AU2008203092A1 - Flashing System - Google Patents

Description

14-JUL-2008 15:40 A J PARK 64 9 3566990 P.03 00 n 32o ReguIation 3.2

AUSTRALIA

PATENTS ACT, 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name of Applicant: Actual Inventors: Address for service in Australia: Invention Title: FLETCHER BUILDING HOLDINGS LIMITED McCLEW, Ian Kurt and PEEL, John A J PARK, Level 11, 60 Marcus Clarke Street, Canberra ACT 2601, Australia Flashing System The following statement is a full description of this invention, including the best method of performing it known to us.

COMS ID No: ARCS-198131 Received by IP Australia: Time 13:47 Date 2008-07-14 14-JUL-2008 15:41 A J PARK 64 9 3566990 P.04 -2o0 The present invention relates to a flashing system and related flashing components, o combinations, assemblies or subassemblies, methods of use and the like, Profiled cladding sheets whether of a metal or other material (eg, fibre cement, plastic whether fibre reinforced or not, etc) nevertheless need to accommodate joinery for opening into a structure whether the true building envelope or not. Of particular concern are opening that arc to receive window frames or door frames.

C'I The present invention recognises that that use of for example, long run metal cladding S forms such as those typified by our range of products (www.dimond.co.nz) or as in our New S Zealand registered design number 408759 will be enhanced if such products can be offered in 00 10 conjunction with an easy to use flashing system for such openings. The present invention 0 recognises an advantage to be derived from a method of sealing such cladding sheets to a flashing CN prior to fitment of a window frame and/or window flange about the opening.

It is therefore an object of the present invention to at least provide the public with a useful choice for a flashing system and related aspects of it as previously stated.

In this specification the term "cladding panel" is defined as a panel for use on the exterior of a building, the panel being made from metal, plastic or any other suitable material, and being a panel which may be of a corrugated shape or otherwise.

In this specification the term "profile features" is defined as the corrugations or other features present in the a cladding panel. They may run horizontally or vertically.

In an aspect the invention consists in a head for an opening in a building where the building is clad at least in part by multiple panels having horizontally extending profile features, the head comprising: a first and upper flashing affixed to a structure inwardly of the opening and extending outwardly of the opening towards a said panel, a second or lower flashing commencing beneath the upper flashing and extending underneath a lower region of a cladding panel to outwardly of joinery of or for said opening, and wherein the construction and arrangement being such that moisture underneath the cladding that descends onto the upper most flashing is passed as a flow down around the outside of the lower flashing.

Preferably said lower flashing has a cross section at least to some extent conforming to a horizontally running profile feature of the cladding panel. Alternatively vertically running.

Preferably said lower flashing includes spacing features or attachments to allow ventilation to the cavity behind the cladding panel above both flashings.

COMS ID No: ARCS-198131 Received by IP Australia: Time 13:47 Date 2008-07-14 14-JUL-008 15:41 A J PARK 64 9 3566990 -3o 0 Preferably the upper flashing is anchored to the framing behind a cavity batten.

O Preferably the upper extremity of the lower cavity is provided with a hemmed, beaded or other type edge.

Preferably the jomnery is a window frame.

Preferably such a flashing arrangement is used in combination with jamb flashing and/or sill flashing as disclosed herein and/or our New Zealand patent application 556554. The full content of which is herein included by way of reference.

I To a further aspect the present invention consists in either of the flashing components as S foresaid.

0 10 Preferably either or each of said flashing components is substantially as hereinafter :O described with reference to any one or more of the accompanying drawings.

In another aspect the invention consists in a building assembly which includes lapping cladding sheets, the cladding sheets have profiled features that extend horizontally, wherein from the frame and/or from behind a batten a first longitudinally mounted flashing extends downwardly and outwardly, and wherein from below and behind the outward extent of the first flashing, a second longitudinally mounted flashing extends outwardly and downwardly over a joinery assembly.

In a further aspect the invention consists in an assembly comprising or including: a claddable structure having an opening therein, an upper sheet as a cladding panel carried by said structure, a lower sheet as a cladding panel carried by said structure and underlapping a lower part of the upper sheet, an upper horizontally extending flashing member, a lower horizontally extending flashing member, and a window, door or the like assembly in and/or at said opening, wherein said upper flashing member depends from the structure over the opening behind part of said upper cladding sheet, and wherein said lower flashing member laps outside of and down over at least part of said window, door or the like assembly, and wherein at or adjacent the window, door or the like assembly receiving opening, in use, moisture descending behind said upper cladding sheet will be passed by said upper flashing member to between said lower flashing member and said upper cladding sheet to descend outside of the opening.

COMS ID No: ARCS-198131 Received by IP Australia: Time 13:47 Date 2008-07-14 14-JUL-2008 15:41 A J PARK 64 9 3566990 P.06 -4- 0 In another aspect the invention is a flashing suitable as a lower flashing as aforesaid, being S elongate with a cross section defining: a top region that is generally concave on its inside and correspondingly generally Sconvex on its outside (ii) an outreach descending region from the bottom of the top region, and (iii) a descending return from the outreach descending region.

c1 Preferably the top region on its generally concave outside is profiled (eg, by adhered foam S or by other means) to ensure a air passageway will always exist, in use, between such a top region and the general concavity of a horizontal run corrugation of a cladding sheet by which it is to be lapped.

SIn another aspect the invention is a head flashing assembly of a door or window which has C a pair of elongate members mounted with their longitudinal axes at least substantially horizontal to define a pair of mantles, each mantle descending from a proximal region to a distal region, with a first mantle (ie, that mantle more inwardly mounted or located at its proximal region having a distal region) to feed water on its outside downwardly over the outside of the other mantle ("second mantle") behind the exterior cladding from whence that second mantle can feed the water downwardly below beyond the exterior cladding.

In yet another aspect the invention is a flashing suitable as an upper flashing as aforesaid, being elongate with an obtuse inner angled shape cross-section.

In another aspect the invention is, as part of a building having a joinery assembly, closed opening and panel cladding with horizontal nm or vertical run profile features, and a top flashing assembly, flanking jamb flashing assemblies, and a sill flashing assembly, wherein the top flashing assembly is as defined herein, and/or wherein the jamb flashing assemblies are as defined herein or in out New Zealand patent application 556554.

In our NZ556554 the compressible strip or matrix extends transversely beyond the substrate to effect a seal with the flange or sash of the joinery.

Preferably the top flashing assembly protects (eg, as if a mantle) from above each top end region of a jamb assembly.

Preferably the sill flashing assembly is as defined herein or in out New Zealand patent application filed simultaneously herewith.

COMS ID No: ARCS-198131 Received by IP Australia: Time 13:47 Date 2008-07-14 14-JUL-2008 15:42 A J PARK 64 9 3566990 P.07 0 o As used herein the term "and/or" means "and" or or both.

SAs used herein the term following a noun includes, as might be appropriate, the singular or plural forms of that noun.

In this specification where reference has been made to patent specifications, other external documents, or other sources of information, this is generally for the purpose of providing a context for discussing the features of the invention. Unless specifically stated otherwise, reference to such OC external documents is not to be construed as an admission that such documents, or such sources of information, in any jurisdiction, are prior art, or form part of the common general knowledge in the S art.

N, 10 Preferred embodiments of the present invention will now be described in detail with o reference to the accompanying drawings, in which: CN Figure 1 is a perspective view of a jamb flashing, Figure 2 is a perspective view of a jamb flashing with a cladding panel, Figure 3 is a plan view of a window showing a jamb flashing, Figure 4 is front view of a window with a flashing system, Figure 5 is a cross-sectional view of section A-A of Figure 4, Figure 6 is a cross-sectional view of section B-B of Figure Figure 7 is a cross-sectional view of a sill flashing showing the window flange, Figure 8 is a perspective view of the exterior of a flashing assembly, Figure 9 is another perspective view of the exterior of a flashing assembly, Figure 10 is a perspective view of the exterior of a flashing assembly showing a head flashing end cap, Figure 11 is a cross-sectional view of a head flashing assembly showing a spacer, Figure 12 is a front view of a head flashing assembly showing the locations of spacers, Figure 13 is an alternative head flashing, Figure 14 is a further alternative head flashing, Figure 15 is a further alternative head flashing, Figure 16 is a front view of a preferred head flashing showing two spacers, and Figure 17 is a cross-sectional view of section C-C of Figure 13.

Figure 1 shows a perspective view of a jamb flashing 1. The jamb flashing 1 includes an elongate member 2. The elongate member 2 is preferably L-shaped and formed from extruded aluminium, but may be formed from any other suitable material and manufactured using any other suitable method such as roll forming or pressing.

COMS ID No: ARCS-198131 Received by IP Australia: Time 13:47 Date 2008-07-14 14-JUL-2008 15:42 A J PARK 64 9 3566990 P.s08 -6o The inside surfaces 5 and 7 of the elongate member 2 may have compressible strips 3 and 4 o located thereon- The compressible strips 3 and 4 extend perpendicularly from the inside surface and are parallel to the inside surface 7 of the elongate member 2. The compressible strip 3 may be c affixed to the inside surface 7 by any suitable attachment means such as gluing for example. The compressible strip 4 may, in turn, be affixed to the compressible strip 3 by any suitable attachment means. Alternatively, the compressible strips 3 and 5 may both be affixed to die inside surface 5 and may or may not be affixed to the inside surface 7 also.

Whilst it is optional that the compressible strips 3 and 4 are separate items (so as to have S different compressibility). Preferably, the compressible strips 3 and 4 are formed as a unitary item N 10 by any suitable method such as moulding or extrusion. The compressible strips arc preferably 0 O formed from a compressible material such as foamed rubber. The foamed rubber may be nitrile or RPDM closed cell foam strip for example. If the compressible strips are formed as a unitary item, it may be attached to either inside surface 5 or 7, or both, by any suitable attachment means.

A rubber strip 8 may be located on the inside surface 5 and the exposed surface of the compressible strip 4. The rubber strip 8 is preferably butyl rubber which is adhesively attached the surfaces. It is preferred that the rubber strip 8 is a unitary item to avoid a transitional gap attached to the exposed surface of the compressible strip 4. It extends beyond the substrate, laterally of the substrate, to seal to the joinery.

With reference to Figure 2 there is shown a jamb flashing 1 which receives a cladding sheet 10. The cladding sheet 10 is preferably steel such as COLOURSTEELT cladding for example.

Alternatively the cladding sheet 10 may be plastic or any other suitable material such as fibre cement.

The edge 11 of the cladding sheet 10 may be received into the exposed face 12 of the rubber strip 8. The compressible strips 3 and 4 may compress as a result of pressure from the cladding sheet 10. This arrangement of the cladding sheet 10 and the flashing 1 creates a seal. In use, this seal restricts moisture from penetrating the jamb flasling and entering a window or door on which the jamb flashing is incorporated.

The rubber strip 8 may help to restrict damage to the compressible strip 4 as a result of the sharp edge 11 of the cladding sheet 10 contacting it. The rubber strip 8 is preferably a tear resistant strip. The rubber strip 8 is preferably paintable and UV resistant. The resistivity to UV damage ensures the seal provided by the compressible strips is not compromised.

The compressiblec strips 3 and 4 extend in such a way so that the thickness of die two compressible strips is less when beyond the edge 6 of the elongate member 7. This can be achieved by having a compressible strip 3 which extends farther from the inside surface 5 than its COMS ID No: ARCS-198131 Received by IP Australia: Time 13:47 Date 2008-07-14 14-JUL-2008 15:42 A J PARK 64 9 3566990 P.09 -7- 00 accompanying compressible strip 4 and the accompanying rubber strip 8. Likewise if use a unitary O compressible strip as in Figures 11 and 12 of our New Zealand Patent Application 556554.

The height of the inside surface 7 and the compressible strips 3 and 4 is dictated by the profile of the cladding sheet 10 which engages with the jamb flashing 1. For example, a cladding S 5 sheet 10 of a greater depth may require a larger dimensioned inside surface 7 and compressible strips 3 and 4.

C, Figure 3 shows a plan view of a window incorporating the jamb flashings 1. The cladding Ssheets 10 are pressed up against the rubber strip 8 and the compressible strips 3 and 4 to create a L seal which restricts moisture from entering through the flashing. The cladding sheets 10 are affixed N 10 to the elongate member 2 at the point 20. The cladding sheets are preferably affixed at point Susing rivers. However bolts may be used as an alternative to rivets. The cladding sheets 10 are also C affixed to cavity battens 21. Window flanges 22 are located on the jamb flashings 1. The window flanges 22 are located so that they slightly compress the extended ends 24 of the compressible strip 3. The window flanges 22 may support a glass panel 25. The glass panel 25 is in line with the window opening 23 of a wall of a structure.

The sill flashing 26 is located horizontally and below the window opening 23. The top face of the sill flashing 26 may support the jamb flashings 1 in their vertical orientation.

Figure 4 is a front view of a window with a flashing system. The cladding sheets 30 are located so that their corrugations extend horizontally. The cladding sheets 30 are received by the jamb flashing which is located under the side window flange 22.

The upper extent of the top window flange 32 is covered by a head flashing 31. The head flashing 31 extends over the top window flange 32 to prevent moisture from entering the window flashing system, it therefore may act as a mantle. The head flashing 31 and the cladding sheets underlap a top cladding sheet 35. This lapping arrangement of the head flashing 31 and the cladding sheets 30 ensures moisture does not enter the flashing assembly.

Figure 5 shows a cross sectional view of Figure 4 through A-A. The lapping relationship of the cladding sheet 30 and the top cladding sheet 35 is shown. The cladding sheet 30 laps underneath the top cladding sheet 35. The cladding sheet 30 is located to be received by the jamb flashing 1 and may have a lapping arrangement with the bottom cladding sheet Figure 6 shows a cross sectional view of Figure 4 through B-B. The head flashing 31 has folds lines 41 and 42. The fold line 41 creates an overlap with the top window flange 32 so that the head flashing 31 can extend over the window flange. The fold line 42 orientates the upper end of COMS ID No: ARCS-198131 Received by IP Australia: Time 13:47 Date 2008-07-14 14-JUL-2008 15:43 A J PARK 64 9 3566990 -8- 00 the head closure strip so it can assume a lapping relationship with the top cladding sheet 35. A 0 O curved section 43 is complementary with a corrugation of the top cladding sheet A head closure strip 44 extends from the recess between the top cladding sheet 35 and the t head flashing 31. The head closure strip 44 has a substantially vertical upper portion which may engage with a cavity batten 45 of the structure in which it is incorporated. The head closure strip 44 may be affixed to the wall frame (not shown) behind the cavity batten 45 by any suitable means such as nailing or screwing.

The head flashing 31 and the head closure strip 44 are preferably made from sheet metal such as steel or aluminium, however any other suitable material may also be used.

Figure 7 is a cross sectional view of a sill flashing 50. The sill flashing 50 butts to the jamb O flashing 1. The sill flashing includes an elongate member 51. 'he elongate member 51 is preferably C-1 L-shaped and formed from extruded aluminium, but may be formed from any other suitable material and manufactured using any other suitable method such as roll forming or pressing. The jamb flashing I is bottom end slotted in order to allow the cladding 56 to slide into it.

The inside surface 52 of the sill flashing 50 has a compressible strip 53 located thereon.

The compressible strip 53 extends perpendicularly from the inside surface 52. The compressible strip 52 is preferably affixed to the inside surface 57 of the elongate member 51 by any suitable attachment means such as gluing for example. Alternatively, the compressible strip 52 may be affixed to the inside surface 52 and may or may not be affixed to both inside surfaces 52 and 57.

The compressible strip 53 is preferably formed from a compressible material such as foam rubber. The material is preferably Nitrile or fEPDM closed cell foam. The bottom window flange 54 is located on, and may slightly compress the compressible strip 53- 'he bottom window flange 54 may support a glass panel in place.

A bottom cladding sheet 56 is affixed through the elongate member 51 and a cavity batten 59 to the wall frame (not shown) at point 55 preferably with a screw 58. Alternatively, the bottom cladding sheer 56 may be affixed using any suitable fastening means such as nailing, riveting or bolting. It is desirable that a cladding sheet as in Figure 7 has flashing member arm 52 being contacted by two corrugations to reduce any rotational tendency even if there is no similar fixing to that at The bottom cladding sheet 56 may extend such that the edge is engaged with the compressible strip 53.

The sill flashing 50 may support the weight of a window.

COMS ID No: ARCS-198131 Received by IP Australia: Time 13:47 Date 2008-07-14 14-JUL-2008 15:43 A J PAOM 64 9 3566990 P.11 -9- 00 o Figure 8 shows the exterior of a flashing assembly. The bead flashing 31 is shown to o extend over the top window flange 32 to prevent moisture entering the flashing above the top S window flange 32. The cladding sheet 30 and the head flashing 31 are in an under lapping i arrangement with the upper cladding sheet With reference to Figure 9, the cladding sheet 30 is received by the jamb flashing 1 in a sealing engagement.

C, Figure 10 shows the exterior of a flashing assembly with a head flashing end cap 40 located 0O o thereon. The end cap 40 has two slots 41, one on each side. The slot 41 can engage with an edge of Cn S the head flashing 31. As there is a slot 41 on each side, the end cap 40 can be utilised on either ends OO 10 of a head flashing assembly. The end cap 40 has a curved edge 42 which is complementary with the Scurved profile of the cladding sheet 30. This complementary engagement helps to ensure to

C

s moisture does not enter the flashing assembly through the open end.

The end cap 40 or any other cap profiling to the cladding may be made moulded out of plastic or manufactured in any other suitable way and from any other suitable material such as metal.

Figure 11 shows a head flashing assembly. A spacer 50 is located between the head flashing 31 and the top cladding sheet 35. The spacer 50 ensures there is a gap between the head flashing 31 and the top cladding sheet 35. The air gap allows the pressure in the cavity 51 to equalize with the outside pressure. T'he dimensions of the spacer 50 is dictated by any building codes that may apply, preferably the spacer is at least 1mm in thickness.

The spacer 50 is preferably made out of foam but may be made out of any other suitable material such as plastic or rubber.

Figure 12 shows a front of a head flashing assembly. The spacers 50 are located periodically along the width of the head flashing assembly. Their spacing allows air to enter the window cavity between the top cladding sheet 35 and the head flashing 31.

Three alternative head flashings 31 arc shown with reference to Figures 13 to 15. Such head flashings 31 may be adopted depending on the dimensions of the cladding sheet Figure 16 shows a preferred head flashing 31 with spacers 50 located thereon. As shown in Figure 17, the spacer 50 may be applied to the curved region of the head flashing 31 and may be sufficiently flexible so that it conforms with the curved region.

COMS ID No: ARCS-198131 Received by IP Australia: Time 13:47 Date 2008-07-14

Claims (1)

14-JUL-2008 15:43 A J PARK 64 9 3566990 P.12 00 THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS: O O 1. A head flashing assembly, of, for or suitable for an opening in a building where the building is clad at least in part by multiple panels having horizontally extending profile features, the head comprising: S a first and upper flashing affixed to a structure inwardly of the opening and extending outwardly of the opening towards a said panel, a second or lower flashing commencing beneath the upper flashing and extending underneath a lower region of a cladding panel to outwardly of joinery of or for said opening, and S t wherein the construction and arrangement is such that moisture underneath the cladding C 10 that descends onto the upper most flashing is passed as a flow down around the outside of the lower O flashing. Cl 2. A head flashing assembly of claim 1 wherein the panels have horizontally extending profile features. 3. A head flashing assembly of claim 2 wherein said lower flashing has a cross section at least to some extent conforming to the horizontally extending profile features of the cladding panel. 4. A head flashing assembly of any one of the preceding claims wherein the lower flashing is elongate with a cross section defining: a top region that is generally concave on its inside and correspondingly generally convex on its outside (ii) an outreach descending region from the bottom of the top region, and (iii) a descending return from the outreach descending region. A head flashing assembly of claim 4 wherein the top region of the lower flashing has at least one spacing feature located thereon to ensure a air passageway will always exist, in use, between such a top region and a cladding sheet by which it is to be lapped. 6. A head flashing assembly of claim 5 wherein said at least one spacing feature is a foam spacer affixed to the top region of the lower flashing. 7. A head flashing assembly of any one of the preceding claims wherein the joinery is a window frame. 8. A head flashing assembly of any of the preceding claims wherein the upper flashing is affixed to the framing behind a batten. 9. A head flashing assembly of any one of the preceding claims wherein the upper flashing is elongate with an obtuse inner angled shaped cross-section. COMS ID No: ARCS-198131 Received by IP Australia: Time 13:47 Date 2008-07-14 14-JUL-2008 15:44 A J PARK 64 9 3566990 P. 13 11 o- 10. A building assembly which includes lapping cladding sheets, the cladding sheets having Sprofiled features that extend horizontally, wherein from behind a batten a first horizontally mounted flashing extends downwardly Sand outwardly, and wherein from behind the outward extent of the first flashing a second horizontally mounted flashing extends outwardly and downwardly over a joinery assembly. C 11. A building assembly for a claddable structure having an opening therein, the building S assembly comprising or including: San upper sheet as a cladding panel carried by said structure, C, 10 a lower sheet as a cladding panel carried by said structure and underlapping a lower part of 0 the upper sheet, C1 an upper horizontally extending flashing member, a lower horizontally extending flashing member, and a window, door or the like assembly in and/or at said opening, wherein said upper flashing member depends from the structure over the opening behind part of said upper cladding sheet, and wherein said lower flashing member laps outside of and down over at least part of said window, door or the like assembly, and wherein at or adjacent the window, door or the like assembly receiving opening, in use, moisture descending behind said upper cladding sheet will be passed by said upper flashing member to between said lower flashing member and said upper cladding sheet to descend outside of the opening. 12. A flashing being elongate with a cross section defining: a top region that is generally concave on its inside and correspondingly generally convex on its outside (ii) an outreach descending region from the bottom of the top region, and (iii) a descending return from the outreach descending region. 13. The flashing of claim 12 wherein the top region on its generally concave inside is profiled (eg, by adhered foam or by other means) to ensure a air passageway will always exist, in use, between such a top region and the general concavity of a horizontal run corrugation of a cladding sheet by which it is to be lapped. 14. As part of a clad building assembly for a claddable structure having an opening therein, an assembly comprising or including: COMS ID No: ARCS-198131 Received by IP Australia: Time 13:47 Date 2008-07-14 14-JUL-2008 15:44 A J PARK 64 9 3566990 P. 14 -12- o0 a top flashing assembly, o flanking jamb flashing assemblies, and a sill flashing assembly, c- wherein the top flashing assembly is as claimed in any of claims 1 to 9. S 5 15. A building assembly as claimed in claim 14 wherein the top flashing assembly protects (eg, as if a mantle) from above each top end region of a jamb assembly. C, 16. A head flashing assembly as described with reference to any one or more of the o accompanying drawings. o¢ 17. A building assembly as described with reference to any one or more of the accompanying drawings. O 18. A head flashing assembly of a door or window which has a pair of elongate members C, mounted with their longitudinal axes at least substantially horizontal to define a pair of mantles, each mantle descending from a proximal region to a distal region, with a first mantle (ie, that mantle more inwardly mounted or located at its proximal region having a distal region) to feed water on its outside downwardly over the outside of the other mantle ("second mantle") behind the exterior cladding from whence that second mantle can feed the water downwardly below beyond the exterior cladding. COMS ID No: ARCS-198131 Received by IP Australia: Time 13:47 Date 2008-07-14