This disclosure relates to tools and method for the formation of roofing flashing. In particular, this disclosure relates to a hand tool providing the ability to create roofing flashing, particularly kick-out and dormer flashing, from stock flashing substrate material.
Flashing generally refers to roofing components that aid in preventing water leakage where runoff occurs or where two opposing roof surfaces meet, such as roof valleys, the intersection of a dormer wall and a roof surface, chimneys and skylights. So-called “kick-out” flashing is a roofing component generally designed to divert water run-off at an angle from the roof or along an intersection of adjoining roof surfaces. Flashing is commonly made from galvanized steel; however, it may be formed from other materials such as rust-resistant aluminum or copper.
Flashing is generally inserted between roof or wall surfaces and shingles to divert water runoff to a gutter or other desired location. Flashing is commercially available in standard sizes and designs to fit common roof architectures. However, custom-made flashing is sometimes required when roofing a house of unique construction. In this case, flashing can be made by bending and shaping stock pieces of galvanized steel or other stock into a desired shape.
Generally, roofers are exposed to danger by virtue of the heights that they work. Forming stock pieces of steel on a roof can place roofers in further danger because doing so may require cutting stock to form three-dimensional pieces, which exposes sharp edges and can increase the risk of damaging the existing roof. Furthermore, this process may lead to distraction, may require sharp tools, may otherwise present further danger of falling, and can be time consuming.
A tool predisposed to quickly and easily forming desired flashing pieces would reduce the likelihood of the above-mentioned injuries, reduce the amount of time required to form such pieces (and thus reduce the amount of time roofers need to spend at height) and reduce the cost to the homeowner by avoiding expensive, pre-formed flashing pieces. Accordingly, development of a flashing tool is an unmet need in the construction industry, particularly in the housing and roofing sector.
In one general aspect, a roofing tool is disclosed. The roofing tool is predisposed to the formation of custom flashing pieces, such as kick-out and dormer flashing, the shape of which is controllable by the user.
In one exemplary embodiment, a flashing tool includes a handle portion and a spade portion. The spade portion is configured to receive a portion of stock flashing material (e.g., a square of galvanized steel). Upon turning the handle, which is connected to the spade portion, the stock flashing material is formed into a shape that is suitable for installation as kick-out roof flashing.
In one exemplary aspect, a tool for forming flashing is disclosed. The tool includes an elongate rod member, a handle member disposed on a first end of the rod member, and a spade member on a second end of the rod member opposite the first end, wherein the spade member includes first and second spades symmetrically disposed and having a gap therebetween.
Certain advantages of the systems and methods disclosed herein include a tool that rapidly and easily forms roof flashing; reduction in the amount of time a roofer needs to remain at height while installing flashing; cost reduction compared to commercially-available flashing; the ability to make right- or left-handed flashing components without changing tools; the reduction of potential injury from cutting stock pieces (e.g., with tin snips or similar instruments); a reduction in the number of tools a roofer needs to form custom flashing components; and reduced likelihood of injuries due to falls by reducing distractions while operating on the roof; among others.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of any described embodiment, suitable methods and materials are described below. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting. In case of conflict with terms used in the art, the present specification, including definitions, will control.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description and claims.
The present embodiments are illustrated by way of the figures of the accompanying drawings, which may not necessarily be to scale, in which like references indicate similar elements, and in which:
In this embodiment, forming portion 115 includes a top spade 120 and a bottom spade 121 (
Flashing tool 100 can be used to form flashing, in particular, kick-out flashing. While the present example shows the formation of kick-out flashing, it should be understood that any other type of flashing can be formed with flashing tool 100. To form kick-out flashing, a user can begin with a piece of stock material S. In this embodiment, stock material S is galvanized steel; however, any other desired material can be utilized. In this example, if the stock material S is not already pre-formed as a right angle, a user can place a bend that bisects the length of stock material S as shown. Some stock material S is available pre-formed in a right-angle configuration.
Referring to
With the flashing tool 100 positioned in the conformation as shown in
Because the flashing tool 100 was rotated in a clockwise direction, fold F1 derives from edge 130 and fold F2 derives in part from edge 135 of the forming portion 115. It should be evident that, had the user twisted the flashing tool 100 in a counter-clockwise direction, that the S-fold would be in the opposite conformation. Such flexibility allows the user to determine which S-fold conformation is optimal for the direction of the kick-out flashing, taking water runoff direction and other factors into account. In this and other embodiments, the S-fold can be easily flattened to a minimum profile using, e.g., a hammer. It should be understood that the flashing tool 100 need not be rotated exactly 180 degrees to form the S-fold.
In this and other embodiments, the kick-out angle θ formed by the flashing tool 100 can be determined by the greatest distance between left and right edges (e.g., edges 130 and 135) of the top (120) and bottom (121) spades. In general, a smaller distance between edges will result in a smaller angle θ and vice-versa.
Referring now to
In this embodiment, the forming portion 215 includes three angles, 222, 224 and 226, wherein, in this embodiment, angle 222 is a ninety-degree right angle. Dashed line 228 illustrates an alternative embodiment, wherein the bottom portion of forming portion 215 includes additional area (bounded by the dashed line) that can be useful in creating custom folds of flashing stock.
Like flashing tool 100, the top (220) and bottom plates of the forming portion 215 are separated by a gap that is sufficient to receive a portion of flashing stock. In this and other embodiments, the gap may be set so as to receive a single ply of flashing stock between top and bottom plates of the forming portion 215. For example, and without limitation, the gap between top and bottom plates can be between 0.010 inches and 0.02 inches, which may be suitable for residential flashing stock. For industrial applications, the plate gap can be between 0.020 and 0.030 inches, without limitation, to allow receiving thicker flashing stock. In some embodiments, the plate gap can be set to receive two or more stacked flashing stock pieces. For example, for residential applications, the plate gap can be 0.040 inches to allow two flashing pieces to be bent at one time.
In general, forming portion 115 and 215 provide for receiving a portion of flat flashing stock that, when rotated after receiving the flat flashing stock, imparts a kick-out angle to the flashing stock. The flashing stock can then be used as a kick-out flashing piece and installed on a roof, for example.
A number of illustrative embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the various embodiments presented herein. For example, forming portion 115 can be reversibly-attachable to rod 105, allowing different spade sizes to be utilized for forming various kick-out angles θ; rod 105 can be substantially flat, providing an edge surface for forming the right-angle fold in otherwise flat stock material. Accordingly, other embodiments are within the scope of the following claims.
This application claims priority to and the benefit under 35 USC § 119(e) of U.S. Provisional Patent Application No. 62/784,428 filed on Dec. 22, 2018, the contents of which are incorporated by reference in their entirety as if fully set forth herein.
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Number | Date | Country | |
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62784428 | Dec 2018 | US |