US20060137263A1 - Modular flashing system - Google Patents

Modular flashing system Download PDF

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US20060137263A1
US20060137263A1 US11013223 US1322304A US2006137263A1 US 20060137263 A1 US20060137263 A1 US 20060137263A1 US 11013223 US11013223 US 11013223 US 1322304 A US1322304 A US 1322304A US 2006137263 A1 US2006137263 A1 US 2006137263A1
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surface
modular
flashing
extension
right
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Jeff Casey
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Jeff Casey
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    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/62Tightening or covering joints between the border of openings and the frame or between contiguous frames
    • EFIXED CONSTRUCTIONS
    • E06DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06BFIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B1/00Border constructions of openings in walls, floors, or ceilings; Frames to be rigidly mounted in such openings
    • E06B1/62Tightening or covering joints between the border of openings and the frame or between contiguous frames
    • E06B2001/628Separate flexible joint covering strips; Flashings

Abstract

The present invention relates generally to modular flashing systems for use in the construction industry. It provides a plurality of modular flashing entities and modular trim flashing elements designed to be used in concert. The articles provide a unitary structure essentially impervious to atmospheric and environmental elements. The invention provides a modular flashing entity including a first surface, a second surface having a proximal edge and a distal edge removed from the proximal edge, as well as a left end and a right end, wherein the first surface joins the second surface along the proximal edge, and a third surface joined to the second surface along the distal edge thereof In many embodiments an additional fourth surface joined to a left end or to a right end of the second surface and further joined to the third surface. These are useful as drip caps and flashing pans when installing items such as doors and windows. The invention also provides a modular trim flashing element including a first surface and a second surface, wherein the first surface is joined to the second surface at a proximal edge thereof and wherein the first surface has a left end and a right end, wherein the first surface may have extension tabs, or not. The invention also provides kits including the items described above for the convenience of the customer. Additionally the invention provides methods of rendering a portal in a building essentially impervious to atmospheric and environmental elements that employ the modular articles provided herein.

Description

    FIELD OF THE INVENTION
  • The present invention relates broadly to a modular flashing system for use in the construction industry. More specifically, the modular flashing system is installed in various apertures of a building to render the apertures impervious to atmospheric and environmental elements.
  • BACKGROUND OF THE INVENTION
  • Construction of residential and commercial buildings involves introduction of various apertures such as doors, windows, and similar openings to allow passage of individuals and ventilation, for example. These apertures represent potential sources of penetration of undesired elements from the atmosphere or the environment, such as wind, rain, ice, snow, sleet, dust, sand, pollen, and the like. In order to minimize the occurrence of such penetration flashings may be installed during construction. Flashings currently in use include those that are installed by hand at the time of construction of the aperture, using objects or pieces that are initially unformed, and that are fashioned by the craftsperson to fit the aperture. This process is inefficient and laborious. Presently known flashings include a molded one-piece entry door flashing pan (U.S. Pat. No. 5,542,217), and a combination including a horizontal header section, corner sections which are fitted to either end of the header section, and vertical drainage channels, intended primarily as a retrofit for installation into door and window openings where the original waterproofing system has failed (U.S. Pat. No. 6,119,416).
  • In view of the present systems known to the craftsperson, there is an unmet need for a flexible flashing system that accommodates to any size of aperture, and furthermore, to any shape of aperture. Additionally there remains a need for a flashing system that is rapidly installed regardless of the shape of the aperture. There further remains a need to move beyond fixed, standard flashing systems currently in use. The present modular flashing system addresses these needs.
  • SUMMARY OF THE INVENTION
  • The present invention relates generally to modular flashing systems for use in the construction industry. By providing a plurality of articles designed to be used in concert the modular flashing systems are highly flexible with regard to the size and shape of the apertures with which they can be used. In this way architects, contractors, construction engineers and related personnel can rely on a single system, or a small number of systems, to accomplish their objectives. Once installed, the articles of the invention provide a unitary structure essentially impervious to atmospheric and environmental elements.
  • In a first aspect the invention provides a modular flashing entity including
      • a) a first surface,
      • b) a second surface having a proximal edge and a distal edge removed from the proximal edge, as well as a left end and a right end, wherein the first surface joins the second surface along the proximal edge, and
      • c) a third surface joined to the second surface along the distal edge thereof
        As constructed, the modular flashing entity is such that a first direction at which the first surface extends from the proximal edge of the second surface is generally opposite to a second direction at which the third surface extends from the distal edge of the second surface. Furthermore, the modular flashing entity is fabricated such that either
      • i) at least one of a left extension of the first surface extends beyond the left end of the second surface, and a right extension of the first surface extends beyond the right end of the second surface, or
      • ii) the first surface has no extension.
        In important embodiments the modular flashing entity further includes a fourth surface joined to a left end or to a right end of the second surface and further joined to the third surface; i.e., the fourth surface extends from the end of the second surface in a direction that is generally the same as the direction that the third surface extends from the distal edge of the second surface, thus permitting the third and fourth surfaces to be joined to each other. The modular flashing entities are fabricated such that the joined first surface, second surface, third surface, and fourth surface when present form a unitary structure essentially impervious to atmospheric and environmental elements.
  • In an additional important embodiment of the modular flashing entity, a) the second surface is approximately perpendicular to the first surface, and b) the third surface is approximately perpendicular to the second surface. Furthermore, in certain important embodiments of the modular flashing entity, the first surface, the second surface, and the third surface are each essentially planar surfaces. In certain alternative important embodiments of the modular flashing entity, at least the second surface is nonplanar. In still additional embodiments of a modular flashing entity with a nonplanar second surface, the second surface is generally concave facing in the direction established by the first surface. In yet additional important embodiments of the modular flashing entity, the material used for each of the first surface, the second surface, the third surface, and the fourth surface if present, includes a substance chosen from among a metal, a plastic, a polymer, a resin, or a combination of two or more of these substances. The surfaces may all be made of the same material, or they may separately be made of different materials.
  • In a second aspect the invention provides a modular trim flashing element including a first surface and a second surface, wherein the first surface is joined to the second surface at a proximal edge thereof and wherein the first surface has a left end and a right end, wherein either
      • a) a left extension of the first surface extends beyond the left end of the second surface, or a right extension extends beyond the right end of the second surface, or both a left extension and a right extension are present; or
      • b) there is neither a left extension nor a right extension;
        wherein the joined first surface and second surface form a unitary structure essentially impervious to atmospheric and environmental elements. In an advantageous embodiment of the modular trim flashing element the first surface is approximately perpendicular to the second surface.
  • In yet an additional aspect the invention provides a kit including two or more modular flashing entities described in the paragraphs above. In a significant embodiment, the kit further includes at least one modular trim flashing element. The modular trim flashing element includes a first surface and a second surface, such that the first surface is joined to the second surface at a proximal edge thereof The first surface furthermore has a left end and a right end, such that either
      • a) a left extension of the first surface extends beyond the left end of the second surface, or a right extension extends beyond the right end of the second surface, or both a left extension and a right extension are present; or
      • b) there is neither a left extension nor a right extension.
  • In still an additional aspect the invention provides a kit that includes two or more modular flashing entities having a first surface, a second surface, a third surface, and a fourth surface described in the preceding paragraphs. In advantageous embodiments, this kit further includes at least one modular trim flashing element described in the preceding paragraph. In yet additional advantageous embodiments, any kit of the invention includes modular flashing entities wherein the first surface, the second surface, and the third surface are each essentially planar surfaces. In still further advantageous embodiments, any kit of the invention includes modular flashing entities wherein at least the second surface is nonplanar.
  • In yet a further aspect the invention provides a method of sealing a portal in a building against atmospheric and environmental elements, the method including affixing one or more modular flashing entities described in the preceding paragraphs to the portal such that
      • i) the second surface of the flashing entity contacts a portion of the portal framing, and
      • ii) the first surface of a flashing entity contacts an exterior surface of the building adjacent to the portal.
  • In a significant embodiment of the method, the modular flashing entity further includes a fourth surface joined to a left end or to a right end of the second surface and further joined to the third surface; i.e., the fourth surface extends from the end of the second surface in a direction that is generally the same as the direction that the third surface extends from the distal edge of the second surface, thus permitting the third and fourth surfaces to be joined to each other. In yet an additional significant embodiment of the method, the one or more modular flashing entities seal a portal that is generally a rectilinear opening. When the portal is rectilinear, a further significant embodiment of the method further includes affixing at least one modular trim flashing element to the portal, wherein a modular trim flashing element includes a first surface having at least one extension, joined to a second surface at a proximal edge thereof and having a left end and a right end, wherein an extension of the first surface extends beyond the left end of the second surface, or beyond the right end of the second surface, or beyond both ends of the second surface. In yet an additional significant embodiment of the method, the one or more modular flashing entities seal a portal that is at least partly curvilinear. When the portal is curvilinear, an additional significant embodiment is such that the portal includes a circular, elliptical, hyperbolic, parabolic or other curvilinear segment. In yet additional significant embodiments of the method, the affixing includes at least one of gluing, bonding, nailing, screwing, or riveting. In still further significant embodiments of the method, at least one extension of a first surface of a modular flashing entity or at least one extension of a first surface of a modular trim flashing element overlaps a surface of a neighboring modular flashing entity or modular trim flashing element. In yet additional significant embodiments of the method the overlapping surfaces are affixed to each other to provide a sea that is essentially impervious to atmospheric and environmental elements.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1. Schematic representation of a rectilinear portal including a drip cap modular flashing entity (top) and a pan flashing modular flashing entity (bottom).
  • FIG. 2. Schematic representation of a rectilinear portal including modular trim flashing elements along the vertical portions.
  • FIG. 3. Schematic representation of a left pan flashing modular flashing entity and a right pan flashing modular flashing entity.
  • FIG. 4. Schematic representation of a left drip cap modular flashing entity and a right drip cap modular flashing entity.
  • FIG. 5. Schematic representation of a modular flashing entity showing optional left and/or right extensions.
  • FIG. 6. Schematic representation of a modular trim flashing element showing optional left and/or right extensions.
  • FIG. 7. Schematic representation of a curvilinear portal including modular flashing entities affixed therein.
  • DETAILED DESCRIPTION OF THE INVENTION
  • The present invention provides a modular flashing system that includes various embodiments of a modular flashing entity, and various embodiments of a modular trim flashing element, as well as methods for employing these manufactures in the construction industry. The modular flashing system affords protection from penetration of wind, rain, snow, sleet, dust, sand, pollen and similar detrimental atmospheric and environmental elements. The various entities and elements that constitute a modular flashing system are easy to manufacture, easy to install, and afford the ultimate in flexibility and modularity concerning the flashing of the various apertures of a building, as well as attached structures such as decks.
  • As used herein, the term “modular” and similar terms and phrases relate to a component in a system, or to the system that includes such components, wherein the components are designed to be used together in a way that accommodates installations in locations of varying sizes, shapes and designs. Modular flashing components are fitted together and installed adjustably such that apertures and openings are conveniently flashed regardless of size, shape and characteristics.
  • As used herein the terms “portal”, “aperture”, “opening”, and similar terms and phrases relate to an opening in the wall of a building intended, during construction of the building, to accommodate incorporation of a door, a window, a vent, or any related object introduced into the wall of the building.
  • As used herein the term “surface” and similar terms and phrases relate to a portion of an article of manufacture having a first face and a second face on opposite sides of the surface with respect to each other. The thickness of the surface, i.e., a distance measured between the first and second faces, is finite, yet small compared to the length and width of the surface. A surface is considered synonymous with a “sheet”.
  • As used herein the terms “horizontal” and “vertical” when used to describe a surface or a sheet relate to the respective surface or sheet being generally horizontal or generally vertical after the modular flashing entity or modular trim flashing element of which it is a part is installed into a portal that itself has horizontal and vertical segments. For example, a portal may have a horizontal header and sill, and vertical frame faces. Use of “horizontal” and “vertical”, however, is not limiting in describing the invention, and is intended to extend generally to any shape of rectilinear portal even if it includes edges that are other than strictly horizontal or vertical.
  • As used herein, a “normal” to a surface at a particular point is a geometric construct that is perpendicular to the surface as it is defined at the particular point. This meaning assures that even if a surface is not planar, a plane tangential to the surface at the particular point is to used to construct the normal.
  • As used herein, the phrase “approximately perpendicular”, and similar phrases, relates to defining the relationship between two surfaces joined to each other. In determining that a surface is approximately perpendicular to another, the normals used to establish perpendicularity may or may not intersect in three-dimensional space. All that is required is that a projection of a first normal onto a plane containing a second normal intersects with the second normal, and is approximately perpendicular to it. Thus the projection of the first normal may be exactly 90 degrees to the second normal, or deviate from 90 degrees by up to ±1 degree, or up to ±2 degrees, or up to ±4 degrees, or up to ±7 degrees, or up to ±10 degrees, or even a somewhat greater deviation, and still be considered to define surfaces that are approximately perpendicular to each other.
  • In determining whether surfaces are approximately perpendicular to each other, a first normal on one surface is established at a position closest to the point on the second surface at which the second normal is established. From this it is understood that the first normal is reasonably close to a point near the edge joining the two surfaces that is the shortest distance on the second surface from the point where the second normal is established. Alternative methods of establishing whether two surfaces are perpendicular to each other, known to artisans in the field of the invention, may also be used.
  • As used herein the phrase “a first direction that is generally opposite to a second direction”, and similar phrases, relate to directions established with respect to the two faces of a single surface. Opposite directions relate to directions that lead, on the one hand, away from a first face of the surface or sheet, and, on the other hand, away from a second face of the surface or sheet.
  • As used herein, the phrase “unitary structure”, and similar phrases, relate to surfaces joined to each other to form a single, integrated structure, having no openings or discontinuities. A unitary structure is impervious to the passage of a fluid at all locations.
  • As used herein, the phrase “atmospheric and environmental elements”, and similar terms and phrases, relate generally to components of the atmosphere and the environment which are intended to be excluded from the interior of a building. Without limitation, these may include rain, fog, mist, other forms of water, snow, sleet, other forms of ice, wind, dust, sand, pollen, particulate matter, and the like.
  • As used herein, the term “affix” and similar terms and phrases, relate generally to permanently fixing a modular flashing entity or a modular trim flashing element to a portal frame. The resulting installation is impervious to atmospheric and environmental elements. Affixing may be accomplished, by way of nonlimiting example, by binding, bonding, use of nails, use of screws, use of rivets, use of staples, gluing, cementing, caulking, and so forth. Any equivalent way of affixing the object to the portal frame is within the scope of the invention.
  • A portal is typically framed into a building's structure. As used herein, there is an exterior face of the building a portal has an exterior face adjacent the opening of the portal that is essentially continuous generally with the exterior face of the building. In the nonlimiting example of residential construction, the exterior face includes sheathing, such as plywood sheathing, and is generally considered to be part of the portal framing. Likewise a portal has an interior face adjacent the opening of the portal that is essentially continuous generally with the interior face of the building. The wall of a building generally has a certain depth of a few or several inches. The frame of the portal extends the full extent of this depth with a “frame face” that is substantially perpendicular to both the interior face of the portal and to the exterior face of the portal. In the nonlimiting example of residential construction, the depth of the frame face may commonly be defined by the use of 2″×4″ studs, or 2″×6″ studs, and so forth.
  • A portal generally may have any shape designated by an architect, designer, or contractor. Common shapes included within the scope of the invention are defined as rectilinear, e.g., shapes having four linear edges intersecting at right angles to each other, such as rectangles and squares. Other rectilinear shapes include triangles, trapezoids, pentagons, and so forth, without limitation for purposes of this invention. Additionally portals that fall within the scope of the invention include generally any portal with curvilinear edges, i.e., edges that are not linear and do not intersect with adjacent edges with defined angular values. Such portals have shapes, by way of nonlimiting example, that are circular, oval, elliptical, sectors of such shapes, sectors of other geometric constructs such as hyperbolic, parabolic, and generally defined by any trigonometric or transcendental function.
  • During construction of a building, a door, a window, or a comparable object is installed into a portal. Frequently but not in all cases these items are preassembled with thresholds, jambs and related framing components, and the entire assembly is introduced into the aperture as a single unit. Once installed, casement trim and related finishing are installed; these integrate the assembly or object with the edges of the portal and adjacent sheathing.
  • Advantageous embodiments of the invention are used in rectilinear portals, especially in rectangular or square portals. In the Figures accompanying this disclosure, the same reference number may be used in more than one Figure if it refers to the same component. In addition, in all the Figures accompanying this disclosure, the objects portrayed are not necessarily rendered to scale. FIGS. 1 and 2 show generally a rectangular portal that may be, by way of nonlimiting example, a door, viewed from the exterior of a building. The portal is designated by dashed lines, and has a frame face 12 seen in profile in FIGS. 1 and 2. The exterior casement trim surrounding the installed article has an outside edge shown in FIGS. 1 and 2 by 12. That is, the casement trim is installed over the exterior face defined by 12 and 14 in FIGS. 1 and 2. In a nonlimiting example of a portal for a door, or a window, the upper segment of the framing may be termed a “header”, the lower segment may be a “sill”, and the sides may be “jack studs”.
  • A complete installation of a modular flashing system surrounds all appropriate portions of a single object installed in a portal. For sake of clarity, in embodiments of a modular flashing system used in a rectilinear portal, portions of the system are separately represented in FIGS. 1 and 2. Nevertheless, it is to be understood that these separately represented components actually constitute components employed as the flashing for a single portal and the object installed therein.
  • A modular flashing entity is employed to seal an upper (header) and lower (sill) horizontal portions of the portal. When used to seal the lower portion, the flashing system employs components that constitute an assembly termed “pan flashing”. These are shown at the lower horizontal segment of the portal in FIG. 1 generally by 20A (left), 20B (right) and 30 (center). When used to seal the upper portion, the flashing system employs components that are similar in design to those used in the pan flashing, but are termed a “drip cap” in this case and has different dimensional details to accommodate it to the casement trim. The corresponding components of the drip cap are labeled with the same references, 21A, 21B and 31 in FIG. 1. The pan flashing is shown in greater detail, in perspective, in FIG. 3 and the drip cap is shown in greater detail, in perspective, in FIG. 4. Although not shown in FIG. 1, bottom, the parts of the pan flashing are identified by the same reference numbers as used for the drip cap (FIG. 1, top); these references are explicitly identified in FIG. 3.
  • Viewed from the exterior of the portal frame, the drip cap has a left modular flashing entity 21A (FIGS. 1 and 4, left) and a right modular flashing entity 21B (FIGS. 1 and 4, right). Viewed from the exterior of a portal, a substantially vertical surface 24 of the drip cap extends upward from a distal edge (further from a viewer in FIGS. 1 and 4) of a substantially horizontal surface 26 of the drip cap. In this frame of reference, the distal edge is intended to abut the exterior face of the sheathing or the building wall. In FIG. 1 (top), the horizontal surface 26 is rendered as a heavy line, intended to show that a viewer sees surface 26 edge-on, substantially at the level of the exterior edge of the casement trim, 14. At the proximal edge (closer to a viewer in FIGS. 1 and 4) of the horizontal surface 26 an additional vertical surface 22 projects downward from the horizontal surface, i.e., in a direction opposite to that at which vertical surface 24 projects upward from the distal edge. In addition, the vertical surface 24 of the left modular flashing entity 21A has an extension, or tab, 25 projecting leftward beyond the limit of the horizontal surface 26 to which it is attached (FIG. 1, top, left hand side; FIG. 4, left), to permit sealing the entity to a corresponding tab of a modular trim flashing element (see below) installed along the vertical exterior edge of the casement trim 14; and conversely, the right modular flashing entity 21B has a corresponding extension, or tab, 25 projecting rightward from the horizontal surface 26 to accomplish the same objective (FIG. 1, top, right hand side; FIG. 4, right).
  • Correspondingly, as viewed from the exterior of the portal frame, the pan flashing has a left modular flashing entity 20A (FIGS. 1 and 3, left) and a right modular flashing entity 20B (FIGS. 1 and 3, right). A substantially vertical proximal surface 24 of the pan flashing extends downward from a proximal edge (closer to a viewer in FIGS. 1 and 3) of a substantially horizontal surface 26 of the pan flashing. In this frame of reference, the proximal edge is intended to lie at the exterior face of the portal frame or the building wall. The horizontal surface is shown in FIG. 3 with shading getting progressively darker toward a distal edge (further from a viewer in FIG. 3) of the surface 26, i.e., moving away from the viewer toward the interior face of the frame, or the interior wall of the building. In FIG. 1 (bottom), the horizontal surface is rendered as a heavy line, intended to show that a viewer sees the horizontal surface edge-on, substantially at the level of the frame surface or sill 12 (just as shown for the drip cap with reference numbers, FIG. 1, top). At the distal edge of the horizontal surface 26 (FIG. 3) an additional vertical distal surface 22 projects upward from the horizontal surface, i.e., in a direction opposite to that at which vertical surface 24 projects downward from the proximal edge. In addition, the proximal vertical surface 24 of the left modular flashing entity has an extension, or tab, 25 projecting leftward beyond the limit of the horizontal surface 26 to which it is attached (FIG. 1, bottom, left hand side; FIG. 3, left), to permit sealing the entity to a corresponding tab of a modular trim flashing element (see below) installed along a vertical exterior edge of the casement trim 14; and conversely, the right modular flashing entity has a corresponding extension 25 projecting rightward from the horizontal surface 26 to accomplish the same objective (FIG. 1, bottom, right hand side; FIG. 3, right). In common embodiments, in which the modular flashing system is used with an aperture that is finished with casement trim after a door or window is installed, the tab 25 extends beyond an outer edge of the casement trim (see FIG. 1, bottom). When so extended, the tab 25 overlaps a corresponding tab of a modular trim flashing element (see below).
  • In a most general embodiment, the modular flashing entities of the invention are provided by the above description. In use, at least a left and right modular flashing entity (i.e., either drip caps or flashing pans) are affixed to an upper horizontal surface of the exterior casement trim, or to the sill of the portal frame, respectively, and abutted or overlapped with each other to establish a seal between them. In an additional embodiment a third modular flashing entity 30 or 31 (FIG. 1, top and bottom; FIG. 5) may be interposed between the left and right modular flashing entities. Such a third flashing entity is described above, having a proximal vertical surface 34, a horizontal surface 36, and a distal vertical surface 32 (FIG. 5). It may be used as shown, or after rotation by 180 degrees about an axis perpendicular to the figure sheet. The proximal vertical surface may have a left extension tab 35 or a right extension tab 35, or both a left and a right extension tab, or its proximal vertical surface 24 may have no extension tab on either the left or right side. In all cases in which a third modular flashing entity 30 or 31 is used, without or with extension, it is abutted or overlapped with the left modular flashing entity 20A or 21A and the right modular flashing entity 20B or 21B and sealed.
  • In an optimal embodiment of the invention, the left modular flashing entities 20A or 20B and the right modular flashing entities 20B or 21B have an additional vertical end surface 28 included (FIG. 1, top and bottom; FIG. 3 and FIG. 4). The left modular entity has a left end surface, and the right modular entity has a right end surface. The end surface 28 is joined to a left edge, or a right edge, respectively, of the horizontal surface 26, and extends in the same direction as the interior vertical surface 22. The end surface 28 additionally is joined to the interior vertical surface 22 at the left edge, or the right edge, respectively, thereof When the end surfaces 28 are used, an optimal seal against atmospheric and environmental elements is established.
  • Whether the vertical end surfaces 28 are used or omitted, the horizontal surface 26 of a drip cap rests atop a portion of the casement trim of a door aperture or a window aperture with the distal vertical surface 24 against the building wall or sheathing. When end surfaces 28 are used, they accommodate the vertical portion of the exterior casement trim. Likewise, the horizontal surface 26 of a pan flashing rests on the door aperture sill, or a window aperture sill below and in front of the interior vertical surface 22. When end surfaces 28 are used, the door assembly or window assembly is set inside the space defined by the two end surfaces 28.
  • In the case that a portal has a rectilinear shape, such as a rectangle or square, the vertical portions of the portal are fitted with at least one modular trim flashing element, or modular side flashing, shown in FIG. 2 generally at 40A and 40B, and at 50, as well as in FIG. 6. A modular trim flashing element includes a first surface (FIG. 2, 44 and 54; and FIG. 6, 54), joined to a second surface ((FIG. 2, 42 and 52; and FIG. 6, 52) at a proximal edge thereof The first surface has a left end and a right end, wherein either
  • a) a left extension of the first surface extends beyond the left end of the second surface (FIG. 6, 56A), or a right extension extends beyond the right end of the second surface (FIG. 6, 56B), or both a left extension and a right extension are present; or
  • b) there is neither a left extension nor a right extension.
  • The optional inclusion of the left extension and the right extension, or tab, is indicated by the dash-dot lines in FIG. 6. In common use as a modular system, one modular side flashing with a left extension and one modular side flashing with a right extension are employed for each of the left and right vertical exterior casement trim. In other embodiments a third modular trim flashing element is used between the side flashing articles with the left extension and the right extension described in the preceding sentence. The third modular trim flashing element may abut or overlap with the first two trim element units. Thus, the third modular trim flashing element may have no extensions on either end, or it may have at least one of a left extension or a right extension, or both.
  • Two embodiments of a modular flashing entity for a curvilinear portal are shown in FIG. 7, viewed from the exterior of a building incorporating the portal. In the representation of FIG. 7, the shape of the portal is substantially oval. The portal may, for example, be intended for a window of this shape. The portal is designated by dashed lines, and has a frame face seen in profile in FIG. 7, at 112. At a certain distance from the frame surface, which may be any arbitrary distance, or a distance defined by the thickness of the material used to frame the portal, an installed casement trim having an oval shape, and having an exterior limit at 110, surrounds the portal.
  • A closed curvilinear opening such as shown in FIG. 7 has no end. Since there is no end, no surface corresponding to the fourth surface 28 described above, and depicted in FIGS. 1-4, is employed. In certain embodiments of the invention a common modular flashing entity is employed all around the aperture. Alternatively, the upper portion of a closed curvilinear portal may be considered as an upper exterior casement trim, and may accommodate modular flashing entities formed as drip caps; and the lower portion of the portal may be considered as a sill of a portal, and accommodate modular flashing entities fashioned as flashing pans. Thus, in an embodiment such as shown in FIG. 7, a modular flashing entity that is a drip cap is shown generally at 120, and a modular flashing entity that serves as a pan flashing is shown generally at 121. The drip cap 120 has a substantially vertical distal surface 124 extending upward from a distal edge of a second, curvilinear, surface 126. In this frame of reference, the distal edge is intended to lie at the exterior face of the building wall. In FIG. 7, the second surface is rendered as a heavy line 126, intended to show that a viewer sees surface 126 edge-on, substantially at the level of the exterior casement trim 110. At the proximal edge of the second surface 126 an additional vertical proximal surface 122 projects from the second surface, in a direction opposite to that at which vertical exterior surface 124 projects from the proximal edge.
  • In the pan flashing embodiment 121 shown in FIG. 7, a substantially vertical distal surface 122 extends upward from a distal edge of a second, curvilinear, surface 126. In this frame of reference, the distal edge is intended to lie at an interior edge of a curvilinear portal frame. Again, the second surface is rendered as a heavy line 126, intended to show that a viewer sees surface 126 edge-on, substantially at the level of the portal frame. At the proximal edge of the second surface 126 an additional vertical proximal surface 124 projects from the second surface, in a direction opposite to that at which vertical exterior surface 122 projects from the proximal edge.
  • In addition, the vertical surface 124 of both the drip cap embodiment and the pan flashing embodiment has an extension 125 projecting beyond the limit of the second surface 126 to which it is attached, to permit sealing the entity to a neighboring modular flashing entity. Alternatively, a curvilinear modular flashing entity may have neither a counterclockwise nor a clockwise extension, or it may have both. In use, adjacent modular flashing entities are installed either abutting each other (for example, when no extensions are used), or with overlapping extensions (when at least one of a counterclockwise extension or a clockwise extension is used).
  • Materials used to fabricate a modular flashing entity or a modular trim flashing element described herein include metals, plastic, polymers, resins, or a combination of any of them may be used to manufacture the item. By way of nonlimiting example, a metal article may be made of aluminum, anodized aluminum, steel, galvanized steel, copper or an alloy thereof, tin or an alloy thereof, and so forth. Plastics, polymers and resins include, by way of nonlimiting example, polyethylene, polypropylene, polyvinyl chloride, butyl polymers, a nylon, polystyrene, and the like, and any derivative or modification of the above. Equivalent materials may be employed in manufacturing the modular articles disclosed herein and are included within the scope of the claimed invention.
  • The articles may be manufactured by any of several processes known to artisans in the field of the invention. For metal articles, stamping, pressing, rolling and milling processes are well known and may be used to prepare the modular articles of the invention. Plastic, polymeric or resinous articles likewise can be prepared in the same way. In addition, the latter group of materials may be fashioned into the articles of the invention by other processes suitable for working these materials. Such processes include, by way of nonlimiting example, molding, injection molding, thermosetting processes, extrusion processes, and the like. Any equivalent process or method of shaping articles of manufacture suitable for preparing the modular articles of the invention may be employed to fashion the modular articles of the invention. Regardless of the materials and methods used to fabricate the modular flashing entities and modular trim flashing elements, in optimal embodiments of the invention all edges at the junctions of the various surfaces of the articles are sealed and rendered impervious to atmospheric and environmental elements.
  • The various articles of the invention may be assembled into kits for commercial dissemination. The kits all include a plurality of modular flashing entities disclosed herein. Thus the articles included in the kit may be modular flashing entities having a first surface, a second surface and a third surface described above. Depending on need and particular aspects of design, a modular flashing entity included in the kit may have no extension, or a left extension, or a right extension, or both a left and a right extension; these structures have all been described above. In alternative embodiments of a kit of the invention, a modular flashing entity may have a fourth surface as described above on either the left side, or the right side. These alternative options may be combined in permutation to provide a wide range of kits containing a plurality of articles of several particular designs, to accommodate a broad selection of construction needs. A kit may include a modular flashing system that is a drip pan system, or a pan flashing system, or both. In addition, a kit may include modular flashing entities designed to fit curvilinear rather than rectilinear apertures. Alternatively, a curvilinear modular flashing entity may have neither a counterclockwise nor a clockwise extension, or it may have both. A plurality of such curvilinear modular flashing entities is included in a kit.
  • In all the kits of the present invention, the modular flashing systems are contained within a suitable package. The package includes descriptive literature concerning the articles and instructions on their use and installation.
  • Installation of an appropriate combination of modular flashing entities and modular trim flashing elements serves to render a portal in a building into which the components are installed essentially impervious to atmospheric and environmental elements. Generally, this is accomplished by affixing at least one, and more commonly several, modular flashing entities and/or modular trim flashing elements to the portal. As noted above, any of the several varieties of the modular flashing entity may be used in order to be fitted into the shape and dimension of the portal; specifically, an entity having no extension on the first surface may be used (for example if it is installed between other entities having end extensions), or an entity having a left extension may be installed (for example at a left end of a rectilinear portal), or an entity having a right extension may be installed (for example at a right end of a rectilinear portal), or, as required, an entity with both a left and a right extension may be installed (for example, to overlap with a neighboring entity). In important embodiments of this method, a modular flashing entity has an additional fourth surface (FIGS. 3 and 4, 28) joined to an end of the second surface and further joined to the third surface. The fourth surface extends from the end of the second surface in a fourth direction that is generally the same as the direction that the third surface extends from the distal edge of the second surface. The fourth surface is at a left end, or a right end, of the modular flashing entity and is used to abut the left side, or the right side, respectively, of a rectilinear portal once installed. When present, the fourth surface, together with the other surfaces to which it is joined, serve as a receptacle for a finished door or window assembly (pan flashing), or fit over the top of casement trimming surrounding the top and sides of door or window installation (drip cap).
  • In addition, in order to provide protection to a portal against atmospheric and environmental elements, the side elements or modular trim flashing elements described herein are also installed, along the vertical portions of the portal. A modular trim flashing element having an appropriate extension tab directed upward may be used at an upper end of the portal frame, and an extension having an extension tab directed downward may be used at a lower end of the portal frame. The extension tabs overlap with tabs extending from the modular flashing entities and serve to provide sealing surfaces at comers in a rectilinear portal.
  • The modular flashing entities and the modular trim flashing elements are affixed to a portal in a way that ensures structural integrity and effective sealing against atmospheric and environmental elements. This can be accomplished by any means known to an artisan in the field of the invention, including, by way of nonlimiting example, gluing, bonding, nailing, screwing, or riveting. Any equivalent means of affixing the articles to the portal are within the scope of the invention.
  • A nonlimiting example of a construction process for a rectilinear door or window using the modular flashing systems of the present invention includes:
      • 1. Install the modular flashing entities that are the pan flashing members in a rough door or window opening. These articles will contact the sill, the jack studs or portal frame, and the sheathing beneath the door or window.
      • 2. Install the door or window, which frequently is a preassembled unit, into the pan flashing members and into the opening. It is envisioned that a threshold component of the door assembly fits into the receptacle formed by surfaces 22, 26, and 28 of FIG. 3.
      • 3. Install exterior casement trim around the installed door or window assembly.
      • 4. Install the modular side flashing along the vertical faces of the casement trim, at the sides of the portal, starting at the bottom of the casement trim, and working up to the top. These articles will contact the sheathing and the exterior vertical casement trim, and tabs, if present, will overlap with tabs from the pan flashing.
  • 5. Install the drip cap members over the top of the casement trim. These will contact the horizontal casement trim above the door or window, and the sheathing. Tabs, if present, will overlap with tabs from the modular trim flashing elements.
  • 6. Finally, install the siding to be used as the exterior of the finished building. The siding will cover most components of the flashing members.
  • Any equivalent method of installing a modular flashing system described herein is included within the scope of the present invention.

Claims (26)

  1. 1. A modular flashing entity comprising
    a) a first surface,
    b) a second surface having a proximal edge and a distal edge removed from the proximal edge, wherein the first surface joins the second surface along said proximal edge, the second surface having in addition a left end and a right end, and
    c) a third surface joined to said second surface along the distal edge thereof, wherein the first surface extends from the proximal edge of the second surface in a first direction that is generally opposite to a direction that the third surface extends from the distal edge of the second surface, and either
    i) at least one of a left extension of the first surface extends beyond the left end of the second surface, and a right extension of the first surface extends beyond the right end of the second surface, or
    ii) the first surface has no extension.
  2. 2. The modular flashing entity described in claim 1 wherein the joined first surface, second surface and third surface form a unitary structure essentially impervious to atmospheric and environmental elements.
  3. 3. The modular flashing entity described in claim 1 wherein
    a) the second surface is approximately perpendicular to the first surface, and
    b) the third surface is approximately perpendicular to the second surface.
  4. 4. The modular flashing entity described in claim 1 further comprising a fourth surface joined to an end of the second surface and further joined to the third surface, wherein the fourth surface extends from the end of the second surface in a direction that is generally the same as the direction that the third surface extends from the distal edge of the second surface.
  5. 5. The modular flashing entity described in claim 4 wherein the joined first surface, second surface, third surface, and fourth surface form a unitary structure essentially impervious to atmospheric and environmental elements.
  6. 6. The modular flashing entity described in claim 1 wherein the first surface, the second surface, and the third surface are each essentially planar surfaces.
  7. 7. The modular flashing entity described in claim 1 wherein at least the second surface is nonplanar.
  8. 8. The modular flashing entity described in claim 7 wherein the second surface is generally concave with respect to a direction established by the first surface.
  9. 9. The modular flashing entity described in claim 1 wherein each of the first surface, the second surface and the third surface separately comprise a substance chosen from a metal, a plastic, a polymer, a resin, or a combination of two or more of them.
  10. 10. The modular flashing entity described in claim 4 wherein the first surface, the second surface, the third surface and the fourth surface separately comprise a substance chosen from a metal, a plastic, a polymer, a resin, or a combination of two or more of them.
  11. 11. A modular trim flashing element comprising a first surface and a second surface, wherein the first surface is joined to the second surface at a proximal edge thereof and wherein the first surface has a left end and a right end, wherein either
    a) a left extension of the first surface extends beyond the left end of the second surface, or a right extension extends beyond the right end of the second surface, or both a left extension of the first surface extends beyond the left end of the second surface and a right extension extends beyond the right end of the second surface; or
    b) there is neither a left extension nor a right extension;
    wherein the joined first surface and second surface form a unitary structure essentially impervious to atmospheric and environmental elements.
  12. 12. The modular trim flashing element described in claim 11 wherein the first surface is approximately perpendicular to the second surface.
  13. 13. A kit comprising a plurality of modular flashing entities described in claim 1.
  14. 14. The kit described in claim 13 further comprising at least one modular trim flashing element, wherein the modular trim flashing element comprises a first surface and a second surface, wherein the first surface is joined to the second surface at a proximal edge thereof and having a left end and a right end, wherein either
    a) a left extension of the first surface extends beyond the left end of the second surface, or a right extension extends beyond the right end of the second surface, or both a left extension of the first surface extends beyond the left end of the second surface and a right extension extends beyond the right end of the second surface; or
    b) there is neither a left extension nor a right extension.
  15. 15. A kit comprising a plurality of modular flashing entities described in claim 4.
  16. 16. The kit described in claim 15 further comprising at least one modular trim flashing element, wherein the modular trim flashing element comprising a first surface and a second surface, wherein the first surface is joined to the second surface at a proximal edge thereof and having a left end and a right end, wherein either
    a) a left extension of the first surface extends beyond the left end of the second surface, or a right extension extends beyond the right end of the second surface, or both a left extension of the first surface extends beyond the left end of the second surface and a right extension extends beyond the right end of the second surface; or
    b) there is neither a left extension nor a right extension.
  17. 17. A kit comprising a plurality of modular flashing entities described in claim 6.
  18. 18. A kit comprising a plurality of modular flashing entities described in claim 7.
  19. 19. A method of sealing a portal and its associated casement trim in a building against atmospheric and environmental elements, the method comprising affixing one or more modular flashing entities described in claim 1 to the portal such that
    i) the second surface of the flashing entity contacts a portion of the portal framing, and
    ii) the first surface of a flashing entity contacts an exterior face of the building adjacent to the portal.
  20. 20. The method described in claim 19 wherein the modular flashing entity further comprises a fourth surface joined to an end of the second surface and further joined to the third surface, wherein the fourth surface extends from the end of the second surface in a fourth direction that is generally the same as the direction that the third surface extends from the distal edge of the second surface.
  21. 21. The method described in claim 19 wherein the one or more modular flashing entities seal a portal that is generally a rectilinear opening.
  22. 22. The method described in claim 19 further comprising affixing at least one modular trim flashing element to the portal, wherein a modular trim flashing element comprises a first surface having at least one extension, joined to a second surface at a proximal edge thereof and having a left end and a right end, wherein an extension of the first surface extends beyond the left end of the second surface, or beyond the right end of the second surface, or beyond both ends of the second surface.
  23. 23. The method described in claim 19 wherein the one or more modular flashing entities seal a portal that is at least partly curvilinear.
  24. 24. The method described in claim 23 wherein the portal includes a circular, elliptical, hyperbolic, parabolic or other curvilinear segment.
  25. 25. The method described in claim 19 wherein the affixing comprises at least one of gluing, bonding, nailing, screwing, or riveting.
  26. 26. The method described in claim 19 wherein at least one extension of a first surface of a modular flashing entity or at least one extension of a first surface of a modular trim flashing element overlaps a surface of a neighboring modular flashing entity or modular trim flashing element.
US11013223 2004-12-14 2004-12-14 Modular flashing system Abandoned US20060137263A1 (en)

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US20060123713A1 (en) * 2002-12-16 2006-06-15 Faurholdt Jesper H Flashing member with adaptable corner segments
US20080157518A1 (en) * 2006-12-27 2008-07-03 Huber Engineered Woods Llc One step exterior flashing device
US20090025299A1 (en) * 2007-07-24 2009-01-29 Quanex Corporation Entryway for disposition in a door opening of a building
US20100139178A1 (en) * 2008-12-08 2010-06-10 Benjamin Obdyke Incorporated Flexible Flashing Material And Method of Manufacture
EP2692978A1 (en) * 2012-08-03 2014-02-05 Walter Gutjahr Sealing device for a moisture tight door connection
US20140215931A1 (en) * 2013-02-06 2014-08-07 Mortor Net USA, Ltd. Adjustable drip edge corner

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US6305132B1 (en) * 2000-02-23 2001-10-23 Mark C. Smith Molded interior window frame assembly
US6327820B1 (en) * 1997-11-10 2001-12-11 Vkr Holding A/S Kit of elements and a method of using the kit for flashing a roof-penetrating element
US6401402B1 (en) * 2001-02-07 2002-06-11 Mark F. Williams Pre-folded flashing systems and method
US6401401B1 (en) * 2000-10-20 2002-06-11 Mark F. Williams Multi-component flashing systems
US6681530B1 (en) * 1999-12-01 2004-01-27 Robert D. Givens One-piece flashing

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US4555882A (en) * 1983-10-20 1985-12-03 Moffitt Gregory A Moisture guard for window frames, door jambs and the like
US5018333A (en) * 1990-08-09 1991-05-28 Ronald Bruhm Elastomeric weather seal flashing and method of manufacture
US5542217A (en) * 1994-09-13 1996-08-06 Larivee, Jr.; William V. Molded one-piece entry door flashing pan
US5581959A (en) * 1995-04-18 1996-12-10 Occhipinti; Vincenzo J. Bendable drip cap
US6327820B1 (en) * 1997-11-10 2001-12-11 Vkr Holding A/S Kit of elements and a method of using the kit for flashing a roof-penetrating element
US6119416A (en) * 1999-01-30 2000-09-19 Plastic Components, Inc. Flashing system
US6681530B1 (en) * 1999-12-01 2004-01-27 Robert D. Givens One-piece flashing
US6305132B1 (en) * 2000-02-23 2001-10-23 Mark C. Smith Molded interior window frame assembly
US6401401B1 (en) * 2000-10-20 2002-06-11 Mark F. Williams Multi-component flashing systems
US6401402B1 (en) * 2001-02-07 2002-06-11 Mark F. Williams Pre-folded flashing systems and method

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060123713A1 (en) * 2002-12-16 2006-06-15 Faurholdt Jesper H Flashing member with adaptable corner segments
US20080157518A1 (en) * 2006-12-27 2008-07-03 Huber Engineered Woods Llc One step exterior flashing device
US20090025299A1 (en) * 2007-07-24 2009-01-29 Quanex Corporation Entryway for disposition in a door opening of a building
US7877940B2 (en) 2007-07-24 2011-02-01 Quanex Corporation Entryway for disposition in a door opening of a building
US20100139178A1 (en) * 2008-12-08 2010-06-10 Benjamin Obdyke Incorporated Flexible Flashing Material And Method of Manufacture
EP2692978A1 (en) * 2012-08-03 2014-02-05 Walter Gutjahr Sealing device for a moisture tight door connection
US20140215931A1 (en) * 2013-02-06 2014-08-07 Mortor Net USA, Ltd. Adjustable drip edge corner
US9151039B2 (en) * 2013-02-06 2015-10-06 Mortar Net Usa, Ltd. Adjustable drip edge corner

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