AU2016100544B4

AU2016100544B4 - A flashing product

Info

Publication number: AU2016100544B4
Application number: AU2016100544A
Authority: AU
Inventors: Moustafa AL MASRI; Khaled ALLOUCH
Original assignee: Ews Roofing Pty Ltd
Current assignee: Ews Roofing Pty Ltd
Priority date: 2016-05-06
Filing date: 2016-05-06
Publication date: 2017-11-02
Anticipated expiration: 2024-05-06
Also published as: AU2016100544A4

Abstract

A FLASHING PRODUCT Abstract A flashing product 51 comprising an elongated rigid flashing 61 and an elongated flexible flashing 71 joined to the elongated rigid flashing, wherein the elongated flexible flashing and the elongated rigid flashing form an overlapping prefabricated flashing product able to seal an elongated intersection of vertical wall and pitch roof below.

Description

A FLASHING PRODUCT

Field of the invention [001] The present invention relates to a flashing product and in particular to a flashing product for a wall-roof joint of an upper storey.

[002] The invention has been developed primarily for use in/with an upper storey and will be described hereinafter with reference to this application. However, it will be appreciated that the invention is not limited to this particular field of use.

Background of the Invention [003] A flashing product is a protective member that is used to seal an intersection of a wall and roof or two other external surfaces. It is particular to keep the structure watertight by providing a specialised.

[004] Generally in wooden structures the outer wooden surface is formed by overlapping elongated boards extending horizontally. By the upper board overlapping the lower board any water running down the outer surface will continue downwards and not be able to seep into the building. However when reaching the lower portion of the wall the overlapping stops. Therefore at this point flashing is required to stop seepage into the building at the lower intersection. The aim of the flashing is to have the water continue on a downward path over the building structure below and thereby keep the building watertight. Flashing therefore generally needs to be malleable.

[005] There are generally three types of flashing.

[006] The first type is a rigid metal sheeting which is thin enough to be pressed and moulded into shape with substantial force such as with a hammer. However the bulk of the job undertaken by rigid metal sheeting in to stay in place and form a continuation of the outer surface by close fitting to the outer building material. The trouble with such flashing is when there are deviations from planar wall surfaces and difficulty in blocking small water channels behind the flashing due to the inconsistent outer building surface.

[007] A second type of flashing is a form of malleable sheet lead. This is particularly useful in that it can be readily manipulated into non-uniform areas and pressed tightly against the outer building surface. However such material is quite expensive. An even larger problem is that such material is very heavy. Therefore it is difficult to maintain a vertical orientation and difficult to use in large elongated locations. The weight of a 5 metre sheet can be extremely difficult and heavy to handle. Therefore this materia! is more useful for pointing situations or smal! areas and used in smaller sized portions.

[008] A third type is a flexible flashing material. This can be formed of a plastic base such as a polyurethane and have an outer waterproof malleable thin surface as a lead replacement. However due to the thinness of the material it is very lightweight and readily flexible. This has its benefits in allowing for the material to be shaped into unusual positions but generally then requires sealing around all of its edges, Therefore this form of material is usually used in small locations such as pointing or chimneys etc.

[009] It can be seen that in large areas the usual forms of flashing have substantial downfalls.

[0010] These problems are exacerbated due to the increased prevalence of two storey detached houses such as shown in Figure 1. In such houses the entire second storey is often over a verandah or lower floor roof around two three or four sides. Further if the base footprint is not merely a square shape but an extended U shape the amount of intersection between the upper storey vertical wall and the lower storey pitched roof or iower structure is extensive. Therefore the problems of prior art flashings are substantially limiting and causes problems including: a) in not allowing an easy construction technique; b) in greater risk of water seepage over extended amounts of intersecting surfaces; c) in difficulty in using such massively heavy material such as lead sheeting; d) in the extensive costs due to the material; e) in the extensive time troubles in sealing all of the intersections; f) in the lack of an effective flashing system that is in keeping with the time efficiencies of other building processes such as framing, wall building, roofing; g) in the lack of an effective flashing product.

[0011] The present invention seeks to provide a flashing product and system, which will overcome or substantially ameliorate at least one or more of the deficiencies of the prior art, or to at least provide an alternative, [0012] It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country.

Summary of the Invention [0013] According to a first aspect of the present invention, a flashing product is provided by a flashing product which includes an elongated rigid flashing and an overlapping elongated flexible flashing.

[0014] It can be seen that the invention of a flashing product provides the benefit of providing the benefits of two types of flashing in a single integrated product.

[0015] According to a second aspect of the present invention, a flashing product is provided a flashing product comprising an elongated rigid flashing; an elongated flexible flashing joined to the elongated rigid flashing, wherein the elongated flexible flashing and the elongated rigid flashing form an overlapping prefabricated flashing product able to seal an elongated intersection of vertical wall and pitch roof below.

[0016] It can be seen that the invention of a flashing product provides the benefit of versatility.

[0017] According to a third aspect of the present invention, a flashing product is provided wherein the elongated rigid flashing includes an overhang under which is joined the elongated flexible flashing and allowing the elongated flexible flashing to extend at an angle matching the pitch of the roof to the wall of the upper storey.

[0018] The elongated rigid flashing can comprise two elongated rigid planar flashing portions forming a vertical portion and an overhang portion extending at an angle relative to each other matching the pitch of the roof and wherein the overhang is overlapping the elongated flexible flashing.

[0019] Preferably the elongated rigid flashing is substantially planar and can extend along a lower portion of an upper storey wall and the overlapping elongated flexible flashing can extend over the adjacent roof to provide a waterproof sealing [0020] Preferably the elongated rigid flashing is substantially planar with a lower elongated deflecting overhang which overhangs the overlapping elongated flexible flashing wherein the elongated rigid flashing has a foldback which clamps the overlapping elongated flexible flashing beneath the overhang.

[0021] In one form the invention provides a flashing product including a flashing product comprising an elongated rigid flashing; an elongated flexible flashing joined to the elongated rigid flashing, wherein the elongated flexible flashing and the elongated rigid flashing form an overlapping prefabricated flashing product able to seal an elongated intersection of vertical wall and pitch roof below.

[0022] Preferably the elongated rigid flashing includes an overhang under which is joined the elongated flexible flashing and allowing the elongated flexible flashing to extend at an angle matching the pitch of the roof to the wail of the upper storey [0023] Preferably the elongated rigid flashing comprises two elongated rigid planar flashing portions forming a vertical portion and an overhang portion extending at an angle relative to each other matching the pitch of the roof and wherein the overhang is overlapping the elongated flexible flashing.

[0024] Preferably the elongated rigid flashing is substantially planar and can extend along a lower portion of an upper storey wall and the overlapping elongated flexible flashing can extend over the adjacent roof to provide a waterproof sealing [0025] The invention in one form provides a flashing product according to any one of the preceding claims wherein the elongated rigid flashing is substantially planar with a lower elongated deflecting overhang which overhangs the overlapping elongated flexible flashing wherein the elongated rigid flashing has a foldback which clamps the overlapping elongated flexible flashing beneath the overhang; wherein the a flashing product can be substantially assembled with improving security including any one or more of the following: i. improvements in structure and assembly including construction to minimise weight, cost, and to improve sealability; ii. Improvements in useability; iii. Improvements in versatility in allow ready adaptability for differently pitched roofs and walls and roofs of the same or different materials.

[0026] It can be seen that in another form the invention achieves an aim of providing effective flashing at the vertical wall of a higher storey over a pitched roof of a lower storey by way of a method of using one or more flashing products according to any one of the preceding claims including the steps of: a) Providing at least one of the flashing products in an elongated form; b) Attaching the rigid flashing portion to upright building surface above a sloping roof; c) Extending flexible flashing portion from rigid portion and attaching to sloping roof; d) At corners bending rigid portion length around corner and overlap with rigid flashing around corner; e) At corners provide a protruding end of flexible portion extending beyond rigid portion and extending around corner and overlap with flexible portion extending in opposite direction; wherein a continuously sealed flashing in provided around building.

[0027] Other aspects of the invention are also disclosed.

Brief Description of the Drawings [0028] Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

Fig. 1 is a general diagrammatic view of a building structure for which the flashing product in accordance with a preferred embodiment of the present invention can be used;

Fig. 2 is a detail of the general diagrammatic view of a building structure of Fig. 1; Fig. 3 is a diagrammatic cross sectional view of the detail of the diagrammatic view of a building structure of Fig. 2;

Fig. 4 is a photographic view of a flashing product in accordance with a preferred embodiment of the present invention;

Fig. 5 is a diagrammatic cross sectional view of the detail of the diagrammatic view of the flashing product of Fig. 4;

Fig. 6 is a diagrammatic front view of the detail of the an embodiment or modification of the flashing product of Fig. 4 having lateral extension portions enabling for flashing around corners of buildings;

Fig. 7 is a flow diagram of a preferred method of forming a flashing product of the invention;

Fig. 8 is a flow diagram of a preferred method of using one or more flashing products of the invention; and

Figs. 9 and 10 are diagrammatic views of various standard pitch angles of roofs to which the invention can be applied.

Description of Preferred Embodiments [0029] It should be noted in the following description that like or the same reference numerals in different embodiments denote the same or similar features.

[0030] The invention is primarily for but not limited to use in providing flashing for two storey detached houses such as shown in Figs. 1, 2 and 3. There is shown a house 11 having a first storey 21 and a second storey 22 capped by a roof 32. A pitched roof extends from the lower edge 41 of the second storey to overhang and form a verandah for the first storey 21. In other forms the first storey walls could extend downwards from substantially the outer edge of the pitched roof 31 to form a larger footprint for the first storey than the footprint for the upper storey 22.

[0031] The outer walls of the upper storey 22 can be a vertical wall covered with overlapping horizontal elongated boards, or board sheeting, or bricks or the like. The pitched roof 31 can form a continuous waterproof surface by being covered with overlapping tiles, or wooden or slate shingles or board sheeting or the like and have a pitch angle P°.

[0032] This pitch angle as shown in Figs. 9 and 10 is usually standardized and can be a of:

DELETION OF DRAWINGS AMP INSERTION AS FIGS 9 and 10 [0033] Cleariy water from rainwater can run down the outer wall 22 and can run down the pitched roof 31. However there is needed flashing at the intersection 41.

[0034] Flashing Product [0035] Referring to the drawings and particularly Figs. 3, 4 and 5 there is shown flashing product 51 for use in sealing the intersection 41 between the vertical wall of the upper storey 22 and the pitched roof 31 of the lower storey 21.

[0036] The flashing product 51 is an elongated form for extending along the elongated linear intersection 41 and includes an elongated rigid flashing 61 with an elongated flexible flashing 71 joined to the elongated rigid flashing to form an integrated flashing product 51 that can be readily used in fixed lengths such as 5 metres long. Due to the choice of thin rigid metal forming the elongated rigid flashing 61 and the lightweight polyurethane or the like flexible flashing 71 the weight of the overall flashing product is able to be handled by a single user and the materials are integrated and therefore can be readily attached to the upright wall of the upper storey 22 and be affixed to the upper surface of the pitched roof 31 to form a continuation of the rainwater path down the wall and over the roof without any possibility of seepage at intersection 41.

[0037] To ensure the water flows over the elongated rigid flashing 61 and over the elongated flexible flashing 71, the elongated rigid flashing 61 has an underneath foldback 64 extending from a front edge 65 which clamps the overlapping elongated flexible flashing 74 beneath the overhang and allows protrusion 72 beyond the front edge 65 of the elongated rigid flashing 61. This allows the elongated flexible flashing 72 to extend at an angle matching the pitch of the roof. Further the water can flow over the elongated rigid flashing 61 and the elongated flexible flashing 71 as they form an overlapping prefabricated flashing product 51 and not able to penetrate uphill and underneath the rigid flashing 61 beyond the U shape sealing formed by the overlapping flexible portion 74 in the foldback 64 and the and enables sealing of the elongated intersection 41 of vertical wall 22 and pitched roof 31 below.

[0038] In the form of the preferred embodiment shown in the drawings the flashing product 51 has the elongated rigid flashing 61 comprising a first elongated rigid planar flashing portion 62 forming a vertical portion and an overhang portion 63 extending at an angle relative to each other matching the pitch P° of the roof and wherein the overhang portion 63 is overlapping the elongated flexible flashing 74, The foldback 64 is used to clamp the overlapping elongated flexible flashing beneath the overhang.

[0039] Adaptability of Flashing Product [0040] In various embodiments of the flashing product there can be a range of heights X of the upright portion 62 of the rigid flashing 61 and the extension Y of the overhang portion 63 from the upright portion 62 to the front surface 65 of the foldback 64. Further extension Z can be altered so that there is adaptability to the amount 72 of the roof contacting portion 72 of the flexible flashing 71 to ensure suitable protrusion beyond the front surface 65 of the rigid flashing 61 and to ensure sufficient attaching surface to the roof 31.

[0041] Construction of flashing product [0042] A flashing product of the invention can be created in a novel and inventive manner by the flashing product being formed in a number of steps as shown in Fig. 7.

[0043] In step 101 there is the providing an elongated flexible flashing and in step 102 there is provided an elongated rigid flashing able to be bent under force.

[0044] Step 103 requires the capturing of the elongated flexible flashing 71 in a turnover 64 of an elongated edge of the elongated rigid flashing 61. This can be achieved by metal bending to form a front face 65 and an underneath turnover 64. Applying compression to the turnover 64 holds the elongated flexible flashing 71 permanently and fixedly to the rigid flashing 61. The elongated flexible flashing 71 has an upper surface 75 hat is presented to the weather and therefore has a water resistant and aesthetic look while the under surface 75 is adhesive to allow further integrating connection in the overhang 64 and contact adhesion to the roof 31.

[0045] In one example the flashing product 51 is formed as:

[0046] Therefore the elongated rigid flashing is substantially planar and can extend along a lower portion of an upper storey wall and the overlapping elongated flexible flashing can extend over the adjacent pitched roof to provide a waterproof sealing.

[0047] The forming of the flashing product 51 can be further formed after connection of the elongated flexible flashing 71 in turnover 64 of the elongated rigid flashing 61 by angling the rigid flashing at a predetermined spacing from the leading face of the turnover to form the diverging surfaces 62 and 63 of the elongated rigid flashing 61 to match the required pitch angle of the roof below.

[0048] It is important that weight of product is lightweight to allow extended lengths of the combined apparatus and the ability to mount in sections of the order of metres so as to be able to simply use on an entire house. If material is heavy or lengths are short or there is no predefined combined structures then the benefits of easy handling, simple construction, less required manpower is not achieved.

[0049] Use of flashing Product.

[0050] A flashing product of the invention can be used in a novel and inventive manner by the flashing product being used in a number of steps as shown in Fig. 8 to form a continuously sealed flashing in provided around building.

[0051] In step 111 there is the provision of at least one of the flashing products in an elongated form. Preferably these are in 5 metre lengths so that flashing process is efficient over large areas and extension of the intersections 41.

[0052] The process requires Step 112 of attaching the upper section 82 of the rigid fiashing portion 61 to coextending upright building surface above a sloping roof which matches in angle and coextends with the lower section 63; [0053] In Step 113 of extending flexible flashing portion 71 from rigid portion Li-shaped end section 65 which compressably holds the end of the flexible flashing portion and having plastic surface being peelable to reveal adhesive sticky contact surface. This attachment is by sticky adhesive 76 on lower section 72 of the flexible flashing portion 71 under the peelable plastic so as to attach onto the coextending tiles or corrugated roofing.

[0054] A substantial improvement in this product is in its use in sealing with the flashing products 51 around corners. As shown in Fig. 6, this can be accomplished in one form by having a 40 millimetre section of the rigid flashing 61 bent to extend around a vertical corner so as to continue to cover the horizontally extending intersection 41 around the corner. At corners the bending rigid portion length 66 around corner and overlap with rigid flashing around corner. Also at corners in Step 115 there is provide a protruding end 79 of flexible portion 71 extending beyond rigid portion 61 and extending up to 200 millimetres around corner and overlap with flexible portion 79 extending in opposite direction. In this way there is provided a continuously sealed flashing in provided around building.

Interpretation

Embodiments: [0055] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment, but may. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner, as would be apparent to one of ordinary skill in the art from this disclosure, in one or more embodiments.

[0056] Similarly it should be appreciated that in the above description of example embodiments of the invention, various features of the invention are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of one or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the claims following the Detailed Description of Specific Embodiments are hereby expressly incorporated into this Detailed Description of Specific Embodiments, with each claim standing on its own as a separate embodiment of this invention.

[0057] Furthermore, while some embodiments described herein include some but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the invention, and form different embodiments, as would be understood by those in the art. For example, in the following claims, any of the claimed embodiments can be used in any combination.

Different Instances of Objects [0058] As used herein, unless otherwise specified the use of the ordinal adjectives “first”, “second”, “third”, etc., to describe a common object, merely indicate that different instances of like objects are being referred to, and are not intended to imply that the objects so described must be in a given sequence, either temporally, spatially, in ranking, or in any other manner.

Specific Details [0059] In the description provided herein, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known methods, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

Terminology [0060] In describing the preferred embodiment of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as "forward", "rearward", "radially", "peripherally", "upwardly", "downwardly", and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

Comprising and Including [0061] In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” are used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

[0062] Any one of the terms: including or which includes or that includes as used herein is also an open term that also means including at least the elements/features that follow the term, but not excluding others. Thus, including is synonymous with and means comprising.

Scope of Invention [0063] Thus, while there has been described what are believed to be the preferred embodiments of the invention, those skilled in the art will recognize that other and further modifications may be made thereto without departing from the spirit of the invention, and it is intended to claim all such changes and modifications as fall within the scope of the invention. For example, any formulas given above are merely representative of procedures that may be used. Functionality may be added or deleted from the block diagrams and operations may be interchanged among functional blocks. Steps may be added or deleted to methods described within the scope of the present invention.

[0064] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.

Industrial Applicability [0065] It is apparent from the above, that the arrangements described are applicable to the building and renovation and roofing industries.

Claims

Claims The claims defining the invention are as follows:

1. A flashing product able to seal an elongated intersection between a vertical wall of an upper storey of a house and a pitched roof of a lower storey of the house, the flashing product comprising: a. an elongated rigid planar flashing comprising: a vertical portion for the vertical wall of the upper storey, an overhang portion extending at an angle to the vertical portion substantially matching the pitch of the roof, a front edge portion at a lower end portion of the overhang portion, and a foldback portion extending from the front edge portion underneath a portion of the overhang portion, wherein the overhang portion, front edge and foldback portion of the elongated rigid flashing form an elongate recess extending underneath the overhang portion b. an elongated flexible non-metallic flashing having a portion received in a clamping condition within the elongate recess of the rigid planar flashing extending underneath the overhang portion, and a portion extending beneath the elongate recess protruding beyond the overhang portion of the elongated rigid flashing, allowing the protruding portion of the elongated flexible non-metallic flashing to extend at an angle matching the pitch of the roof to the wall of the upper storey; wherein the overhang overlaps at least a portion of the protruding portion of the flexible non-metallic flashing, wherein the elongated flexible non-metallic flashing and the elongated rigid flashing form an overlapping prefabricated flashing product able to seal the elongated intersection of vertical wall and pitched roof below.
2. A flashing product according to claim 1 wherein the flashing product is formed by the steps including: a. providing an elongated flexible non-metallic flashing; b. providing an elongated rigid flashing able to be bent under force; c. capturing elongated flexible non-metallic flashing in a turnover of an elongated edge of the elongated rigid flashing; d. applying compression to the turnover to hold the elongated flexible non-metallic flashing; wherein the elongated rigid flashing is substantially planar and can extend along a lower portion of an upper storey wall and the overlapping elongated flexible non-metallic flashing can extend over the adjacent pitched roof to provide a waterproof sealing.
3. A flashing product according to claim 2 further formed including the steps of: e. angling the rigid flashing at a predetermined spacing from the leading face of the turnover to a required pitch angle of the roof below.
4. A method of using one or more flashing products according to any one of the preceding claims including the steps of: i. providing at least one of the flashing products in an elongated form; ii. attaching the rigid flashing portion to upright building surface above a sloping roof; iii. extending flexible non-metallic flashing portion from rigid portion and attaching to sloping roof; iv. at corners bending rigid portion length around corner and overlap with rigid flashing around corner; v. at corners provide a protruding end of flexible non-metallic flashing portion extending beyond rigid portion and extending around corner and overlap with flexible non-metallic flashing portion extending in opposite direction; wherein a continuously sealed flashing is provided around building.
5. A method of using one or more flashing products comprising: a. an elongated rigid flashing; b. an elongated flexible flashing joined to the elongated rigid flashing with the elongated rigid flashing having an underneath foldback which clamps the overlapping elongated flexible flashing beneath the overhang and allows protrusion beyond the elongated rigid flashing, allowing the elongated flexible flashing to extend at an angle matching the pitch of the roof to the wall of the upper storey wherein the elongated flexible flashing and the elongated rigid flashing form an overlapping prefabricated flashing product able to seal an elongated intersection of vertical wall and pitched roof below; including the steps of: vi. providing at least one of the flashing products in an elongated form; vii. attaching the rigid flashing portion to upright building surface above a sloping roof; viii. extending flexible flashing portion from rigid portion and attaching to sloping roof; ix. at corners bending rigid portion length around corner and overlap with rigid flashing around corner; x. at corners provide a protruding end of flexible portion extending beyond rigid portion and extending around corner and overlap with flexible portion extending in opposite direction; wherein a continuously sealed flashing is provided around building.