Flexible flashings and associated method of manufacture

Abstract

A flexible flashing and method for manufacturing and installing the flashing at a window or other portal in a wall opening is provided. The flashing includes a base member with a plurality of channels that are structured to direct water therefrom, and a face plate extends from the base member. The flashing can be formed, e.g., by a molding operation, and then supported and cooled in a curved configuration. For example, the flashing can be supported in a jig in a configuration that is curved about a first axis that is perpendicular to an axis about which the flashing is curved during installation.

Description

FIELD OF THE INVENTION

This invention relates to the installation of windows or other building members and, more particularly, relates to a flashing and method of manufacturing such a flashing for directing water and preventing leakage of the water at a window or other portal.

BACKGROUND OF THE INVENTION

During a typical installation of a window in a building, a rough opening is first prepared in a wall of the building for receiving the window. The rough opening is defined by two jambs that extend vertically from a head at the top of the rough opening to a sill at the bottom of the opening. A weather resistant barrier material, such as a thin sheet of waterproof paper or plastic can be disposed over the outer surface of the wall, and the barrier material is cut at the rough opening and folded into the opening. The barrier material forms a moisture barrier extending over the outer surface, but due to the cuts in the barrier material does not normally provide a waterproof barrier on the inner surfaces of the rough opening. In particular, the barrier typically defines openings at the intersection of the jambs with each of the head and sill. Flashings can be installed across the head and/or the sill. The head and sill flashings extend outward from the head and sill onto a portion of the outer surface of the wall and upward from the sill onto a portion of each jamb. Thus, the flashings, which are formed of a sheet of material, are cut and bent to correspond to the jambs, the outer wall surface, and the head or sill. Typically, cuts are made in each of the head and sill flashing, each cut extending from a respective corner of the head or sill and the jambs, through the portion of the flashing that is disposed on the outer surface of the wall. Other cuts may be necessary depending on the configuration of the rough opening and the window. For example, if the rough opening has a curved head that corresponds to a semi-circular top portion of the window, the head flashing may be cut a number of times so that the flashing can be sufficiently bent to fit the curvature of the head.

In some cases, water can leak into the opening around the window or even through the window. The water can sometimes penetrate both the barrier material and the flashings, e.g., through the cuts that are made in the barrier material and the flashing during installation. If the water flows into the wall, i.e., between the inner and outer surfaces of the wall, the water can damage to the wall and the window.

U.S. patent application Ser. No. 11/026,664 describes a flexible flashing for installation in a portal, such as a window, in an opening in a wall. The flashing, which can be formed of a unitary molded plastic member, includes a base member and a generally perpendicular face plate that extends therefrom. The face plate is structured to be disposed against the wall while the base member is disposed against a frame of the window or other portal. Water disposed on the base member is directed toward the outer surface of the wall, and thus the flashing can prevent entry of water into the portal or wall. However, it has been found that variation in the angle of the base member relative to the face plate can affect the performance of the flashing. That is, if the angle of the base member is generally less than 90°, and the face plate is disposed against a vertical wall, the base member may tend to direct water toward the face plate. Further, it has been found that the angle between the face plate and the base member may change as the flashing is bent to its curved configuration. For example, although the face plate may be formed in a planar configuration, the face plate may become curved, e.g., as the flashing cools after a hot molding operation. In addition, the base member may cool in a configuration in which the longitudinal edges of the base member have slightly different lengths. If the base member's first longitudinal edge, which is proximate to the face plate, is longer than a second longitudinal edge of the base member that is distal from the face plate, the angle between the face plate and base member may tend to decrease as the flashing is curved about an axis perpendicular to the face plate during installation.

Thus, there exists a need for a method for manufacturing a flashing device for use in a window or other portal installation, such as for preventing the flow of water to the rough opening in the wall and to the inside of the wall. The device should be compatible with conventional windows and other portals and installation methods. In particular, the device should be compatible with windows of other portals with nonlinear sides, such as windows or doors with rounded or otherwise curved top or bottom portions. Preferably, the device should be relatively easy to install and economical to manufacture.

SUMMARY OF THE INVENTION

The present invention provides a flexible flashing and method for use in installing a portal, such as a window, in an opening in a wall. The flashing defines channels for directing water out of the wall to an outer or inner surface of the wall, thereby restricting the passage of water into the wall around the portal. For example, the flexible flashing can be used in connection with the installation of a window that has a curved frame, e.g., at the top and/or bottom of the window, that corresponds to a curved header and/or sill of the opening.

According to one embodiment of the present invention, the flexible flashing includes a base member that defines opposite first and second surfaces extending from a first edge to a second edge. The first surface of the base member defines a plurality of channels that are generally configured to direct water from the first edge to the second edge of the base member. The channels can be tapered or otherwise configured, and ridges defined between the channels can form a surface that is substantially parallel to the second surface of the base member. The flashing also includes a face plate that extends from the base member in a plane generally perpendicular to the base member such that a first edge of the face plate is proximate the base member and a second distal edge of the face plate extends therefrom. Thus, the face plate is structured to be disposed against the wall while the base member is disposed against the frame with the channels configured to direct water from between the frame and portal to the outer surface of the wall. The face plate defines a plurality of slots that extend from the second edge toward the first edge, e.g., partially through the face plate, so that the base member can be flexed to the curved configuration of the frame. An end dam flange that is perpendicular to the base member and the face plate can be provided at one or both longitudinal ends of the flashing, and each end dam flange can be connected to the base member and the face plate to prevent water from flowing from the end of the flashing. Similar to the flashings described above, the flexible flashing can be formed of a unitary molded plastic member.

In some cases, the face plate extends from the first surface of the base member at the first edge of the base member so that the face plate can be disposed against the wall and the first surface of the base member can be disposed toward a curved head of the opening with the base member curved to the curved contour of the head. Alternatively, the face plate can extend from the second surface of the base member at the second edge of the base member so that the face plate can be disposed against the outer surface of the wall and the second surface of the base member can be disposed toward a curved sill of the opening with the base member curved to the curved contour of the sill. Further, more than one of the flexible flashings can be used for a single portal assembly, e.g., with one or more of the flashings used at the header and/or one or more of the flashings used at the sill of the opening.

The present invention also provides an assembly in an opening of a wall, such as a window assembly, a shower door assembly, other portal assembly, or the like. The assembly includes a wall defining first and second opposite surfaces with an opening extending therebetween and one or more flexible flashing configured to correspond to a curved portion of the opening. A window, door, other portal, or the like can be disposed in the opening.

Additionally, the present invention provides a method of installing a window, shower door, or other portal in a wall opening that defines a curved portion, such as a curved head. The method includes disposing the flashing at the curved portion of the wall opening and disposing the portal in the wall opening such that the base member of the flashing is disposed between the curved portion of the wall opening and the portal and the channels are structured to direct water away from the face plate and toward the outer surface of the wall.

Further, the present invention provides a method of manufacturing a flexible flashing in a curved configuration, e.g., using a mold having a curved shape or an associated jig or tool. The flexible flashing can be disposed in a curved configuration in the mold or jig and supported in the curved configuration while cooling, e.g., after forming by hot injection molding. A curvature can be imparted to the flashing as a result of the support by the mold or jig, such that a preferred configuration of the flashing is achieved when the flashing is installed in a curved orientation. More particularly, the flashing can be supported in a first configuration, in which the flashing is bent about a first axis, and the flashing can thereafter be installed in a second configuration, in which the flashing is bent about a second axis. For example, the flashing can be cooled with the first edge of the base member defining a first radius of curvature and the second edge of the base member defining a second radius of curvature that is smaller than the first radius of curvature, e.g., with the flashing curved about an axis parallel to the face plate. Thereafter, the flashing can be installed with the first and second edges of the base member defining substantially equal radii, e.g., with the flashing curved about an axis parallel to the base member. Thus, the flashing can be adapted to be curved to a desired configuration of a window or other portal while maintaining an orientation between the base member and the face plate to direct water out of the portal.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other advantages and features of the invention, and the manner in which the same are accomplished, will become more readily apparent upon consideration of the following detailed description of the invention taken in conjunction with the accompanying drawings, which illustrate preferred and exemplary embodiments, but which are not necessarily drawn to scale, wherein:

FIG. 1 is a perspective view illustrating a flexible flashing according to one embodiment of the present invention;

FIG. 2 is an elevation view illustrating a window assembly including a first flexible flashing similar to the one shown in FIG. 1 installed at the header of the opening in the wall and a second flexible flashing at the sill of the opening;

FIG. 3 is a section view illustrating the first flexible flashing of FIG. 2 as seen along line 3-3 of FIG. 2;

FIG. 4 is a section view illustrating the second flexible flashing of FIG. 2 as seen along line 4-4 of FIG. 2;

FIG. 5 is a perspective view of a flexible flashing, such as the first flexible flashing of FIG. 2, shown in a bent configuration;

FIG. 6 is a schematic view graphically illustrating the operations for forming a flexible flashing according to one embodiment of the present invention;

FIG. 7 is a plan view illustrating a flexible flashing disposed in a jig according to one embodiment of the present invention;

FIG. 8 is a section view of the flexible flashing of FIG. 7 as seen along line 8-8 of FIG. 7;

FIG. 9 is a perspective view of the flexible flashing of FIG. 7 after removal from the jig of FIG. 7; and

FIG. 10 is an elevation view of the flexible flashing of FIG. 7 in a bent configuration.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.

Referring to the drawings and, in particular, to FIG. 1, there is shown a flexible flashing 100 according to one embodiment of the present invention. The flashing 100 is structured to be installed in a wall opening 104 in connection with the installation of a window 102 (FIG. 2) or other portal in the opening 104 so that the flashing 100 directs water out of the opening 104, e.g., to the outside of a building. Accordingly, the flashing 100 is preferably formed of a waterproof material. For example, the flashing 100 can be formed of a variety of materials including polymers, metals, and the like. In one advantageous embodiment of the invention, the flashing 100 is formed as a unitary member of plastic, such as polypropylene, polyethylene, polystyrene, or polyvinyl chloride (PVC). For example, the flashing 100 can be formed by a conventional injection molding operation using one or more dies that cooperably define a die cavity corresponding to the configuration of the flashing 100 so as to form the flashing as a unitary, molded plastic member.

The flexible flashing 100 can be used, e.g., in connection with the installation of a window or other portal that defines a curved frame that corresponds to a curved opening in a wall. For example, as shown in FIG. 2, a window 102 is installed in an opening 104 in a wall 106. The window 102 defines a curved top portion 108 that corresponds to the curved top of the opening 104. In addition to the flashing described in U.S. patent application Ser. No. 11/026,664, incorporated above, flashings for use at the straight sides and corners of windows and other portals are further described in U.S. patent application Ser. No. 10/753,135, titled “Corner Flashing For Windows and the Like,” filed Jan. 7, 2004, and U.S. patent application Ser. No. 11/026,820, titled “Flashings For Windows and the Like,” filed Dec. 30, 2004, the entire contents of each of which is incorporated herein by reference, and the subject flashings of which can be used in combination with the flashings of the present invention.

As illustrated in FIG. 1, the flashing 100 includes a base member 112 and a face plate 122 that extends from the base member 112. The base member 112 defines opposite first and second surfaces 114, 116 that extend from a first edge 118 to a second edge 120. In one embodiment of the present invention, illustrated in FIG. 1, the face plate 122 extends from the first surface 114 of the base member 112 at the first edge 118 of the base member 112.

The first surface 114 of the base member 112 defines a plurality of channels 124 that are configured to direct water from the first edge 118 to the second edge 120 of the base member 112. For example, the channels 124 can be tapered to define a non-uniform depth and, in particular, a depth that increases between the first edge 118 and the second edge 120 so that water on the base member 112 tends to flow in that direction. The channels 124 can be defined between ridges 126, and the ridges 126 can together define a surface that is substantially parallel to the second surface 116 of the base member 112. The second surface 116 of the base member 112 is generally a smooth, continuous surface, i.e., a planar surface when the flashing 100 is in a straight configuration and a smoothly curved surface when the flashing 100 is bent.

The face plate 122, which extends from a first edge 128 to a distal second edge 130, typically extends generally perpendicularly to the base member 112. Thus, as shown in FIG. 3, the face plate 122 can be disposed against the wall 106 while the base member 112 is disposed against the curved top portion 108 of the window 102 with the channels 124 configured to direct water outward from the outer surface 107 of the wall 106, i.e., over the second edge 120 of the base member 112, which can define a lip 132 or other extension.

Further, the face plate 122 defines a plurality of slots 140 that extend from the second edge 130 toward the first edge 128 of the face plate 122, thereby facilitating the bending or flexing of the flashing 100. That is, as the flashing 100 is bent about an axis parallel to the base member 112, the slots 140 are opened or closed accordingly. The slots 140 typically extend from the second edge 130 only partially through the face plate 122 toward the first edge 128. Thus, any water that is disposed on the first surface 114 of the base member 112 cannot easily leak through the slots 140. End dam flanges 142 can be provided at the longitudinal ends of the flashing 100. Each end dam flange 142 is connected to the base member 112 and the face plate 122 to prevent water from flowing from the end of the flashing 100.

In another embodiment of the present invention, the flexible flashing is provided for use with a window or other portal that defines a curved bottom portion 150. In this regard, FIGS. 2 and 4 illustrate a flashing 100a that is disposed between the bottom 150 of the window 102 and a curved sill 152 of the opening 104 in the wall 106. Similar to the flashing 100 described above, the flashing 100a includes a base member 112 with channels 124, and a face plate 122 that extends from the base member 112 and defines slots 140 that affect the flexibility of the flashing 100a. However, in the embodiment of FIG. 4, the face plate 122 extends from the second surface 116 of the base member 112 at the second edge 120 of the base member 112, so that the face plate 122 can be disposed against the outer surface 107 of the wall 106 and the second surface 116 of the base member 112 can be disposed toward the curved sill 152 of the opening 104 with the base member 112 curved to correspond to the curved contour of the sill 152. Thus, the channels 124 of the flashing 100a are configured to direct water toward and through the face plate 122 and out of the wall 106.

The channels 124 of the flashings 100, 100a can be substantially parallel to each other and perpendicular to the face plate 122. Alternatively, in other embodiments of the invention, the channels 124 can be angled relative to the face plate 122. In either case, the channels 124 preferably do not extend through the first edge 118 of the base member 112. Further, as shown in FIGS. 2 and 4 and noted above, the channels 124 can be tapered in depth in a direction away from the first edge 118, i.e., such that each channel 124 defines an increased depth at the second edge 120. In some cases, each channel 124 can be deeper than the ridges 126 and/or the portion of the base member 112 between the first edge 118 and the channels 124, to further prevent the flow of water toward the first edge 118. Thus, water in the channels 124 generally flows toward the second edge 120 and exits the channels 124, i.e., away from the face plate 122 in the embodiment of FIGS. 1 and 3, and through the face plate 122 in the embodiment of FIG. 4.

The ridges 126 that separate the channels 124 define a support surface, which can be substantially parallel to the opposite surface 116 of the base member 112. Thus, the flashings can be used for support, such as when the base member 112 of the flashing 100a is disposed between the wall opening 104 and the window 102 or other portal with the ridges 126 defining a support surface that is parallel to the sill 152 of the wall opening 104. The ridges 126 can be uniform in width or non-uniform in width, e.g., so that each ridge 126 is increasingly narrower in a direction away from the base member 112 to minimize the likelihood of water resting on the ridges 112. In addition, the height of each ridge 126 can be uniform or non-uniform along the length of each ridge 126. For example, each ridge 126 can define a decreased height nearest the second edge 120 so that the ridges 126 are less visually noticeable if the second edge 120 is exposed when installed.

Each of the channels 124 can be angled or tapered to direct water from the opening 104 in which the flashing 100, 100a is disposed. For example, each of the channels 124 can be defined by sidewalls 125 that are disposed at a non-perpendicular angle relative to the second edge 120 of the base member 112. The sidewalls 125 of each channel 124 can be parallel or nonparallel. For example, as shown in FIG. 1, the sidewalls 125 of each channel 124 diverge in the direction of the second edge 120. That is, each channel 124 is tapered to define an increased width at the second edge 120. The depth of the channel 124 also generally increases toward the second edge 120, so that water on the flashings 100, 100a tends to drain to the second edge 120. In this way, if a portion of the flashing 100, 100a is disposed in a non-horizontal orientation, as is the case for the longitudinal ends of both flashings 100, 100a in FIG. 2, the channels 124 of the non-horizontal portions tend to drain water by gravity toward the second edge 120 and out of the wall 106.

In addition, the base member 124 can define an angled portion at the second edge 120. For example, each of the ridges 126 can define an angled lead-in edge 127 at the second edge 120, i.e., a surface that is disposed at about a 45° angle relative to the general plane of the base member 112 and the top surface of the ridges 126. In the case of the flashing 100a disposed between the bottom 150 of the window 102 and the curved sill 152 of the opening 104, as shown in FIG. 4, the angled lead-in edge 127 can facilitate the entry of the window 102 or other portal into the opening 104 after the flashings 100a has been installed. In the case of the flashing 100 (FIG. 3), which is disposed at the curved top portion 108 of the window 102 and a correspondingly curved header 110 of the opening 104 after the window 102 is installed, the angled lead-in edge 127 can direct water off the base member 112 and prevent water from flowing along the second surfaces 116 of the base member 112 back toward the face plate 122.

Typically, each flexible flashing 100, 100a is formed of a unitary molded plastic member, and the end dam flanges 142 and slots 140 are formed during the molding of the flashing 100, 100a. The flexible flashing 100, 100a can be formed in a straight or curved configuration, and typically can be bent after forming, such as in connection with the installation of the window 102 or other portal. Thus, a single flashing 100, 100a can be used for windows having various curved configurations. In addition, the flashing 100, 100a can be formed of a material with sufficient elasticity such that the flashing 100, 100a can be bent to its curved configuration for installation without plastically deforming the flashing 100, 100a. Further, the flashing 100, 100a can also be used for windows or other portals that are not curved. That is, the flashing 100, 100a can be installed in a substantially straight configuration when used in connection with the installation of a typical rectangular window. In that configuration, the base member 112 of the flashings 100, 100a can be disposed horizontally at the header 110 of the opening 104 or between the window 102 and the sill 152.

Each flashing 100, 100a can be formed in various lengths, according to the size of the opening and the length of the curved portion of the opening 104. Further, the flashings 100, 100a can be readily cut or otherwise trimmed to size so that each flashing 100, 100a extends along a desired length of the perimeter of the opening 104. Thus, the flashing 100 can be disposed to extend about any angle or radius and at various curvatures. For example, if the flashing 100 is to be used with a window 102 having a top portion 108 that is curved through a 180° arc, as shown in FIG. 2, the flashing 100 can extend around the entire curved portion of the top 108 of the window 102. Alternatively, the flashing 100 can be disposed about only a portion of the arc defined by the window 102. Further, in some cases, more than one of the flashings 100, 100a can be used in combination at the top or bottom of the window 102. For example, if the window 102 defines an arc that is longer than the length of the flashing 100, two or more of the flashings 100 can be disposed end-to-end so that the flashings 100 in combination extend about the desired portion of the window 102. If multiple flashings 100, 100a are used in one installation assembly, an interface defined between the flashings 100, 100a can be covered or otherwise sealed with a sealant material, such as a strip of tape or other membrane or caulk. The interface can also be sealed using an additional flashing member such as an L-shaped flashing member that corresponds generally in cross-section to the base member 112 and face plate 122, which can be disposed on the ends of the multiple flashings 100, 100a to cover the interface therebetween.

Each flashing 100, 100a can be secured to the wall 106 or the window 102, e.g., using fasteners 144, such as nails, screws, or the like. Before or after the window 102 or other portal is disposed, siding materials 160 such as vinyl or aluminum siding strips, wood shingles, stucco, or bricks are typically disposed on the outer surface 107 of the wall 106. In addition, as is known in the art, the outer surface 107 of the wall 106 can be covered by a laminar sheet of a moisture barrier material 162, and the sheet 162 can be folded into the opening 104 before the window 102 and siding materials 160 are installed. According to the present invention, the second edge 120 of the flashings 100, 100a can be disposed outside the sheet 162 of barrier material, such that the flashing 100 drains water outside the wall 106, outside the barrier sheet 162, and inside or outside of the siding 160. The flashing 100 at the top of the window 102 is typically disposed with the face plate 122 under the barrier sheet 162 and the siding 160 so that any water on the outer surface of the barrier sheet 162 or the siding 160 is directed onto the flashing 100 and then outward from the wall 106. The flashing 100a at the bottom of the window 102 is typically disposed over the barrier sheet 162 and can be made to cover any cuts or holes in the barrier sheet, such as cuts that are made to facilitate the folding of the sheet 162 into the opening 104 or cuts or holes resulting from wear.

During installation of the flashings of the present invention, such as the installation of flashing 100 at the header 110 of the opening 104 as shown in FIG. 3, the flashing 100 is typically curved about an axis generally parallel to the base member 112. Thus, as illustrated in FIG. 5, according to a typical installation, the first and second edges 118, 120 of the base member 112 are curved to form arcs having radii R₁, R₂ corresponding to the radius of the window 102 or other portal in which the flashing 100 is to be installed. It has been observed that, in some cases, the bending of a straight flashing to the curved configuration illustrated in FIG. 5 results in a change in the relative orientation of the base member 112 and the face plate 122. In particular, it has been noted that bending the flashing 100 about an axis parallel to the base member 112 can result in a slight reduction of the angle between the base member 112 and the face plate 122, such that the second edge 120 “rises” and the radius R₂ defined by the second edge 120 is slightly greater than the radius R₁ defined by the first edge 118. Although the present invention is not limited to any particular theory of operation, it is believed that the nonuniformity in the radii R₁, R₂ may be a result of a change in the configuration of the flashing 100 as the material cools after forming. For example, if the flashing 100 cools in a configuration in which the face plate 122 is curved, such that the length of the first edge 118 is slightly shorter than the length of the second edge 120, during installation the flashing 100 may tend to curve to a configuration in which the first edge 118 is shorter than the second edge 120, e.g., such that the radius R₁ is less than the radius R₂. In some cases, the angle imparted to the base member 112 relative to the face plate 122 may reduce the effectiveness of the flashing 100 for directing water out of the portal. That is, if the face plate 122 is disposed against a vertical surface as illustrated in FIG. 2, the base member 112 may be non-horizontal and angled such that water is directed toward the first edge 118 instead of the second edge 120.

FIG. 6 schematically illustrates a series of manufacturing operations 200-208 for forming a flashing according to one embodiment of the present invention. As illustrated, the flashing 100 can be formed by a molding process, generally indicated by reference numeral 200. For example, the flashing 100 can be formed of plastic such as polypropylene that is injection molded in a die or otherwise molded to the desired shape of the flashing 100. When a die is used for molding, the flashing 100 is typically cooled at least partially in the die. As indicated by reference numeral 202 in FIG. 6, the flashing 100 is typically formed to a substantially straight configuration as a result of the molding process. Upon removal from the die, the flashing 100 is still typically hot and may be subject to moderate “forming” by configuring the flashing 100 and cooling the flashing 100 in the desired configuration. Accordingly, the flashing 100 can be disposed in a jig 210, i.e., a tool adapted to support the flashing 100 in a desired configuration, as generally indicated by reference numeral 204 in FIG. 6.

The jig 210, which is also illustrated in FIGS. 7 and 8, is adapted to support the flashing 100 in a curved configuration. In particular, the jig 210 can support the flashing 100 so that the base member 112 is substantially flat and the face plate 122 is curved, with the first edge 118 being curved to a greater radius R₁′ than a radius R₂′ of the second edge 120 and, hence, to a longer length than the length of the second edge 120. As illustrated in FIGS. 7 and 8, the jig 210 includes a first member 212 that is substantially flat for supporting the base member 112. If the flashing 100 defines a lip 132 or other non-planar feature, the first member 212 of the jig 210 can define a correspondingly contoured feature 214 or shape. A second member 216 of the jig 210 can be disposed over the base member 112, e.g., against the tops of the ridges 126, so that the base member 112 is supported between the first and second members 212, 216 of the jig 210. As shown in FIG. 7, the second member 216 of the jig 210 defines a curve or arc so that the flashing 100 can be bent from its straight configuration (shown in broken lines) to be disposed against the second member 216 and in a configuration defining a desired curvature. Stops 218 can be provided proximate the ends of the flashing 100 and/or opposite the flashing 100 from the curved portion of the second member 216, to further restrain the flashing 100 in the desired configuration.

Thus, after the flashing 100 is formed, and typically while the flashing 100 is still hot, the flashing 100 can be disposed in the jig 210 and at least partially cooled in the jig 210. The flashing 100 can be cooled to room temperature in the jig 210, or the flashing 100 can be removed from the jig 210 while still at a somewhat elevated temperature, though typically after the flashing 100 has cooled sufficiently so that the curved configuration of the jig 210 is at least partially imparted to the flashing 100. Thus, upon removal of the flashing 100 from the jig 210, the flashing 100 has a curved configuration, as generally indicated by reference numeral 206 in FIG. 6. That is, in a natural (i.e., unloaded or unrestrained) condition, the flashing 100 defines a curvature, though the flashing 100 in its natural state is typically curved less than the curvature defined by the jig 210.

The jig 210 can be designed and structured to impart sufficient curvature to the flashing 100 so that the flashing 100 can be installed in a desired configuration while maintaining a predetermined orientation between the face plate 122 and the base member 112. The optimum curvature of the jig 210 can be determined according to such factors as the dimensions and configuration of the flashing 100, the desired configuration of the flashing 100 in its installed condition, the temperature and material properties of the flashing 100 upon insertion into and removal from the jig 210, and the like. For example, the radius of curvature provided by the jig 210 (i.e., corresponding to radius R₁′ of the flashing 100) can be between about ⅙ of a major length of the flashing 100 and about 6 times the major length of the flashing 100, such as between about ⅓ of the major length of the flashing 100 and about a distance equal to the major length of the flashing 100. The major length refers to the longest dimension of the flashing, e.g., the length between the end dam flanges 142. Although not shown to scale, in the embodiment illustrated in FIG. 1, the flashing 100 is formed in a length of about 6 feet, and the jig 210 defines a curvature having a radius of 2 feet, 3 inches. According to one embodiment, after cooling in the jig 210, the flashing 100 can have a natural curvature with a radius R₁′ that is greater than the major length of the flashing 100, such as between about 1 and 10 times the major length of the flashing 100. For example, the radius R₁′ of a flashing that is 6 feet long can be between about 6 feet and 30 feet, such as about 15 feet, i.e., between about 1 and 5 times the length of the flashing, such as about 2.5 times the length of the flashing.

As indicated by reference numeral 208 of FIG. 6, and further illustrated in FIG. 10, the flashing 100 can be installed in a curved configuration and, in particular, curved about an axis that is generally parallel to the base member 112. That is, during installation, the flashing 100 can be bent about an axis B (FIG. 6) that is substantially perpendicular to an axis A (FIG. 6) about which the flashing 100 is curved during cooling in the jig 210. If the first edge 118 of the base member 112 is curved to define a greater length than the second edge 120 of the base member 112, the first edge 118 of the base member 112 can tend to curve to a radius R₁ that is equal to or slightly greater than the radius R₂ of the second edge 120 in the installed configuration. Thus, a sufficient angle can be maintained between the base member 112 and the face plate 122 so that the base member 112 is configured to direct water toward the second edge 120 when the face plate 122 is disposed against a vertical surface in an installation.

In the illustrated embodiment of FIGS. 6-10, the flashing 100 is curved about the first axis A (which is generally parallel to the plane of the face plate 122 and aligned with the midpoint of the length of the flashing 100) while cooling in the jig 210 and curved about the second axis B (which is generally perpendicular to the first axis A and parallel to the base member 112) when installed. In other embodiments of the present invention, the flashing 100 can instead be curved about the same axis during cooling and installation. That is, the jig 210 can be configured to support the flashing 100 in a configuration that is similar to the configuration desired for installation, i.e., the configuration illustrated in FIG. 10. In either case, the flashing 100 can be manufactured using a jig or, alternatively, by forming the flashing directly in the curved configuration, e.g., using a die that defines the desired curvature. That is, as indicated by reference numeral 209 in FIG. 6, the manufacture can proceed between the operations indicated by reference numerals 200 and 206 without the use of a jig. In this regard, the die, mold, or other structure used for forming the flashing 100 in the molding process 200 can be structured to define a curved configuration so that the flashing 100 is formed in the curved configuration and then supported by the die in the curved configuration, typically until the flashing 100 has at least partially cooled. It is noted that formation of the flashing 100 directly in the curved configuration can possibly complicate and increase the cost of manufacturing the dies and/or performing the molding process, though such a manufacture may be desired in some cases.

The curved flashing 100, which results from either direct forming in the curved configuration or cooling in the jig 210, can define a degree of curvature that is greater or lesser than the curvature of the window or portal and, hence, the installed flashing. That is, the flashing 100 can be curved to a greater or lesser extent during installation, though the pre-curvature of the flashing 100 generally improves the ability of the flashing 100 to take on the desired curvature while maintaining a desired orientation between the base member 112 and face plate 122. Typically, the flashing 100 can be pre-curved to a configuration that allows the flashing 100 to be used in portals having a range of sizes and curvatures.

Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. A method for manufacturing a flexible flashing for use in a portal installation in a curved opening of a wall, the method comprising: forming the flashing, the flashing comprising: a base member defining opposite first and second surfaces extending from a first edge to a second edge; and a face plate extending from the base member generally perpendicular to the base member, the face plate defining a first edge proximate the first edge of the base member and extending therefrom to a second distal edge; supporting the flashing in a curved configuration while heated and such that the first edge of the base member defines a first radius of curvature extending from an axis which is generally parallel to the face plate and the second edge of the base member defines a second radius of curvature from said axis, the first radius of curvature being greater than the second radius of curvature; and at least partially cooling the flashing in the curved configuration such that the flashing is structured to be installed with the face plate in a substantially planar configuration against the wall, the base member curved to correspond to the curved opening of the wall, and the base member disposed at a desired angle relative to the face plate.

2. A method according to claim 1 wherein said forming step comprises molding the flashing in a die.

3. A method according to claim 2 wherein said cooling step comprises at least partially cooling the flashing in the die, the die being structured to support the flashing in the curved configuration.

4. A method according to claim 1 wherein said forming step comprises molding the flashing as a unitary member of molten plastic.

5. A method according to claim 1 wherein said forming step comprises forming the flashing with each of the face plate and the base member in a substantially planar configuration, and further comprising bending the flashing to the curved configuration of said supporting step.

6. A method according to claim 1 wherein said supporting step comprises disposing the flashing in a jig subsequent to said forming step, the jig defining the curved configuration and being structured to restrain the flashing in the curved configuration.

7. A method according to claim 1 wherein said supporting step comprises supporting the flashing with the first radius of curvature being between about ⅙ of a major length of the flashing and about 6 times the major length of the flashing.

8. A method according to claim 1 wherein said supporting step comprises supporting the flashing with the first radius of curvature being between about ⅓ of a major length of the flashing and about a distance equal to the major length of the flashing.

9. A method according to claim 1 wherein said supporting step comprises supporting the flashing with the first radius of curvature being less than about 6 feet.

10. A method according to claim 1 wherein said supporting step comprises supporting the flashing with the first radius of curvature being less than about 3 feet.

11. A method according to claim 1, further comprising installing the flashing at the opening of the wall with the face plate disposed in a generally planar configuration and the base member disposed in a curved configuration corresponding to the curved opening of the wall, the base member being substantially perpendicular to the face plate and thereby configured to direct water in a direction from the first edge of the base member to the second edge of the base member.

12. A method according to claim 1, further comprising forming a plurality of channels in the first surface of the base member, the channels being configured to direct water in a direction from the first edge of the base member to the second edge of the base member and thereby direct water on the base member outward from the wall.

13. A method according to claim 1, further comprising forming a plurality of slots in the face plate, the slots extending from the second edge of the face plate toward the first edge of the face plate.

14. A method according to claim 1 wherein said supporting and cooling steps comprise cooling the flashing in the curved configuration such that the base member is structured to be disposed substantially perpendicular to the face plate when the face plate is installed in a planar configuration with the base member curved to correspond to the curved opening of the wall.

15. A flexible flashing for use in a portal installation in a curved opening of a wall, the flashing comprising: a base member defining opposite first and second surfaces extending from a first edge to a second edge; and a face plate extending from the base member in a plane generally perpendicular to the base member, the face plate extending from the first edge of the base member to a distal edge, such that the face plate is structured to be disposed against the wall with the base member disposed against the curved opening of the wall, wherein the flashing in an unloaded condition defines a curved configuration with the first edge of the base member defining a first radius of curvature extending from an axis which is generally parallel to the face plate and with the second edge of the base member defining a second radius of curvature extending from said axis that is lesser than the first radius of curvature such that the base member is structured to be disposed at a desired angle relative to the face plate when the flashing is installed with the face plate in a substantially planar configuration and the base member curved to correspond to the curved opening of the wall.

16. A flexible flashing according to claim 15 wherein the flashing is a unitary member formed of plastic.

17. A flexible flashing according to claim 15 wherein the first radius of curvature is between about 1 times a major length of the flashing and about 10 times the major length of the flashing.

18. A flexible flashing according to claim 15 wherein the flashing is structured to be installed with the face plate disposed in a generally planar configuration and the base member disposed in a curved configuration corresponding to the curved opening of the wall such that the base member is substantially perpendicular to the face plate and thereby configured to direct water in a direction from the first edge of the base member to the second edge of the base member.

19. A flexible flashing according to claim 15 wherein the flashing defines a plurality of channels in the first surface of the base member, the channels being configured to direct water in a direction from the first edge of the base member to the second edge of the base member and thereby direct water on the base member outward from the wall.

20. A flexible flashing according to claim 15 wherein the flashing defines a plurality of slots in the face plate, the slots extending from the edge of the face plate toward the base member.