U.S. patent application number 10/736332 was filed with the patent office on 2005-02-10 for monolithic vent pipe flashing and method of manufacture thereof.
Invention is credited to McLane, Brian J., McLane, John L..
Application Number | 20050028456 10/736332 |
Document ID | / |
Family ID | 34119017 |
Filed Date | 2005-02-10 |
United States Patent
Application |
20050028456 |
Kind Code |
A1 |
McLane, John L. ; et
al. |
February 10, 2005 |
Monolithic vent pipe flashing and method of manufacture thereof
Abstract
A monolithic vent pipe flashing for use with a vent pipe
projecting from a surface, such as a roof. The flashing includes a
primary barrier with an upper surface and a lower surface, with the
lower surface abutting the surface from which the vent pipe
projects. A vent pipe cover is attached to and extends from the
primary barrier. The vent pipe cover includes a vent pipe cover
bore for receiving the vent pipe. The vent pipe cover body includes
a first end and a second end, and the first end is attached to and
overlaps a portion of the lower surface of the primary barrier. A
secondary seal barrier is at least partially attached to the
portion of the first end overlapping the lower surface of the
primary barrier. A method of manufacturing a vent pipe flashing is
also disclosed.
Inventors: |
McLane, John L.;
(Pittsburgh, PA) ; McLane, Brian J.; (Pittsburgh,
PA) |
Correspondence
Address: |
WEBB ZIESENHEIM LOGSDON ORKIN & HANSON, P.C.
700 KOPPERS BUILDING
436 SEVENTH AVENUE
PITTSBURGH
PA
15219
US
|
Family ID: |
34119017 |
Appl. No.: |
10/736332 |
Filed: |
December 15, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60492936 |
Aug 6, 2003 |
|
|
|
Current U.S.
Class: |
52/58 |
Current CPC
Class: |
E04D 13/1407
20130101 |
Class at
Publication: |
052/058 |
International
Class: |
E04D 001/36 |
Claims
The invention claimed is:
1. A vent pipe flashing for use in connection with a vent pipe
projecting from a surface, the flashing comprising: a primary
barrier having an upper surface and a lower surface, with the lower
surface of the primary barrier configured to abut the surface from
which the vent pipe projects; a vent pipe cover attached to and
extending from the primary barrier, the vent pipe cover including a
vent pipe cover bore for receiving the vent pipe and defined by a
Vent pipe cover body having a first end and a second end, at least
a portion of the first end attached to and overlapping a portion of
the lower surface of the primary barrier; and a secondary seal
barrier at least partially attached to the portion of the first end
overlapping the lower surface of the primary barrier.
2. The vent pipe flashing of claim 1, wherein a portion of the
primary barrier, the first end of the vent pipe cover body and a
portion of the secondary seal barrier are bonded together.
3. The vent pipe flashing of claim 2, wherein the the portion of
the primary barrier, the first end of the vent pipe cover body and
a portion of the secondary seal barrier are bonded by at least one
of heat fusing process and an applied adhesive material.
4. The vent pipe flashing of claim 1, wherein at least one of the
primary barrier, the vent pipe cover and the secondary seal barrier
comprise a bitumen material, a rubber, a polymer and a synthetic
material.
5. The vent pipe flashing of claim 1, wherein the vent pipe cover
is formed in one of a tubular shape and a frustoconical shape.
6. The vent pipe flashing of claim 1, further comprising an
attachment mechanism configured to connect at least a portion of
the vent pipe flashing to the vent pipe.
7. The vent pipe flashing of claim 6, wherein the attachment
mechanism is at least one of a clamp, a ratchet mechanism and a
securement device.
8. The vent pipe flashing of claim 1, wherein at least a portion of
the lower surface of the primary barrier is attached to the surface
from which the vent pipe projects.
9. The vent pipe flashing of claim 8, wherein the lower surface of
the primary barrier is attached to the surface from which the vent
pipe projects via an applied adhesive material.
10. A method of manufacturing a vent pipe flashing, comprising the
steps of: (a) providing a first substantially planar section of
material; (b) providing a second substantially planar section of
material having a substantially centrally positioned opening and
having an upper surface and a lower surface; (c) providing a third
substantially planar section of material having a substantially
centrally positioned opening and having an upper surface and a
lower surface; (d) rolling the first section of material into at
least one of a substantially tubular or substantially frustoconical
shape, thereby creating a vent pipe cover portion having a first
end and a second end and a vent pipe cover bore; (e) inserting the
first end of the vent pipe cover portion through the opening of the
second section of material; (f) positioning the first end of the
vent pipe cover, such that at least a portion of the first end of
the vent pipe cover portion is abutting and overlapping the lower
surface of the second section of material; (g) bonding the
overlapping portion of the vent pipe cover portion to the lower
surface of the second section of material; (h) aligning the opening
of the third section of material with the vent pipe cover bore; and
(i) bonding the upper surface of the third section of material to
at least a portion of the overlapping portion of the vent pipe
cover portion and the lower surface of the second section of
material.
11. The method of claim 10, wherein, prior to the bonding step (g),
the overlapping portion of the vent pipe cover is "fingered" to
provide an abutting surface between the overlapping portion of the
vent pipe cover and the lower surface of the second section of
material.
12. The method of claim 10, wherein the bonding step (g) is
achieved by at least one of a heat fusing process and an applied
adhesive material.
13. The method of claim 10, wherein the bonding step (i) is
achieved by at least one of a heat fusing process and an applied
adhesive material.
14. The method of claim 10, wherein, after the bonding step (g),
the method further comprises the step of heating and melting the
overlapping portion of the vent pipe cover portion on the lower
surface of the second section of material to provide a
substantially uniform and enhanced seal area.
15. The method of claim 10, wherein, after the bonding step (i),
the method further comprises the step of heating and melting the
upper surface of the third section of material on at least-a
portion of the overlapping portion of the vent pipe cover portion
and the lower surface of the second section of material to provide
a substantially uniform and enhanced seal area.
16. The method of claim 10, wherein at least one of the first
section of material, the second section of material and the third
section of material comprise a bitumen material, a rubber, a
polymer and a synthetic material.
17. A kit for manufacturing a vent pipe flashing, comprising: a
first substantially planar section of material; a second
substantially planar section of material having a substantially
centrally positioned opening; and a third substantially planar
section of material having a substantially centrally positioned
opening.
18. The kit of claim 17, wherein at least one of the first section
of material, the second section of material and the third section
of material comprise a bitumen material, a rubber, a polymer and a
synthetic material.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/492,936 filed Aug. 6, 2003, entitled "Monolithic
Vent Pipe Flashing and Method of Manufacture Thereof".
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to flashing and
methods of manufacturing flashing and, in particular, to a
monolithic vent pipe flashing for use in connection with a vent
pipe projecting from a surface, such as a roof or the like, and a
method of manufacturing this monolithic vent pipe flashing.
[0004] 2. Description of Related Art
[0005] Virtually every structure, including homes, buildings, etc.,
include one or more vent pipes extending from a surface of the
structure. These vent pipes are used to exhaust air, fumes, gases,
steam, vapor and other similar gaseous or semi-gaseous material
from the interior of the structure. Since the vent pipe projects
from the surface, typically the roof surface, the joint or
interface between the body of the vent pipe and the roof surface
requires a seal. Specifically, a seal is required, such that
rainwater and other debris and material cannot accumulate in the
gap between the vent pipe body and the roof surface. Accumulation
of debris, water and other material may damage both the vent pipe,
as well as the roofing material. Further, leakage can occur and
damage the interior of the structure.
[0006] Accordingly, vent pipe flashing has been developed for
placement over the vent pipe to prevent such leakage or other
damage. Various flashing apparatus and systems have been developed
to cover and otherwise seal the interface between the vent pipe and
the roof surface or structure. For example, such apparatus and
systems are disclosed in U.S. Pat. No. 6,279,272 to Nill, Jr.; U.S.
Pat. No. 6,244,006 to Shue et al.; U.S. Pat. No. 6,102,076 to
Romero, Jr. et al.; U.S. Pat. No. 6,047,739 to Nixon; U.S. Pat. No.
5,694,724 to Santiago; U.S. Pat. No. 5,687,773 to Ryan et al.; U.S.
Pat. No. 5,394,663 to Jackson; U.S. Pat. No. 5,036,636 to Hasty;
and U.S. Pat. No. 4,442,643 to Stadheim. However, such apparatus
and systems have several drawbacks.
[0007] These prior art systems are typically made from a single
piece or layer of seal material, and this material is fused or
bonded directly onto the modified roof membrane. Accordingly, such
prior art apparatus and systems require additional caulking and do
not provide a multi-layer seal. Also, such prior art systems and
apparatus must be constructed on the job site and cannot be
prefabricated. Further, prior art apparatus and systems must
utilize a specifically cut roof membrane that conforms to the exact
shape of the vent pipe. In addition, since prior art apparatus and
systems must be attached directly to the roofing membrane, this
leads to other drawbacks since the membrane is often rough and does
not allow effective sealing.
SUMMARY OF THE INVENTION
[0008] It is, therefore, an object of the present invention to
provide a monolithic vent pipe flashing and method of manufacturing
thereof that overcome the deficiencies of the prior art. It is
another object of the present invention to provide a vent pipe
flashing that includes multiple layers and does not require direct
fusion or bonding to the roof membrane surface. It is another
object of the present invention to provide a vent pipe flashing and
a method of manufacturing wherein the vent pipe flashing can be
made or prefabricated offsite. It is a still further object of the
present invention to provide a vent pipe flashing that allows the
roof membrane to be cut in a non-specific manner. It is yet another
object of the present invention to provide a vent pipe flashing
that does not require additional caulking and provides an effective
seal, thereby preventing leakage or other damage to both the vent
pipe and the roof surface.
[0009] The present invention is directed to a monolithic vent pipe
flashing that can be used in connection with a vent pipe projecting
from a surface, such as the roof of a structure. The flashing
includes a primary barrier with an upper surface and a lower
surface. The lower surface of the primary barrier abuts the surface
from which the vent pipe projects. A vent pipe cover is attached to
and extends from the primary barrier. The vent pipe cover includes
a vent pipe cover bore for receiving a vent pipe. The vent pipe
cover bore is defined by a vent pipe body having a first end and a
second end. At least a portion of the first end is attached to and
overlaps a portion of the lower surface of the primary barrier. The
flashing also includes a secondary seal barrier attached to the
portion of the first end overlapping the lower surface of the
primary barrier.
[0010] The present invention is also directed to a method of
manufacturing a monolithic vent pipe flashing. This method includes
the steps of: providing a first substantially planar section of
material; providing a second substantially planar section of
material having a substantially centrally-positioned opening and
having an upper surface and a lower surface; providing a third
substantially planar section of material having a substantially
centrally-positioned opening and having an upper surface and a
lower surface; rolling the first section of material into at least
one of a substantially tubular or substantially frustoconical
shape, thereby creating a vent pipe cover having a first end and a
second end and a vent pipe cover bore; inserting the first end of
the vent pipe cover through the opening of the second section of
material; positioning the first end of the vent pipe cover, such
that at least a portion of the first end of the vent pipe cover is
abutting and overlapping the lower surface of the second section of
material; bonding the overlapping portion of the vent pipe cover to
the lower surface of the second section of material; aligning the
opening of the third section of material with the vent pipe cover
bore; and bonding the upper surface of the third section of
material to at least a portion of the overlapping portion of the
vent pipe cover and a lower surface of the second section of
material.
[0011] The present invention, both as to its construction and its
method of operation, together with the additional objects and
advantages thereof, will best be understood from the following
description of exemplary embodiments when read in connection with
the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a side sectional view of a vent pipe flashing
according to the present invention;
[0013] FIG. 2 is a side sectional view of the vent pipe flashing of
FIG. 1 as installed in connection with a vent pipe;
[0014] FIG. 3 is another sectional view of the vent pipe flashing
of FIG. 1 as installed in connection with the vent pipe;
[0015] FIG. 4 is a top view of stock material for use in connection
with the method of manufacturing vent pipe flashing according to
the present invention;
[0016] FIG. 5 is a bottom view of an intermediate step of the
method of manufacturing the vent pipe flashing of FIG. 1; and
[0017] FIG. 6 is a further step in the method of manufacturing the
vent pipe flashing of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0018] For purposes of the description hereinafter, the terms
"upper", "lower", "right", "left", "vertical", "horizontal", "top",
"bottom" and derivatives thereof shall relate to the invention as
it is oriented in the drawing figures. However, it is to be
understood that the invention may assume various alternative
variations and step sequences, except where expressly specified to
the contrary. It is also to be understood that the specific devices
and processes illustrated in the attached drawings, and described
in the following specification, are simply exemplary embodiments of
the invention. Hence, specific dimensions and other physical
characteristics related to the embodiments disclosed herein are not
to be considered as limiting.
[0019] The present invention is directed to a monolithic vent pipe
flashing 10 and method of manufacturing this vent pipe flashing 10.
A preferred embodiment of the vent pipe flashing 10 is illustrated
in FIGS. 1-3, and several steps in the method of manufacturing the
vent pipe flashing 10 are illustrated in FIGS. 4-6. Further, the
vent pipe flashing 10 is particularly adapted for use in connection
with a vent pipe 12 that projects from a surface 14 of a structure
(not shown), such as a building, home, etc.
[0020] In a preferred and non-limiting embodiment, the vent pipe
flashing 10 includes a primary barrier 16 having an upper surface
18 and a lower surface 20. The lower surface 20 of the primary
barrier 16 abuts the surface 14 from which the vent pipe 12
projects. The vent pipe flashing 10 also includes a vent pipe cover
22 attached to and extending from the primary barrier 16. The vent
pipe cover 22 includes a vent pipe cover bore 24 and is sized and
shaped such that it can receive the vent pipe 12. This vent pipe
cover bore 24 is defined by a vent pipe cover body 26 having a
first end 28 and a second end 30. At least a portion of the first
end 28 of the vent pipe cover body 26 is attached to and overlaps a
portion of the lower surface 20 of the primary barrier 16. Finally,
the vent pipe flashing 10 includes a secondary seal barrier 32 that
is at least partially attached to a portion of the first end 28 of
the vent pipe cover body 26 that overlaps the lower surface 20 of
the primary barrier 16.
[0021] As seen in FIG. 1, a triple-seal area is provided at the
interface or vent pipe cover bore 24 portion of the vent pipe cover
22. While this view is exaggerated and it appears that the
secondary seal barrier 32 and first end 28 of vent pipe cover body
26 project from the primary barrier 16, as detailed hereinafter,
the method of manufacturing the vent pipe flashing 10, including
the bonding of these surfaces, provides a more uniform and
substantially flat surface. The bonding process may be a heat
fusing process or an adhesive material may be used to attach the
layers. The view of FIG. 1 was exaggerated to better illustrate the
primary barrier 16, the vent pipe cover 22 and secondary seal
barrier 32. In addition, it is envisioned that the vent pipe
flashing 10 can be manufactured from any number of suitable
materials, such as rubber, a polymer or other synthetic material.
However, in one preferred and non-limiting embodiment, the vent
pipe flashing 10 is manufactured from a bitumen material.
[0022] Further, as seen in FIG. 1, the vent pipe cover 22 may have
a substantially tubular shape, or alternatively, may have a
frustoconical shape. In using a frustoconical shape, the vent pipe
cover 22 allows rain and other liquid or similar material to more
easily traverse down the vent pipe cover body 26 and not pocket in
any area of the vent pipe flashing 10. This, in turn, assists in
the longevity and effectiveness of the vent pipe flashing 10.
[0023] The vent pipe flashing 10 according to the present
invention, as installed on the surface 14 surrounding the vent pipe
12 is illustrated in FIGS. 2 and 3. Specifically, the vent pipe
flashing 10 and, in particular, the vent pipe cover portion 22 is
placed over the vent pipe 12. In this manner, the vent pipe 12
extends through the vent pipe cover bore 24, and the vent pipe
cover 22 is sized such that the vent pipe 12 extends beyond the
second end 30 of the vent pipe cover body 26.
[0024] In order to further attach the vent pipe flashing 10 to the
vent pipe 12, an attachment mechanism 34 is used. Any number of
attachment mechanisms 34 are envisioned, such as clamps, ratchets
or other manner of securing the second end 30 of the vent pipe
cover body 26 to the vent pipe 12. Once installed, the primary
barrier 16 and the secondary seal barrier 32 abut the surface 14,
in this embodiment, the roof membrane surface 36. Below the roof
membrane 36 typically is an insulation layer 38, and below this
insulation layer 38 is the roof deck 40. As installed, the vent
pipe flashing 10 of the present invention provides a secured and
sealed area around the interface between the vent pipe 12 and the
surface 14. It is also envisioned that the lower surface 20 of the
primary barrier 16, or at least a portion thereof, is attached to
the surface 14, such as by use of an adhesive material.
[0025] The present invention is also directed to a method of
manufacturing the vent pipe flashing 10. First, a first
substantially planar section of material 42 is provided. Also
provided are a second substantially planar section of material 44,
which includes a substantially centrally-positioned opening 46 and
a second section of material upper surface 48 and lower surface 50.
A third substantially planar section of material 52 is also
provided, and like the second section of material 44, the third
section of material 52 includes a substantially and
centrally-positioned opening 54 and includes an upper surface 56
and lower surface 58.
[0026] The first section of material 42 is rolled into a
substantially tubular or substantially frustoconical shape, which
creates the vent pipe cover 22 as discussed above. Next, the first
end 28 of the vent pipe cover body 26 is inserted through the
opening 46 of the second section of material 44. The first end 28
of the vent pipe cover body 26 is positioned, such that at least a
portion of the first end 28 of the vent pipe cover body 26 is
abutting and overlapping the lower surface 50 of the second section
of material 44. One manner of providing this abutting interface is
to "finger" the first end 28 of the vent pipe cover body 26, such
as is shown in FIG. 5.
[0027] Next, the overlapping portion 60 of the vent pipe cover
portion 22 is bonded to the lower surface 50 of the second section
of material 44. The opening 54 of the third section of material 52
is aligned with the vent pipe cover bore 24. Finally, the upper
surface 56 of the third section of material 52 is bonded to at
least a portion of the overlapping portion 60 of the vent pipe
cover portion 22, as well as the lower surface 50 of the second
section of material 44. Once complete, the vent pipe flashing 10,
as described above, is manufactured.
[0028] In one preferred and non-limiting embodiment, the first end
28 of the vent pipe body cover 26 is heat fused to the lower
surface 50 of the second section of material 44 (the primary
barrier portion 16). See FIG. 5. Once the first end 28 is fused, a
"buttering" technique is used to melt the first end 28 and create a
more uniform lower surface 50 of the second section of material
44.
[0029] Similarly, the third section of material 52 (the secondary
seal barrier portion 32) is heat fused to the lower surface 50 of
the second section of material 44. See FIG. 6. As with the first
end 28 of the vent pipe cover body 26, the third section of
material 52 may be "buttered" to again provide a uniform lower
surface 50 of the second section material 44. Using a "buttering"
technique, the lower surface 50 remains substantially planar, which
creates a better seal between the vent pipe flashing 10 and the
surface 14.
[0030] In this manner, a vent pipe flashing 10 and method of
manufacturing thereof are provided that overcome the drawbacks of
the prior art. The vent pipe flashing 10 according to the present
invention includes three pieces of heat-fused material and is
usable in any vent pipe 12 that is similar in size. The present
method of manufacture allows the vent pipe flashing 10 to be
pre-made or prefabricated away from the job site, which allows for
the storing and selling of this vent pipe flashing 10 for use in
various applications and for use with various structures. The size
of the primary barrier 16 and secondary seal barrier 32 allows the
surface 14 (roof membrane surface 36) to be cut around the vent
pipe 12 in a non-specific manner, which saves additional time to
the installer. Still further, the present method and vent pipe
flashing 10 is particularly useful and accounts for tar or roofing
buildup at the bottom of the vent pipe 12. The present method and
vent pipe flashing 10 does not require any additional caulking and
has a multi-surface and beneficial effective seal around the vent
pipe 12.
[0031] This invention has been described with reference to the
preferred embodiments. Obvious modifications and alterations will
occur to others upon reading and understanding the preceding
detailed description. It is intended that the invention be
construed as including all such modifications and alterations.
* * * * *