554148
Patents Form # 5
III IIII mill II mil HI
*10055648920*
NEW ZEALAND
Patents Act 1953
COMPLETE SPECIFICATION
AFTER PROVISIONAL # : 554148 DATED : 27 March 2007
TITLE: FLASHING
We, VANLUK DESIGN LIMITED
Address: 33 Timothy Place, Avondale, Auckland, New Zealand Nationality: A New Zealand company do hereby declare the invention for which we pray that a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the following statement:
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- 1
FEE CODE 1050
intellectual property office of n.z
2 6 MAR 2008
RECEIVED
Received at IPONZ on 25 September 2009
FLASHING
The invention relates to a flashing system for penetrations in building construction and to a method of installation. The invention is directed particularly but not solely towards a flashing system for a cavity wall construction for penetration by various building services 5 and can be used for penetration through any wall or walls.
Background of Invention
Existing penetrations through walls such as cavity construction traditionally use foil backed butyl tape patch systems to air-seal around any building service like a pipe or cable 10 penetration. These systems and methods of air sealing are a mucky and scrappy way of attempting to peripherally seal around a penetration and are unsightly and imprecise in their effectiveness. Penetrations can be used by building services such as for example pipes,
cables or ducting which are required to be air or moisture sealed.
These types of penetrations are generally located between and adjacent to any supports or studs. An additional requirement is to maintain the fire rating of any particular building constructions and be flexible enough to 'ride' with any building movement or building services movement. There also can be problems with weatherproofing and vermin proofing.
Creating any air sealable penetration through a wall can be time consuming and messy. This type of work is highly dependent on workmanship and skill and does not allow for any later alteration or accidental movement or impact with the services.
In this specification unless the contrary is expressly stated, where a document, act or item of 25 knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was at the priority date, publicly available, known to the public, part of common general knowledge; or known to be relevant to an attempt to solve any problem with which this specification is concerned.
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Object of the Invention
It is an object of the invention to provide an improved flashing system and method of installation that ameliorates some of the disadvantages and limitations of the known art or at least provide the public with a useful choice.
Summary of Invention
In a first aspect the invention resides in a cavity wall flashing system for air sealing a penetration of a building service through a cavity wall construction to form a cavity wall air seal whereby said cavity wall construction includes a first wall spaced from a second wall to 10 form a cavity therebetween having inner surfaces therein, the flashing system including a flashing having a shaped body portion and sealing means, the flashing body portion comprising a first end and a second end and a flashing wall portion therebetween, with there being an outwardly extending flange portion at the first end of the flashing body, being adapted to in use be fixable to an inner surface of the first wall of the cavity, and an outer 15 surface of the building service is sealed to the flashing body whereby the flashing is adapted to allow the building service in use to be slidably moved in or out there-through to maintain the integrity of an air seal at the said first wall of the cavity, such that the cavity wall air seal is formed when the building service is positioned and in place, the second wall of the cavity is air sealing engaged to the building service.
Preferably the orientation of the flange is parallel to the base of the flashing.
Preferably the flange portion of the flashing is fixedly connected to the wall.
Preferably the flashing has a base that can be penetrated.
Preferably the flashing is ring-shaped to allow the building service to pass therethrough.
Preferably the ring shaped flashing is made up of elongate components which in use abut end 30 to end to form said ring.
Preferably the flashing body portion include a first channel portion having a depth which forms a recess in use which is facing away from said building service wherein said channel
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portion has re-entrant walls and is adapted in use to slidably capture a strap member having tensioning means such that the flashing is held against the building service.
Preferably there is a second channel portion which is less in depth than the first channel 5 which in use sealing abuts any building service when in use and said second channel includes a central rib therein.
Preferably the sealing means is a movable and flexible sealant which is applied between the building service and the walls.
Preferably, the flashing can be formed from thermoprene - extruded rubber and plastics.
Preferably the penetration or hole through the wall with the building service can be air and or moisture sealed.
In a second aspect of the invention there is disclosed a method of air sealing the penetration of building services through a cavity wall construction (including outer cladding and an inner wall of gib or RAB) using a cavity wall flashing system for air sealing a penetration of a building service through a cavity wall construction to form a cavity wall air seal whereby 20 said cavity wall construction includes a first wall spaced from a second wall to form a cavity therebetween having inner surfaces therein, the flashing system including a flashing having a shaped body portion and sealing means, the flashing body portion comprising a first end and a second end and a flashing wall portion therebetween, with there being an outwardly extending flange portion at the first end of the flashing body, being adapted to in use be 25 fixable to an inner surface of the first wall of the cavity, and an outer surface of the building service is sealed to the flashing body whereby the flashing is adapted to allow the building service in use to be slidably moved in or out there-through to maintain the integrity of an air seal at the said first wall of the cavity, such that the cavity wall air seal is formed when the building service is positioned and in place, the second wall of the cavity is air sealing 30 engaged to the building service, the method including;
- feeding the building service through a hole in the first wall and fixing to a wall support with a bracket;
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-selecting suitable flashing having a preformed hole therein that approximately corresponds to the building service diameter or thickness(will be slightly larger to allow sealing therebetween);
- affixing one side of a fixing tape to the underside of flange portion of the flashing; 5 -cleaning and or priming a surface of one of the walls or RAB/building wrap surface;
-sliding said flashing hole of the flashing, over said building service to meet said first wall; -fixing the flashing in place with the flange portion abutting the surface of the one wall and forming an airtight seal with the first wall;
-building service can then be slidably moved in or out of the hole to allow adjustment or 10 replacement or installation, while maintaining the air seal with the first wall;
-cutting another hole in the second wall;
- sliding said other wall over the building service to abut the flashing and
- making sure that the hole in the said second wall is larger enough to then apply a seal between the said second wall hole edge and outer surface of the building service to form an
air sealed cavity wall.
Preferably the method includes applying a tensioning strap to the outer periphery of the flashing and tensioning said strap against the outer surface of the building service.
Brief Description
The invention will now be described, by way of example only, by reference to the accompanying drawings:
Figure 1 is a perspective assembled and unassembled view of the flashing system in use. 25 Figure la is a front perspective view of the flashing.
Figure lb is a rear perspective view of the flashing.
Figure 2 is cross section of the flashing in place with water piper penetrating therethrough Figure 3 is another cross-sectional view with a cable penetration Figure 4 is a perspective view of another form of the flashing 30 Figure 5 is a cross section of the flashing of figure 4.
Figure 6 is a cross section of the installation of figure 4.
Figures 7-10 are cross sections showing the installation procedure for the flashing of figures 4 and 5.
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Figure 11 is a cross section of a wall section using two flashings.
Description of Drawings
The following description will describe the invention in relation to preferred embodiments of 5 the invention, namely a flashing. The invention is in no way limited to these preferred embodiments as they are purely to exemplify the invention only and that possible variations and modifications would be readily apparent without departing from the scope of the invention.
As shown in figures 1-3 there is shown a flashing system including a flashing 1 having body portion 2 being generally hat-shaped forming a recess therein having an outer edge 3 at a lower end forming a flange, said recess forming an open area and at an upper end of the hat-shaped body portion, there is an inner edge 4 forming a base of the body portion. There is a perpendicular distance 5 forming walls therebetween the open surface area and base surface 15 area of the hat shape. The flashing walls can be orientated at any angle with respect to the flashing base and flange such as for example at an angle as shown in figures 1-3 or at right angles as shown in figures 4-6. The flashing can be located through a wall wherever one needs to direct any building service. Generally this location is between any vertical wall supports or studs and is also adjacent to those studs.
Said distance 5 can be less in dimension that the thickness or depth dimension 7 of a first cavity 6 in a cavity wall construction or can be such a dimension as to allow another wall panel to cover the flashing to form the cavity 6. For example dimension 7 can be 20mm. Cavity wall construction includes a typical construction formed by the cavity 6 between two 25 walls 8 & 9 having battens or studs or framing 10 therebetween. Cavity 6 is likely to be a ventilated and drained outer cavity which can be for example 20mm thick. The walls 8 and 9 can be formed of any material combinations such as wallboard, cladding with or without building paper to form a building wrap etc but in this example wall 8 minimally includes a rigid air barrier (a panel as in figure 1) or a flexible air barrier such as building paper (figures 30 2 & 3). Wall 9 can be any material adapted to provide adequate weather proofing with or with out coatings.
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In use the wall 8 can be termed an inner wall having an inner wall surface 8A and outer wall surface 8B. Wall 9 can be termed an outer wall having an inner wall surface 9A and outer wall surface 9B. The outer edge 3 of the flashing 1 forms a periphery of an in use outwardly facing planar ring shaped surface 11 being adapted to affix to wall surface 8A of a wall 8 5 with said wall surface 8A being within cavity 6. The periphery can be any shape extending from the wall though a ring shape or circular shape or flange is shown in the figures. Cavity 6 can be thought of as an outer cavity in a typical wall construction which is located closest to the outside of any building.
As shown in figures 2 and 3 wall 8 can be abutted and affixed to any support structure 12 such as for example a timber stud wall having studs and nogs or dwangs which in turn though not shown can have an internal wall layer (plaster board for example) to form an inner cavity 15 having an inner wall 16
Ring shaped surface 11 of flashing 1 can have fixing means 13 thereon allowing attachment to any other surface such as wall surface 8 A. Fixing means 13 can be for example separately attached to or formed with the flange. Some examples of fixing means are self adhesive tape or adhesive/glue in combination with or without other forms of fastening.
Base surface 4 is formed of a penetrable thickness dimensioned and adapted to allow any building service 14 to enter the sealingly penetrate there-through and through the cavity 6 in either direction. To form any penetration through the flashing 1 this can be carried out by separately forming an aperture in the base surface 4 by punching or drilling or cutting which can done before installation or after installation of the flashing. Alternatively the penetration
can be formed by the building service 14 itself eg self drilling.
The flashing 1 can be used with any type of building services 14 such as for example pipes having an outer surface as shown in figure 2 (typical penetration is through the building wrap and exterior cladding like for a water pipe and tap) or cables as in figure 3 or ducts as in
figures 4-6. The flashing 1 can be fabricated from rubber or rubberized plastics or any material that allows for a flexible sealing fit with any type of building service.
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As shown in figure 2 outer wall 9 can be for example 'Eterpan' 8mm thick cladding or outer cladding, the building wrap can include building paper 15 as shown in figures 2 & 3 and flashing 1 can be for example MG-50 with fixing seal. Wall cladding 9 can have an external coating 17 thereon and timber framing 10 can include vertical studs and 94x44 nogs 5 (oriented vertically). Also shown are means 18 for drainage within cavity 6 which includes Xpress clad horizontal runners with the cladding shown as being panels separate by a gap 19 of 10mm.
In figure 3 for the cable 14 for an electrical fitting such as a light, there is shown the same 10 ventilated and drained cavity (20mm) and flashing 1 (MG-50 with fixing seal), external cladding 9 can be for example cement panels such as Eterpan 9mm thick having an external coating, with the inner wall 8 can be formed of a cement sheet and building paper, framing 10 can include H3 battens with internal framing having 94x44 nogs. As shown in figures 2 and 3, sealant S can be applied to the periphery of the building service 14 and the outer 15 cladding sheet 9. This sealant S can also be applied to the outside face and to the hole through the flashing 1, to seal around the building service as required. The material type or combination as selected for flashing 1 and also the other flashings of this specification, can be self sealing in that they can be flexible/resilient/malleable to seal against any of the periphery of a penetration by a building service(s) or any gap there-through.
For the flashing 1 as shown in figures 1-3 there is also disclosed a method of penetration of building services (eg pipe) through a cavity wall (for example having outer cladding and inner wall) construction using a flashing system whereby a building service can sealingly penetrate through the wall construction and flashing. The method includes:
-cut a neat hole or aperture in any wall barrier or rigid air barrier (RAB);
- feed your pipe through the hole and fix to an appropriate adjacent stud using a suitable bracket (in a new build this would be done before the internal linings are fitted giving access from the inside of the building);
- select suitable flashing having a preformed hole therein (or one that can be formed) that 30 corresponds approximately to the pipe size and die cut butyl tape ring being double peel backed with wax paper;
-peel waxed paper from one side of die cut butyl tape ring;
- affix the sticky side of the tape ring to the underside of flange of flashing;
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- clean and or prime the surface of one ofnt eh walls like for example an inner wall of a cavity which can include or be RAB/building wrap surface;
- peel back waxed paper from the remaining side of the die cut butyl tape ring;
- fix the flashing in place with the flange portion of the flashing abutting the RAB/building 5 wrap;
- cut anther hole in the outside cladding sheet or outer wall;
- slide cladding sheet over the building service (eg pipe or cable) to abut the flashing and
- make sure that the hole in the cladding sheet is larger enough to slidably fit over the pipe and
- then apply a seal between the sheet edge and pipe (eg any air gap between the pipe and inner or other wall) in accordance with a sealant manufacturer's recommendations to form a weather tight or air seal complementing the modern cavity design.
In a variation to the above method the penetration through the wall or cavity walls can be 15 created after attaching the flashing to the wall surface or the sealing can be carried out for the RAB before cutting the hole for the cladding sheet.
In figures 4-10 there is shown a variation in a flashing system including a flashing 30 whereby it can be formed using an extrusion process which is more useful for larger 20 penetrations through walls and cavities. Flashing 30 is generally ring shaped which can be formed as one piece or in elongate components which can be end abutted to form the ring. In use they can be formed or wrapped around the outer surface of the build service (eg a pipe having an outer surface) and then adhere to the wall inside the cavity and then strapped by tensioning to the pipe outer surface. Similarly to the flashing of figures 1-3 the material of 25 the flashing needs to be formed of a material type that allows it to be extruded or moulded and be flexible enough in a sealing sense to allow it to seal around any penetration during both installation of itself and during installation of the building service. Additionally as before the flashing is only fixed to one of the walls that form the cavity which allows the pipe or building service to be moved or replaced without the air seal being damaged.
As shown in figures 4 and 6 there is a proposed cavity 40 which is provided initially with only one wall 41 which is in use can be an inner wall 41. This cavity 40 can be termed an outer cavity having an outer frame (not shown) therein which is ventilated with drainage
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means. An outer wall 43 (can be 9mm cladding mechanically fixed using lOg SS screws x 20mm) is attached to the outer frame 42 after installation of the flashing 30. A penetration 44 which, is for example, a duct having an outer surface 45. Inner wall 41 has an outer surface 46 and inner surface 47 while outer wall 43 has an inner surface 48 and outer surface 5 49. Outer surface 49 is external to a building 50. Inner wall 41 can be part of an inner cavity 51 having a frame (not shown) therein and a wall 52 which can be internal lining eg plaster board.
This type of flashing is especially useful in allowing for larger air seal penetrations in certain types of construction such as for large ducting and pipes. As shown in figures 4 & 5 the 10 installation includes a flashing 30 (eg MG 100 pipe flashing with fixing tape) having a general hat shape with an open top end 32 to fit the pipe through and bottom closed end 33 joined in between by a wall portion 34 and various sealing means 35 and fixing means 36. Open end 32 form a planar ringed surface 37 and bottom end 33 forms a planar base surface 38.
However in another orientation as shown in the figures, flashing 30 which if considering the hat shape which included the whole flashing in cross section, can now be narrowed to one cross section which still has a top end 32 and bottom end 33 but is in general a double channel shaped section with channel walls and a channel base whereby one of the channels is 20 larger 53 than the other 54. For the larger channel 53 one of the channel walls comprises a first vertical channel wall portion 55 with a strengthening rib 56 protruding therefrom and into a channel 57.
Also for the larger channel 53 there is a second channel wall portion 58 parallel to the first 25 channel wall portion 55 but being shorter in length. Another rib 59 protrudes from wall portion 58 which mutually opposes and faces rib 56 to form a re-entrant channel for the larger channel.
The smaller channel 54 which faces outwardly in a mutually opposing direction to the larger 30 channel 53 extends from a common planar base 60 having an outwardly protruding rib 61. Walls 58 of the smaller channel 54 both protrude beyond the base 60 at a distance similar to rib 61 to form the smaller channel 54 (non re-entrant), being oriented on the opposite side of the channel base.
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In use the smaller channel 54 sealingly abuts the circular peripheral surface 45 of the penetration 44. Sealer is used to fill any gap between all the walls 43 and 41 and peripheral surface 45 of the penetration 44, If the flashing is formed in two halves then with a tension 5 means 63 which can be in the form of a tie or metal strap/band or cable for example, which in use fits within the outwardly facing larger channel 53 of the flashing, can be used to maintain the flashing shape around the pipe which is wrapped or cold formed around the pipe and then tightened.
As shown in figure 5 the left hand side wall can be 20mm in length, right hand side wall can be 9mm, the width can be 18mm, the re-entrant portions can be 4mm, the gap between the re-entrant portions can be 6mm, and the depth of the slot is 3mm.
During installation of the flashing 30 as shown in figures 7-10 the following steps can be 15 used for at least one flashing 30 and a pipe/cable-building service:
1. figure 7-form building having an inner cavity 51 formed with a frame between internal lining 52 and inner wall 47;
2. Figure 8 - create hole/penetration for building service (eg pipe) through lining 52, cavity 51 and inner wall 47 and between framing;
3. Figure 8 -seal between inner wall 47 and pipe as shown;
4. Figure 9- slide or cold form component parts of flashing 30 over pipe to fix and affix fixing tape to outer surface 46 of inner wall 41;
. figure 10- attach outer wall 43 with hole, over pipe 44 to meet or abut outer short wall 34 of flashing 30.
6. Figure 10- seal gap between the hole and outer surface of pipe.
These steps can be varied without effecting the end result depending on the installers preferences such as for example the holes in the flashing can be formed after being provided with the pipe or cable or ducting or the sealing as shown in figure 8 can be carried out when 30 installing the flashing.
For another type of large penetration as shown in figure 11, there is another flashing system for which there can be two flashings 30 and 31 with one being attached to inner wall surface
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46 while a second flashing can also be inserted in the same cavity 40 which will be adjacent to the first flashing and attached to the inner surface 48 of the outer wall 43. The flashings here can be made up of halves or ring components as required or desired. The installation includes the following steps of:
1. forming building having inner wall 41;
2. forming hole in inner wall 41;
3. pushing pipe through hole of inner wall 41;
4. applying tape to an outer surface of a first channel wall portion (larger wall portion or rim/flange portion of a hat shape flashing body) of the first flashing, facing inwardly of the
building 50;
. wrapping two halves of one of the flashings around the pipe with flashing first channel wall portion 55 abutting the inner wall surface of the cavity 40;
6. applying and tighten straps to make first flashing tied to both the one surface of the cavity and the flashing to the pipe outer surface using the tape;
7. now for the second flashing which is to be attached to the outer wall panel 43;
8. wrap two halves of second flashing around protruding pipe 44 such that it can be located a set distance from the first flashing 30 but being oriented in a mirror image to have the first channel wall portion 55 facing outwardly;
9. place double sided tape on outwardly facing surface of the second flashing;
10. slide outer wall 43 with hole over the pipe to abut the one exposed side of the tape;
11. apply sealant between hole in the outer wall 43/inner wall 41 and the pipe outer surface 45 (a gap)
This method can be varied in several ways such as for example sealing inner wall 44 before 25 attaching second flashing to the pipe or starting the procedure having only the outer wall 43 first and then applying the inner wall 41 lastly. Any number of flashings and walls and cavities can be combined. The flashings of this specification can include just the flashing or any part which can be sold separately as is or the part or flashing can be sold in a kit form having an assembly or system with instructions which can include sealant, preformed holes 30 with a range of hole sizes and overall flashing diameters and depths (base to flange distance), with tensioning means like the strap or an integral tightening method
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To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the description herein are purely illustrative and are not intended to be in any 5 sense limiting,
Advantages a) Provides air and moisture seal for penetration of any building service(s) through a cavity wall construction.
b) Such a flashing system can be used on any wall or cavity wall.
c) Modest manufacturing cost d) Simple installation e) Allows for later installation of any building services therethrough without the flashing seal being damaged.
f) Can be extruded or moulded.
g) Flashing can be made in ring components h) Flashings can be made with a preformed hole therein or the hole can be created during installation.
i) Straightforward method of installation
Variations
Throughout the description of this specification, the word "comprise" and variations of that word such as "comprising" and "comprises", are not intended to exclude other additives, components, integers or steps.
Any number of cavity walls or just walls can be formed together or any number of flashings can be used together or separately. Each flashing can be formed in one single piece or it may be formed in parts.
It will of course be realised that while the foregoing has been given by way of illustrative 30 example of this invention, all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is hereinbefore described.
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