The invention relates to construction materials for weatherproofing a structure, and more particularly, to an expandable flashing device for weatherproofing and a related system for weatherproofing a structure including a plurality of expandable flashing devices.
Modern construction requires a structure to be weatherproofed in order to comply with various building code requirements. Regardless of building codes, it is necessary to weatherproof a structure as a simple matter of quality construction. One known type of material used to weatherproof the exterior of a structure is flashing. The term “flashing” generally refers to relatively thin pieces of impervious material that are installed to prevent penetration of water into a structure from a joint or connection. Flashing is also commonly used within a larger weather resistant barrier (WRB) system in which flashing is coupled with other types of barrier materials.
Flashing is commonly used in building construction to eliminate or substantially decrease water seepage around objects exposed on the exterior of a building such as windows, roof eves, roof valleys, chimneys, roof vents, exterior walls, and door openings. Flashing may be constructed of thin pieces of metallic material such as aluminum, copper, steel, and metal alloys. More recently, flashing may also be made of composite materials to include molded plastic and others.
With respect to roofing construction, it is particularly important to ensure a roof has a robust weatherproofing design which will effectively deflect and carry water away from seems or joints and valleys where water runoff is concentrated. Without a properly designed weatherproof roof, disastrous damage can occur to the entire structure in which water is capable of damaging both exterior components and the interior of the building. Roofing replacement and repair can be extremely expensive and time-consuming, not to mention costly damage that can be sustained by the interior of a structure and the owner's possessions therein.
There are a number of drawbacks to traditional or common flashing designs. One significant disadvantage is that during construction, a significant number of flashing pieces must be measured and cut in order to match a structure's dimensions at those locations where flashing is required. Sizing and cutting flashing during installation complicates construction efforts.
Another disadvantage of common commercial flashing is that they are manufactured in a relatively long sections or pieces which require the flashing to be transported on a vehicle that has a sufficient length. Accordingly, flashing is most commonly delivered by trailer trucks or trains which may add to the cost of transporting the materials.
Yet another disadvantage of common flashing designs is that the exposed edges or sides of the flashing are not reinforced and accordingly, the edges may become bent or disfigured during transportation and handling.
Considering the drawbacks or disadvantages associated with, common flashing designs, there is a need for a flashing design which provides a user with automatic options for sizing. There is also a need for a flashing design which maintains the simplicity of current designs, but also provides a more robust solution with respect to rigidity and strength of the flashing, particularly at locations around the periphery or edges of the flashing.
According to one preferred embodiment of the invention, it includes an expandable flashing device comprising first and second pieces of flashing that overly one another and hems or folded edges located on opposite lateral sides of the pieces that hold the pieces together yet allow the pieces to slide or shift with respect to one another. In a first stowed position, the pieces overlap one another and in an expanded second position, the pieces may be pulled apart to increase an overall length of the device. The maximum length of material that overlaps between the pieces is defined as the overlap range. The overlap range defines the range to which the device can be shortened or lengthened to fit a particular installation. A minimum flashing length refers to the minimum length of the pieces when they are fully overlapped, while a maximum flashing length refers to the length of the pieces when there fully pulled apart or expanded.
According to one aspect of this first preferred embodiment, the opposite lateral sides of the pieces that incorporate the hems or folded edges may include fully closed hems, partially open hems, or combinations thereof. In one preferred embodiment, the device at each opposite lateral side has a fully closed hem for the interior piece of material and a partially open hem for the exterior piece of material that overlaps the interior piece. A fully closed hem can be defined as a bend created on a piece of material at approximately a 180° angle. A partially closed hem can be defined as a bend created on a piece of material at an angle of approximately 150-160° thereby leaving an opening at the bend of approximately 20-30° in which the bend of the interior piece is nested.
The overlapping or nested pieces of flashing material are capable of being selectively sized so that the overall length of the flashing can be lengthened or shortened depending upon the particular installation where the flashing is to be installed. To selectively size the flashing, a user may simply grasp either piece of flashing and pull or push the flashing pieces to set the flashing device at the desired length. During this manipulation, the partially open hems allow sliding engagement of the pieces to take place, but the nested closed hems ensure that the pieces of flashing material remain connected.
The shape of the flashing pieces may be formed to meet specifications for a particular installation. For example, in one preferred embodiment, the flashing may be defined as a drip edge flashing in which both of the pieces are bent at an approximately 90° angle along a longitudinal axis and length of the material.
In another preferred embodiment, the flashing may be defined as L-flashing that is typically adapted for use in sealing an object that may protrude above the surface of a roof such as a skylight or roof vent. In this embodiment, the L-flashing may adopt flashing pieces that are bent at greater or less than 90° angles depending upon the pitch of the roof where the object is mounted on the roof, but the L-flashing of the invention may be provided with a 90° angle.
In yet another preferred embodiment, the flashing may be defined as counter flashing which is similar to the L-flashing, except that the overall width of the flashing pieces may be greater to account for an increased surface area over which weatherproofing is required according to building code requirements.
In yet another preferred embodiment, the flashing may be defined as roof to wall flashing which is again similar to the L-flashing, except that the overall width of the flashing pieces may be greater and one side edge of the flashing may have a width that is significantly different than the width of the other side edge.
In yet another preferred embodiment, the flashing may be defined as valley flashing in which the flashing pieces include a V-shaped bend that extends along a central longitudinal axis of the flashing pieces.
In each of the embodiments, it is contemplated that a user may selectively choose which type of hem to use on the opposing side edges of the flashing pieces. As mentioned, one combination includes use of a fully closed hem and a partially open hem.
Considering the above features of the invention, in one aspect, it may be considered a flashing device especially adapted for weatherproofing a structure, comprising: (i) a first piece of shaped material having a length and opposite lateral side edges; (ii) a second piece of shaped material having a length and opposite lateral side edges; (iii) said opposite lateral side edges of said first and second pieces each having a hemmed edge formed thereon, each hemmed edge including a hem made in both said first and second pieces of material; (iv) wherein said hems on each opposite lateral side edge includes a closed hem and a partially open hem; and (v) wherein said first piece overlaps said second piece and said closed hem and said partially open hem on each opposite lateral side edge are nested with one another.
According to another aspect of the invention it may be considered a flashing device especially adapted for weatherproofing a structure, comprising: (i) a first piece of shaped material having a length and opposite lateral side edges; (ii) a second piece of shaped material having a length and opposite lateral side edges; (iii) said opposite lateral side edges of said first and second pieces each having a hemmed edge formed thereon, each hemmed edge including a hem made in both said first and second pieces of material; (iv) wherein said hems on each opposite lateral side edge includes a closed hem and a partially open hem; and (v) wherein said first piece selectively overlaps said second piece to cover said first piece and said closed hem is placed within said partially open hem on each opposite lateral side of said first and second pieces thereby enabling said pieces to be selectively slidable with one another to adjust a desired length of the flashing device between a minimum and maximum flashing length.
According to yet another aspect of the invention it may be considered a flashing system especially adapted for weatherproofing a structure, comprising at least first and second flashing devices according to either of the above described aspects of the invention.
According to yet another aspect of the invention it may be considered a method of installing flashing for use in weatherproofing a structure, said method comprising: providing a flashing device comprising: (i) a first piece of shaped material having a length and opposite lateral side edges; (ii) a second piece of shaped material having a length and opposite lateral side edges; (iii) said opposite lateral side edges of said first and second pieces each having a hemmed edge formed thereon, each hemmed edge including a hem made in both said first and second pieces of material; (iv) wherein said hems on each opposite lateral side edge includes a closed hem and a partially open hem; and (v) wherein said first piece selectively overlaps said second piece to cover said first piece and said closed hem is placed within said partially open hem on each opposite lateral side of said first and second pieces; determining a length on said structure that requires weatherproofing; installing said flashing device on said structure; and selectively sliding the first or second pieces to adjust a length of the flashing device between a minimum and maximum flashing length and to match said determined length on said structure.
A number of optional features may be adopted with any of the above described aspects, these optional features including: (i) a longitudinal bend extending along a length of the first and second pieces and located at a selected width distance between said opposite lateral side edges; (ii) said closed hem is formed by a closed bend made in a lateral side edge of one of said first or second pieces, said closed bend having a bend angle of approximately 180°; (iii) said partially open hem is formed by a partial bend made in a lateral side edge of one of said first or second pieces, said partial bend having a bend angle of approximately 150-160°; (iii) an offset distance is provided between a tip of a free end of said first piece and an exposed surface of said first piece; (iv) an end gap is provided between facing lateral side surfaces of the first and second pieces; and (v) a longitudinal gap is provided between facing longitudinal side surfaces of bended portions of said first and second pieces.
Other features and advantages of the invention will become apparent from a review of the following description taken in conjunction with the drawings.
The first flashing piece 12 may be further described as having a first side or surface 16 and a second side or surface 18, each side being disposed on opposite sides of the longitudinal bend 15. Similarly, the second flashing piece may also be further described as having a first side or surface 20 and a second side or surface 22 with each side being disposed on opposite sides of the longitudinal bend 15.
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In each of the installed embodiments as illustrated, it should be apparent that the length of the device can be adjusted to accommodate specific peculiarities in the various installation applications for varying types of structures. The adjustability of the length of the device reduces downtime associated with sizing and cutting of material. Further, there is some additional strength that is provided from the device since there is at least some length of the device that is overlapped with two pieces of material. The seams provided along both lateral edges of the device ensure that the device can be easily adjusted for desired lengths, yet the respective pieces of material will remain connected to one another.
According to yet another aspect of the invention, in another embodiment, it can be considered a flashing system that includes a plurality of selected types of flashing devices according to the other preferred embodiments of the devices of the invention disclosed herein. Accordingly, the flashing system may comprise a selected combination of flashing devices for installation on a structure which requires multiple areas to be weatherproofed.
According to yet another aspect of the invention, in another embodiment, it can be considered a method of installing flashing for use in weatherproofing a structure. The method includes providing a flashing device according to any of the above described devices of the invention. Once a flashing device is selected, a user determines a length on the structure that requires weatherproofing. The selected flashing device is installed in which the first or second pieces are adjustable between a minimum and maximum flashing length to match the determined length on the structure where weatherproofing is required.
Although the invention has been described herein with respect to multiple preferred embodiments of a device, system and method, it should be understood that various changes and modifications to these embodiments can be made commensurate with the scope of the claims appended hereto.