Patent Application
20050262782
The present invention relates generally to weatherproofing of windows and doors, and in particular to a self flashing assembly that aids in reducing moisture and air flow around a window or door.
Many of the current weatherizing installations for doors and windows provide inadequate protection from air and moisture. In some instances, contractors do not weatherize windows and doors to cut costs and labor. Where flashing is not installed with a door or window, or there is poor installation, air and moisture are able to pass around the window or door. Moisture can collect in the walls and cause a host of problems. Moisture deposits in a wall soak insulation material and greatly decrease the insulative effectiveness thereby requiring additional heating or cooling. Further, collected moisture due to poor flashing installation causes mold growth within walls. Mold can be a health concern for building occupants. Further still, the moisture allowed to collect within a wall does serious damage to the structure of a building, in some cases rotting out floors and/or walls around windows or doors.
In an attempt to weatherize doors and windows for stucco homes, building paper is applied to the wall surfaces. The building paper is disposed around window and door openings. The opening is lined with caulking and the window (or door) placed within the opening. Tape is subsequently applied around the window or door and extends to the building paper. Stucco or siding is then erected over the tar paper and taping. One disadvantage of this weatherizing installation is the need for multiple installation steps that increase labor costs. Additionally, if the caulking or tape is poorly applied breaches are present or develop over time. Such breaches allow moisture collection within the wall. To cut costs, in some instances contractors forego taping and simply erect stucco or siding around the window or door without otherwise weatherizing.
Another method for weatherizing doors and windows includes wrapping a protective barrier material around a building and trimming the material around openings in walls for doors and windows. Caulking is applied around the openings and the windows and/or door are placed in the opening. The windows or doors are then nailed into the wall surface through nailing fins extending from the windows or doors. The area around the windows and doors is then taped in a similar manner as described above. As above, with the installation for a stucco surface, increased labor is a disadvantage of this method. Further, if the tape, caulking, or elastomeric material are improperly applied gaps form that allow air passage and undesirable moisture collection within the wall.
What is needed is a flashing system that overcomes the shortcomings of previous weatherizing methods. What is further needed is a flashing system that decreases labor costs, installation time, and overcomes the problems associated with moisture collection.
A weatherproofing flashing assembly, for example a self flashing assembly, includes a frame for a window or door. Preinstalled flashing is coupled along the frame and includes overlapping portions substantially adjacent to at least one intersection of the flashing (e.g. the intersection of two ends of the flashing) so the flashing is continuous around at least a portion of the frame. In another option, preinstalled flashing includes flashing coupled to the frame prior to installation of the frame, for example, during manufacture of a window or door assembly.
Several options for the flashing assembly follow. In one option the flashing assembly includes brackets coupled to the frame. The brackets extend from the frame substantially parallel to a plane defined by the frame. In another option, at least a portion of the preinstalled flashing is adhered to frame. In yet another option, the preinstalled flashing includes at least one boss dimensioned and configured to engage with at least one groove on the frame to couple the preinstalled flashing to the frame. In still another option, at least one clamping member is coupled to the frame. The clamping member, in one example, secures the preinstalled flashing to the frame. The preinstalled flashing is self sealing, in another option. Optionally, the preinstalled flashing includes an adhesive disposed along at least a portion of one side of the preinstalled flashing. In another option, the preinstalled flashing is pliable, foldable and bendable.
In yet another option, the preinstalled flashing is coupled to the frame along at least an upper frame member and side frame members. The preinstalled flashing includes, in one option, overlapping portions substantially adjacent to at least two corners defined by the upper frame member and side frame members. The preinstalled flashing is coupled to the frame along a lower frame member, in another option, and the preinstalled flashing includes overlapping portions substantially adjacent to the side frame members and the lower frame member.
In another embodiment, a method for installing a weatherproofing flashing assembly includes providing a window frame. Flashing is coupled along the frame to form a window or door assembly prior to installation of the window or door assembly. Portions of the flashing are overlapped substantially adjacent to at least one intersection of the flashing. In one option, the flashing is continuous around at least a portion of the frame.
Several options for the method follow. In one option, securing the frame within the opening includes coupling at least one bracket extending from the frame to a surface such as a wall. In another option, a portion of at least one bracket is bent from a storage position. In the storage position, the bracket is adjacent to the frame. In yet another option, the frame is secured within a wall opening by coupling the flashing to the surface. In one example, the frame is secured by piercing the flashing and the surface with pins (for example nails, screws, staples or the like). In another option, the flashing self seals around the pins. In yet another option, engaging one side of the flashing to the surface includes adhering the flashing to the surface. In still another option, backing paper adhered to the flashing is removed therefrom. Removing the backing paper exposes the adhesive used to adhere the flashing to the surface, in one example. The flashing is unfolded from a storage position where the flashing is folded against the frame, in one option. In another option, engaging one side of the flashing to the surface includes overlapping a first flashing segment coupled to an upper frame member over a second flashing segment coupled to one side frame member and a third flashing segment coupled to another side frame member. In still another option, supplemental flashing is lapped over the first flashing segment, second flashing segment and third flashing segment substantially adjacent to the upper frame member and side frame members. Optionally, engaging one side of the flashing to the surface further includes overlapping the second and third flashing segments over a fourth flashing segment coupled to a lower frame member. Supplemental flashing is lapped over the second, third and fourth flashing segments substantially adjacent to the side frame members and lower frame member, in another option. In another option, the flashing is trimmed to fit within confined spaces, for example between closely spaced windows.
The weatherproofing flashing assembly for a window or door assembly allows for quick effective flashing installation. Error prone and labor intensive caulking and taping procedures are unnecessary with flashing coupled to the frame. Flashing and the door or window assembly are provided as a single unit. In one option, the flashing is preinstalled with the door or window assembly. The flashing and brackets for securing the frame within an opening are folded against the frame in a compact storage position. Installing the flashing involves unfolding it from the frame, engaging it to a wall surface and overlapping portions of the flashing segments with one another. If desired supplemental flashing is provided substantially adjacent to the upper member and side members, and side members and lower member. In another option, the flashing is rigid, or a combination of rigid and pliable portions, and engaged to the wall surface with nails or the like. A gasket is provided, if desired, substantially adjacent to the upper member and side members, and side members and lower member to further seal the flashing against moisture and air flow. Moreover, the overlapping nature of the flashing segments ensures a continuous substantially weatherproof barrier is disposed around at least the upper member and side members of the frame. Further, the pliable flashing allows for installation on nonstandard surfaces, for instance, between windows if the flashing is trimmed.
These and other embodiments, aspects, advantages, and features of the present invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art by reference to the following description of the invention and referenced drawings or by practice of the invention. The aspects, advantages, and features of the invention are realized and attained by means of the instrumentalities, procedures, and combinations particularly pointed out in the appended claims and their equivalents.
In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the present invention. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.
In the embodiment shown in
As shown in
In another option, the flashing 108 is coupled to a window assembly having a triangular, semicircular geometry, or the like. The flashing 108 includes segments coupled to the frame that overlap substantially adjacent to corners of the frame. In another option, the segments of flashing 108 overlap substantially adjacent to the intersections of the segments. Where the window assembly frame has a circular or ovular geometry the flashing 108 includes segments coupled to the frame that overlap, in yet another option, at least once at a location around the frame.
Referring again to
One suitable flashing 108 material includes a polyethylene base, for example, Tyvek® StraightFlash™, manufactured by DuPont of Wilmington, Del. or Grace Ice & Water Shield®, manufactured by Grace Construction Products of Cambridge, Mass. Other suitable flashing 108 materials include, but are not limited to, polyvinyl chloride, rubber or the like. The pliable flashing 108 is self sealing around nails, screws, and staples that may pierce the flashing during installation and application of exterior finishing systems (e.g. siding or the like). In other words, when pierced, the pliable flashing 108 seals around the nail, or the like. In another option, the flashing 108 is constructed from a more rigid material, for example, aluminum or zinc coated steel. The flashing 108, in yet another option, includes at least one rigid portion and a pliable portion. In one example, pliable supplemental flashing 121 is disposed along the rigid flashing 108, as described above, to provide a self sealing secondary barrier around the frame 102. In one option, the flashing 108 extends from the frame. The flashing 108 extends from the frame 102, optionally, at least 4 inches. The flashing 108 is coupled to the frame 102 during manufacture of the window assembly 100, in another option. In yet another option, the flashing 108 is preinstalled before installation of the window assembly 100 within an opening.
In one option, the window assembly 100 is secured to a surface with brackets 500, as shown in the perspective rear view of
To secure the frame 102 to a wall in an option, nails are driven through the brackets 500. In the example shown in
As shown in
Optionally, the gasket 600 is coupled to the flashing segments 114, 116, 118, 120 and/or wall system with an adhesive, nails, or the like, as described above with regard to the flashing 108. The gasket 600 is self-sealing and seals around nails or the like driven through the gasket 600 and flashing segments 114, 116, 118, 120 to seal punctures in the flashing segments. The gasket 600 further seals the window assembly 100 and provides enhanced weatherproofing. The gasket 600 augments the barrier against moisture and airflow provided by the flashing segments 114, 116, 118, 120. At least one gasket 600 and the window assembly 100 are optionally included with each other as a kit.
The flashing 108 includes a first flashing segment 114, second flashing segment 116 and third flashing segment 118. In a similar manner to the flashing 108 of window assembly 100, the flashing segments 114, 116, 118 overlap to define a continuous and substantially weatherproof barrier. The first flashing segment 114 and second and third flashing segments 116, 118 overlap substantially adjacent to the upper member 704 and side members 706, in one option. In another option, the flashing segments 114, 116, 118 overlap adjacent to the corners of the frame 702 defined by the upper member 704 and side members 706. The flashing segments 114, 116, 118 overlap at the intersections of the flashing segments 114, 116, 118, in yet another option. In this example, for a door assembly 700, the flashing 108 is constructed with similar materials described above for the window assembly 100. Optionally, flashing segments 114, 116, 118 are coupled to a wall with adhesive, tape, nails, screws, staples or the like. In one option, the door assembly 700 includes brackets to secure the frame 702 within a wall opening. In another option, where the flashing 108 is constructed with more rigid materials (described above) the door assembly 700 is installed without brackets and the fastening means (for example, nails, screws or staples) are driven through the flashing 108 into a wall. In still another option, where the flashing 108 includes more rigid materials, a pliable gasket or supplemental flashing is coupled to the flashing segments 114, 116, 118, as described above with regard to the window assembly 100. When the flashing segments 114, 116, 118 are coupled to a wall face, in one option, the gasket correspondingly engages the flashing segments and wall face to further seal the door assembly 700 and provide enhanced weatherproofing. An adhesive and/or fastening means (for example nails) are used to engage the gasket to the wall face, in another option.
In one option, the frame is secured within the opening with brackets bent from a storage position adjacent the outer perimeter of the frame into an orientation substantially parallel with a plane defined by the upper member and side members. The brackets are bent into this orientation before seating of the window assembly within a wall opening. In an option, the brackets extend from the frame to the face of a wall. In another option, the brackets include orifices. The orifices are dimensioned and configured to receive nails, staples, screws or the like to secure the frame within the opening.
In another option, before seating the window assembly, the flashing, including flashing segments are unfolded from a storage position where the flashing is folded adjacent the outer perimeter of the frame. In the option including brackets, the flashing segments are unfolded from the storage position before the brackets are bent into the orientation for securing the frame. In an example, the flashing segments lay over the brackets at least in the storage position. In another option, securing the frame within the opening includes coupling the flashing to the wall by piercing the flashing and wall with pins (including but not limited to nails, screws, staples or the like). In the option where the flashing is a pliable material, the flashing self-seals around the pins.
In yet another option, the flashing includes an adhesive that is covered with a backing paper. The backing paper is removed prior to engaging the flashing to the wall system surrounding the opening. The flashing is then adhered to the face of the wall system. In one option, the flashing is sufficiently pliable so it may be folded back away from the wall before adhering to allow for securing of the frame with the brackets (described above).
In still another option, the first flashing segment coupled to an upper frame member is overlapped over a second flashing segment and third flashing segment coupled to side frame members. In this option, disposing the first flashing segment over the second and third flashing segments allows accumulated moisture to run over the first segment and not otherwise leach behind the second and third flashing segments where it might otherwise seep to the inner side of the wall system. The overlap of the first segment over the second and third segments substantially prevents moisture from undesirably moving behind the flashing. In yet another option, the second flashing segment and third flashing segment are lapped over a fourth flashing segment coupled to a lower frame member (described above).
The flashing assembly described herein allows for quick effective flashing installation. Error prone and labor intensive caulking and taping procedures are unnecessary with flashing coupled to the frame. Preferably, the flashing and the door or window assembly are provided as a single unit from the manufacturer. In an example, the flashing comes preinstalled with the door or window assembly. The flashing and brackets, for securing the frame within an opening, are folded against the frame in a compact storage position. Installing the flashing involves unfolding it from the frame, engaging it to a wall system and overlapping portions of the flashing segments with one another. If desired supplemental flashing is provided substantially adjacent to the upper member and side members, and side members and lower member. In another option, the flashing is rigid, or a combination of rigid and pliable portions, and engaged to the wall system with nails or the like. A gasket is provided, if desired, along the flashing to further seal the flashing against moisture and air flow. Moreover, the overlapping nature of the flashing segments ensures a continuous substantially weatherproof barrier is disposed around at least the upper member and side members of the frame. Further, the pliable flashing allows for installation on nonstandard surfaces, for example between windows if the flashing is trimmed.
It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. It should be noted that embodiments discussed in different portions of the description or referred to in different drawings can be combined to form additional embodiments of the present application. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.
