof wall flashing comprising a cavity suitable for second layer recoverability that is built into the flashing itself allows for tying into existing flashing when encountering a wall without removal and/or replacement of existing flashing.
Drip edges that provide a cavity allow a shingle to be securely and easily fastened to a building envelope by better spreading the load of the fasteners across the shingle, both increasing their resistance to wind uplift and nail blow through.
In one embodiment of the present disclosure provides a drip edge comprising a flange configured to rest against a roof surface following installation on a perimeter of the roof surface; and a flap hingedly extending from a terminal edge of the flange configured to be positioned a predefined distance towards the center of the roof surface, as measured from an edge of the roof surface on which the flange is configured to be mounted, following installation of the flange on the roof surface, wherein the flap and the flange, in combination, form a cavity configured to retain a shingle therein.
Another embodiment of the present disclosure provides such a drip edge, the drip edge further comprising a kick extending downwards from a terminal edge of the flange opposite the terminal edge of the flange on which the flap extends from, the terminal edge of the flange opposite the terminal edge of the flange on which the flap extends from being configured to be adjacent the edge of the roof surface on which the flange is configured to be mounted after installation on the roof, wherein the kick 312 is configured to abut a wall and direct moisture away from the wall following installation of the flange on the building envelope.
A further embodiment of the present disclosure provides such a drip edge, wherein the drip edge further comprises at least one protrusion in the flange.
Yet another embodiment of the present disclosure provides such a drip edge, wherein the at least one protrusion in the flange comprises a stiffening feature.
A yet further embodiment of the present disclosure provides such a drip edge, wherein the stiffening feature comprises at least one rib
Still another embodiment of the present disclosure provides such a drip edge, further comprising at least one protrusion in the flap hingedly extending from a terminal edge of the flange.
A still further embodiment of the present disclosure provides such a drip edge, wherein each of the at least one protrusion in the flap hingedly extending from a terminal edge of the flange is parallel to each of the at least one protrusion in the flange.
Even another embodiment of the present disclosure provides such a drip edge, wherein the drip edge further comprises at least one protrusion or recess in the flange.
An even further embodiment of the present disclosure provides such a drip edge, wherein the drip edge further comprises at least one protrusion or recess in the flap hingedly extending from a terminal edge of the flange.
A still even another embodiment of the present disclosure provides such a drip edge, further comprising at least one protrusion or recess in the flange.
A still even further embodiment of the present disclosure provides such a drip edge, wherein at least one protrusion or recess in the flange is aligned with at least one recess or protrusion, respectively in the flap hingedly extending from a terminal edge of the flange.
Still yet another embodiment of the present disclosure provides such a drip edge, wherein a terminal edge of the flap hingedly extending from a terminal edge of the flange is configured to align with a terminal edge of the flange parallel to and opposite from the terminal edge of the flange on which the flap extends from.
A still yet further embodiment of the present disclosure provides such a drip edge, wherein a terminal edge of the flap hingedly extending from a terminal edge of the flange is configured to align with a portion of the flange short of a terminal edge of the flange parallel to and opposite from the terminal edge of the flange on which the flap extends from.
Even yet another embodiment of the present disclosure provides such a drip edge, wherein a terminal edge of the flap hingedly extending from a terminal edge of the flange is configured to retain a starter shingle retained in the cavity configured to retain the starter shingle such that at least a portion of a topside thereof is unobstructed, allowing a portion thereof to adhere to a shingle in an overlying course of shingles.
An even yet further embodiment of the present disclosure provides such a drip edge, wherein a terminal edge of the flange parallel to and opposite from the terminal edge of the flange on which the flap extends from comprises a rounded nose configured to extend off of the roof, following installation thereon.
Still even yet another embodiment of the present disclosure provides such a drip edge, wherein a terminal edge of the flange parallel to and opposite from the terminal edge of the flange on which the flap extends from comprises a 90 degree corner configured to abut a fascia or rake following installation on the roof.
A still even yet further embodiment of the present disclosure provides such a drip edge, wherein a terminal edge of the flap hingedly extending from a terminal edge of the flange that is opposite from and parallel to the terminal edge of the flange from which the flap extends comprises a closed hem.
Yet still even another embodiment of the present disclosure provides such a drip edge, wherein an upper face of the flap hingedly extending from a terminal edge of the flange in configured to be expandable by an installer.
A yet still even further embodiment of the present disclosure provides such a drip edge, wherein the upper face of the flap hingedly extending from a terminal edge of the flange comprises a plurality of lacerations therein configured to allow the expansion thereof.
A yet still even another further embodiment of the present disclosure provides such a drip edge, wherein the intersection of a terminal edge of the flange with a terminal edge of the flange from which the flap extends comprises a closed hem.
Another embodiment of the present disclosure provides such a drip edge, wherein the flap hingedly extending from the terminal edge of the flange comprises a plurality of apertures therethrough.
A further embodiment of the present disclosure provides such a drip edge, wherein the plurality of apertures are dispersed both horizontally and longitudinally across the flap hingedly extending from the terminal edge of the flange.
Yet another embodiment of the present disclosure provides such a drip edge, wherein the plurality of apertures are dispersed longitudinally across the flap hingedly extending from the terminal edge of the flange and wherein the plurality of apertures are configured to indicate predefined nailing locations for fastening a shingle to the drip edge using nails.
A yet further embodiment of the present disclosure provides such a drip edge, wherein the drip edge is made of a material selected from the group consisting of aluminum, steel, copper, and plastics.
Still another embodiment of the present disclosure provides such a drip edge, wherein an edge of the intersection of the flap with the terminal edge of the flange from which the flap extends comprises a notch configured to allow multiple drip edges to be interlocked together.
One embodiment of the present invention, as shown in
In embodiments, the wall flashing 109 is designed to extend up a vertical wall before returning onto itself, forming a living hinge 110 while also creating a cavity 103. The inner portion of the hinge 111 is further bent approximately 90 degrees 104 away from the wall flashing 109, resulting in it extending away from the wall flashing 109 perpendicularly, before being folded back on itself, resulting in a closed hem 106 that forms a ledge 105. The material forming the ledge 105 is then further bent upwards at approximately a 90 degree angle 107 and, after extending upwards until it is substantially level with the top portion of wall flashing 109, is angled slightly rearwards until it meets the plane defined by the wall flashing 109 and is subsequently angled once again to remain substantially within the plane defined by the wall flashing 109, forming upper wall flashing.
The ledge 105 created by the closed hem 106 may, in embodiments, be biased towards the wall through a spring effect or hinge, which can be created by virtue of the flashing's construction, through the use of special materials and/or alloys, and in other ways, as would be known to those of ordinary skill in the art.
In embodiments, the ledge 105 may be formed above or below a topmost portion of the wall flashing 109. The ledge 105 may also be bent further from the roof plane than 90 degrees, depending on the siding being installed, so as to further compress the cavity 103, due to the weight of the siding material installed. In addition, the ledge 105 may be designed such that the weight of the siding causes it to become parallel to the roof surface following installation. The ledge 105 may also be bent closer to the roof plane to provide for water discharge off of the ledge.
The installation of siding, stucco or the other exterior wall products onto the ledge allows the hinge 110 of the flashing to act like a spring by compressing the cavity 103 thereby further securing flashings installed at the interface between the wall flashing 109 and the inner portion of the hinge 111, which form the cavity 103.
In another embodiment of the present invention, the ledge is eliminated, but the cavity 201 remains and is built into the flashing itself, allowing for second layer recoverability. In this embodiment, the base flashing 202 extends onto the roof surface and is bent at a 90 degree angle 203, becoming wall flashing 204. In other embodiments, the base flashing 202 and wall flashing 204 may be bent to match the angle created by the roof and wall to be flashed. The wall flashing 204 then extends upwards, in use along a vertical wall, before doubling back onto itself, towards the base flashing 202, creating a hinge 209 and a cavity 201. At a certain point, the inner portion of the hinge, which could also be construed as the outer portion of the cavity, again doubles back onto itself, forming a vertically-oriented closed hem 205 that is substantially parallel to the wall flashing 204. Regarding the material forming the closed hem 205, after extending upwards until it is substantially level with a top portion of wall flashing 204, it is then angled slightly rearwards until it meets the plane defined by the wall flashing 204 and is subsequently angled once again to remain substantially within the plane by the wall flashing 109, forming upper wall flashing 207.
In embodiments, the point 206 of the closed hem 205 creates a continuous straight line 208 that siding materials can follow, proving for a clean, finished siding starting point and edge.
The cavity of embodiments (e.g. 103 and 201) provides protection to the top edge of future flashings. For example, after completion of a second layer roof, the closed hem 205 of the embodiment shown in
In embodiments, the flashing is tapered step flashing that accounts for the width of the shingles to be used, thereby maintaining a straight profile of the ledge 105, closed hem 106, the point 206, and the cavity (103 and 201). The flashing with a cavity (103 and 201) may be fabricated to any length that may be needed or required by local building codes.
For sloped roof applications, the step flashing with cavity or continuous flashing with cavity should be installed commencing towards the eave and working towards the ridge for proper overlap and watershed. On flat roof applications, the starting location of the installation of the flashing is not generally important, however, on flat roof applications, a sealant should be installed at the overlap of the wall flashing (204 and 207) sections and the sections may be secured to the wall through the closed hem 205.
In embodiments, the double coverage flashing is installed along a wall during an initial roofing process. While the benefit of the cavity (103 and 201) may not be apparent during the initial roofing, it will become evident when the roof needs to be replaced or serviced. More specifically, if repair or retrofitting of an existing roofing system constructed in accordance with such embodiments is required, it now becomes possible, without removing existing wall cover material and roofing.
Additionally, a roofing underlayment may be installed along the roof surface and up the vertical incline, followed by the disclosed double coverage flashing. At such a time when a second layer roof is installed, step flashing or wall flashing may then be inserted into the cavity (103 and 201).
Furthermore, the joining of one section of flashing to the next using a notch (e.g. 1000) is important to ensure a continuous cavity is formed therebetween. To achieve such fitment, the closed hem (106 and 205) of embodiments may be notched when joining one section to the next. More specifically, the closed hem (106 and 205) disclosed herein may be notched to provide for a seamless look, metal overlap, and to expose the cavity (103 and 206) without interference of an overlap, which would prevent any subsequent flashing from being installed seamlessly.
In embodiments, the notch 1000 is made on-site using tin snips, while, in other embodiments, the notch 1000 may be formed during the manufacturing process.
The placement of the notch 1000 is very important to achieving the proper overlap. The notched section of the flashing may be the top side facing towards the ridge on sloped roof applications. As such, in
In embodiments, the flashing is folded or gaped at the time of fabrication. The notch 1000 or fold, including expansion or gaping of metal sections via the use of specialty machinery, permits for the elimination of a notch 1000 and allows sections of the flashing disclosed herein to connect in a seamless manner.
Furthermore the flashing disclosed herein, in embodiments, is fabricated without the base flashing (101 and 202). Using such embodiments, the flashing may be installed onto custom fabricated or stock flashings as an additional piece, thereby providing for the future benefits of the cavity without changing the way systems are installed today.
Now specifically referring to
In embodiments, the drip edge 300 comprises closed hems 310, which function to increase the rigidity of portions of the drip edge 300.
In embodiments, the drip edge 300 comprises a nose 306 configured to extend off of a building envelope and/or a fascia portion 308 configured to abut a fascia adjacent the section of roof on which the drip edge 300 is mounted following installation.
In embodiments, a terminal edge of the upper flap 304 of the drip edge 300 stops short of the nose 306, allowing an adhesive mass 320 that may be disposed on the starter shingle 316 to adhere to an overlying course of shingles, in embodiments field shingles, while maintaining the benefits of the drip edge 300 configuration disclosed herein.
In embodiments, the drip edge 300 further comprises a kick 312 configured to direct rain water away from a building envelope on which the drip edge 300 is mounted, the kick 312, in embodiments, forming a lowermost portion of the drip edge 300.
In embodiments, such as those shown in
In embodiments, such as that shown in
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The flashing disclosed herein is, most preferably, fabricated using a metal break of roll former, although other methods could be used, as would be known to one of ordinary skill in the art. The source material, typically metal, may be obtained in flat sheets or in roll form and be slit to the desired width prior to fabrication.
Materials, especially metals, are offered in a variety of gauges and mils, depending on local codes and performance requirements. The dimensions of the gap and the fabricated widths can vary from site to site, depending on the roofing system being installed and site conditions discovered prior to fabrication.
A benefit of this drip edge 300 configuration is that any wind-driven moisture that tries to enter at the interface between an underside of a starter shingle 316, in embodiments a three tab starter shingle 316 having multiple tabs 318, and the base flashing 101 is returned toward the rake or eave, dependent on which section of roof the drip edge 300 is mounted, as opposed to migrating between and underneath shingles, as is common with prior art configurations.
Lastly, even another benefit of the drip edge 300 disclosed herein is that it ensures proper starter shingle 316 overhang, by design. More specifically, by inserting the starter shingle 316 into the cavity 103 formed by the upper flap 302 and base flashing 101 until it stops, a consistent overlap of the starter shingle 316 from the nose 306 of the drip edge 300 is easily obtained.
The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of this disclosure. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.
This application is a Continuation In Part of U.S. application Ser. No. 16/355,270, filed Mar. 15, 2019, which claims the benefit of U.S. Provisional Applications Nos. 65/659,757, filed Apr. 19, 2018, and 60/643,335, filed Mar. 15, 2018. Each of these applications is herein incorporated by reference, in its entirety, for all purposes.
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| Number | Date | Country | |
|---|---|---|---|
| Parent | 16355270 | Mar 2019 | US |
| Child | 16995318 | US |
