Corner guard

Abstract

A corner guard system and method for waterproofing or flashing a corner intersection in a window, door or other opening, corner joint or other intersection structure. The corner guard in includes a base and an end piece. The base has first and second members joined along a ridge edge at an angle to substantially conform to the shape of the corner intersection. The end piece is joined along an end piece edge with the base at an angle to substantially conform to the shape of the opening ledge and adjacent opening surface. The present invention provides an economical, simple to install and easy to use corner guard as an alternative to the traditional flashing membrane while demonstrating significant advantages in minimizing drafts and water leaks in residential and commercial construction.

Description

PRIORITY CLAIM

[0001] This application claims priority to U.S. Provisional Application No. 60/494,635, filed Aug. 12, 2003, which application is hereby incorporated by reference in its entirety as if fully set forth herein.

FIELD OF THE INVENTION

[0002] This invention relates generally to a system and method for effectively and efficiently waterproofing and flashing corner or joint intersections during construction and, more specifically, to a corner guard and a system and method of installing a corner guard for waterproofing and flashing corner intersections in windows, doors or other openings or along wall, floor or ceiling joints.

BACKGROUND OF THE INVENTION

[0003] It is necessary to waterproof and flash at critical areas around the exterior of residential or commercial buildings in construction to avoid potential water damage, mold and mildew. Construction personnel presently use one of a number of different methods in an effort to waterproof and flash corner or joint intersections during construction. These methods typically incorporate peel and stick membranes that are often times difficult and inefficient to install.

[0004] FIGS. 1A through 1C show an example of the installation of a prior art self-adhering, self-sealing, flexible flashing membrane applied to construction to minimize drafts and water leaks. A frequent example of the type of corner joint or intersection is a window, door or other opening from the exterior to the interior of a structure. Common elements in this situation include an opening 10 defined by an opening surface 12, an interior ledge 14 and corner joints 16. Around a rough window, door or other opening, the flashing membrane is installed as multiple strips that are preferably folded and stapled over the framing to cover over the sill/jam inside corners.

[0005] With reference to FIG. 1A, a flashing membrane strip 20 is installed by placing the membrane strip against surface 12. The membrane strip 20 is typically attached using staples or nails along the top edge, for example at points 22. With reference to FIG. 1B, a second flashing membrane strip 24, cut approximately the width of the opening plus additional fold-over width and length, is installed by placing the second membrane strip along the ledge 14b, folding the excess width over the ledge onto the surface 12, and folding the excess length along the adjacent ledge 14a. With reference to FIG. 1C, a corner joint wing 26, cut approximately the depth of the corner joint 16 plus additional fold-over length, is secured along corner joint 16 with excess length folded over along surface 12.

[0006] This complicated process is frequently confusing and subject to error. Incorrectly overlapping or layering the flashing membrane over time not only fails to prevent, but in fact may increase potential water damage, mold and mildew.

[0007] Thus, there is a need for a corner guard and a system and method for installing a corner guard that addresses the disadvantages associated with current waterproof and flashing procedures.

SUMMARY OF THE INVENTION

[0008] The preferred embodiment of the present invention provides a corner guard for corner joints or intersections in building construction that includes a base and an end piece. The base has first and second members joined together at an angle with respect to each other between first and second ends of the base. The end piece is joined at the first end of the base adjacent the first and second members of the base. The end piece and the first and second members of the base are joined at an angle as between the end piece and each member, respectively.

[0009] In an alternative embodiment, a system incorporating the present invention includes an opening defined by a surface, at least two interior ledges and at least one corner joint at the intersection of the two interior ledges. A corner guard is provided that includes a base and an end piece. The base has first and second members joined together at an angle with respect to each other between first and second ends of the base. This angle is substantially the same as the angle defined by the intersection of the two interior ledges forming the corner joint. The end piece is joined at the first end of the base adjacent the first and second members of the base. The end piece and the first and second members of the base are joined at an angle as between the end piece and each member, respectively. This angle is defined by the intersection of the ledges and the surface.

[0010] An alternative embodiment is directed to a system for waterproofing or flashing corner intersections in windows, doors or other openings that includes an opening defined by a surface, at least two interior ledges and at least one corner joint at the intersection of the at least two interior ledges; a first membrane strip; a means for securing the first membrane strip to the surface; a corner guard for waterproofing or flashing the at least one corner intersection having a base with of first and second members joined together, the base having first and second ends, where the first and second members of the base are joined between the first and second ends at an angle substantially the same as the angle defined by the intersection of the two interior ledges forming the corner joint, and an end piece joined at the first end of the base adjacent the first and second members of the base, wherein the end piece and the first and second members of the base are joined at an angle defined by the intersection of the ledges and the surface; means for securing the corner guard along the intersection of the at least two interior ledges at the corner joint; a second membrane strip; and means for securing the second membrane strip along one of the at least two interior ledges and the surface and overlapping at least part of the base and end piece of the corner guard.

[0011] An alternative embodiment is directed to a method for waterproofing or flashing a corner intersection in a window, door or other opening defined by a surface, at least two interior ledges and at least one corner joint at the intersection of the at least two interior ledges. The steps include placing a first membrane strip against the surface; securing the membrane strip to the surface; placing a corner guard along the intersection of the at least two interior ledges at the corner joint, wherein the corner guard includes a base made up of a first and second member joined together, the base having first and second ends, wherein the first and second members of the base are joined between the first and second ends at an angle with respect to each other, and an end piece joined at the first end of the base adjacent the first and second members of the base, wherein the end piece and the first and second members of the base are joined at an angle as between the end piece and the first and second members, respectively; securing the corner guard along the corner joint; placing a second membrane strip along one of the at least two interior ledges and the surface and overlapping at least part of the base and end piece of the corner guard; and securing the second membrane strip to the at least two interior ledges and the surface.

[0012] In yet an alternative embodiment, a corner guard includes a first sheet of material; a second sheet of material fixed to and substantially transversely intersecting the first sheet of material; and a third sheet of material fixed to and substantially transversely intersecting the first and second sheets of material, wherein the first and second sheets of material do not extend beyond the intersection with the third sheet of material.

[0013] As will be readily appreciated from the foregoing summary, the invention provides an economical, simple to install and easy to use corner guard as an alternative to the traditional flashing membrane while demonstrating significant advantages in minimizing drafts and water leaks in residential and commercial construction.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings:

[0015] FIGS. 1A through 1C illustrate the prior art procedure for applying self-adhering, self-sealing, flexible flashing membrane to rough windows, doors or other openings to minimize drafts and water leaks.

[0016] FIGS. 2 through 4 are isometric views of the corner guard in accordance with the present invention.

[0017] FIGS. 5A through 5C illustrate the procedure for applying the corner guard to rough windows, doors or other openings in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0018] The preferred embodiment of the present invention provides an economical, simple to install and easy to use corner guard as an alternative to the traditional flashing membrane. The present invention offers significant advantages in minimizing drafts and water leaks in residential and commercial construction.

[0019] The present invention may be used with any type of corner joint or intersection on structures where waterproofing or flashing to minimize drafts and water leaks is of value. For example, the corner guard may be used with hand rail caps, deck railing, floor-to-posts, exterior housing structural elements such as roof-to-wall intersections, skylights, deck scuppers or other externally exposed structural corner joints or intersections. The present invention is preferably for use in association with rough window, door or other opening defined by an opening surface, interior ledges and corner joints, and is described in relation to this particular preferred application.

[0020] Referring to FIGS. 2 through 4, the preferred embodiment of a corner guard 100 in accordance with the present invention consists of a base 102 and an end piece 104. The base 102 is comprised of a first member 106 and a second member 108 joined or formed along a ridge edge 110 so as to form a substantially ninety degree angle. The end piece 104 is joined or formed along an end piece edge 112 of the base 102 to form another ninety degree angle. The base first and second members and end piece are preferably substantially flat, sheet materials, made of a plastic or metal substance susceptible to heat welding, gluing, extrusion or forming into the desired corner guard shape.

[0021] Most windows, doors or other openings demonstrate an approximately ninety degree angle at corner joints as well as between the ledge and the opening surface. However, the precise angle to which the first and second members are aligned may vary depending on the shape of the corner joint for which the corner guard is to be used. Similarly, the precise angle to which the end piece and base are aligned may vary depending on the shape of the opening surface and its relationship to the ledge of the opening.

[0022] The base 102 is variable in length, dependent primarily upon the depth of the interior ledge. In the preferred embodiment, the base 102 is between seven and eight inches deep. This allows the preferred corner guard to be adjustably fit on window and rough door openings of different depths. Extra length of the base 102 can be easily removed during installation, as necessary. The preferred size and shape of the end piece 104 varies based on the size and configuration of the interior ledge and opening surface with which it is used.

[0023] The corner guard of the present invention is used with window, door or other openings by placing the corner guard along an interior ledge of one or more corner joints, preferably in conjunction with complementary flashing membrane material. The preferred methodology for installation of the corner guard of the present invention is shown with reference to FIGS. 5A through 5C as used in association with a rough window, door or other opening 10 defined by an opening surface 12, interior ledges 14 and corner joints 16.

[0024] With reference to FIG. 5A, a flashing membrane strip 120 is installed by placing the membrane strip against the opening surface 12. The membrane strip 120 is preferably attached by stapling or nailing the membrane strip 10 along the top edge, for example at points 122.

[0025] As shown in FIG. 5B, the corner guard 100 is installed along the interior ledge 14b at corner joint 16a. More specifically, the base 102 of the corner guard is placed along the corner joint 16a such that the first member 106 is adjacent the ledge 14a, second member 108 is adjacent ledge 14b, ridge edge 110 is aligned along corner joint 16a and end piece 104 overhangs ledges 14a and 14b to rest adjacent surface 12, preferably exterior to membrane strip 120. The corner guard is preferably secured along the ledge 14a or 14b using nails in the first member 106 or second member 108 or both, depending on the opening configuration and user preference. Alternative means of securing the corner guard may be used, such as tacks, staples, pins, screws, adhesives or other equivalent securing options. The base 102 of the corner guard may be cut along the edge opposite the end piece 104 to fit the depth of the particular window, door or other opening. This process is repeated by installation of a second corner guard along the interior ledge at corner joint 16b.

[0026] As shown in FIG. 5C, the methodology continues with the installation of a second flashing membrane 124 along ledge 14b. The second flashing membrane 124 is cut approximately the width of the opening plus additional fold-over width, preferably at least two inches. The second flashing membrane 124 is installed by placing the second membrane along the ledge 14b, folding the excess width over the ledge onto the surface 12 and including the end pieces 104 of the corner guards installed at corner joints 16a and 16b, below the ledge 14b.

[0027] Substantially the same method outlined above may be repeated to install the corner guard at additional corner joints of opening 10. As described above, the corner guard may be used with alternative types of corner joints or intersections on structures where waterproofing or flashing to minimize drafts and water leaks is of value, for example, with hand rail caps, deck railing, roof-to-wall intersections, skylights, deck scuppers or other externally exposed structural corner joints or intersections. In alternative applications, the corner guard may not be used in conjunction with flashing membrane. In these configurations, the base 102 or end piece 104 may be trimmed or sized to fit and secured to other structures having one or more corner joint or intersection of wall, floor, roof or post elements. FIGS. 6 through 8 provide several examples of alternative types of corner joints or intersections on structure with which the present invention may be used. In each of these embodiments the corner guard may be secured to the surface structure using nails, tacks, staples, pins, screws, adhesives or other equivalent securing options. Also, in each example, the corner guard may be used with or without other flashing materials, such as flashing membrane strips.

[0028] FIG. 6 illustrates use of the present invention at the intersection of a half-wall with a vertical wall. In FIG. 6, a half-wall 150 intersects with a substantially vertical wall 152. A side surface 154 of the half-wall intersects vertical wall 152 at joint 158. A top surface 156 of the half-wall intersects vertical wall 152 at joint 160. A second side surface 162 of the half-wall opposite side surface 154 intersects vertical wall 152 at joint 164.

[0029] A corner guard 100a is installed along the top surface 156 and side surface 154 at joints 158 and 160. More specifically, the first member 106a of the base of the corner guard is placed adjacent side surface 154, the second member 108a of the base is placed adjacent top surface 156, and the end piece 104a is placed adjacent vertical wall 152, substantially fitting joints 158 and 160. If desired, a corner guard 100b is installed along the top surface 156 and side surface 162 at joints 164 and 160. More specifically, the first member 108b of the base of the corner guard is placed adjacent side surface 162, the second member 106b of the base is placed adjacent top surface 156, and end piece 104b is placed adjacent vertical wall 152, substantially fitting joints 164 and 160.

[0030] FIG. 7 illustrates use of the present invention at the intersection of vertical walls and a floor. In FIG. 7, a first wall 170 intersects with a second wall 172 at corner joint 174. The first wall 170 and the second wall 172 intersect with a floor 176 at joints 178 and 180, respectively. A corner guard 100 is installed along the intersection of the first and second walls and the floor. More specifically, the first member 106 of the base of the corner guard 100 is placed adjacent the wall 172, the second member 108 of the base is placed adjacent the wall 170, and end piece 104 is placed adjacent the floor 176 such that the angle between the first member 106 and the end piece 104 is substantially the same as the angle between the second wall 172 and the floor 178 at joint 180 and the angle between the second member 108 and the end piece 104 is substantially the same as the angle between the first wall 170 and the floor 176 at joint 178.

[0031] FIG. 8 illustrates use of the present invention with a scupper, for example on a deck. In FIG. 8, a scupper 180 intersects with a floor 182 at joints 184 and 186. A corner guard 100a is installed along joint 184 by placing the first member 106a of the base of the corner guard 100a adjacent an inner wall 188 of the scupper, the second member 108a of the base is placed adjacent the floor 182, and end piece 104a is placed adjacent a wall 190 associated with the scupper. In this embodiment, part of the end piece 104a is removed to facilitate proper fit along joint 184. If desired, a corner guard 100b is installed along joint 186 by placing the second member (not shown) of the base of the corner guard 100b adjacent an inner wall (not shown) of the scupper, the first member 106b of the base is placed adjacent the floor 182, and end piece 104b is placed adjacent a wall 190 associated with the scupper. In this embodiment, part of the end piece 104b is removed to facilitate proper fit along joint 186.

[0032] The present invention overcomes limitations associated with the installation of a traditional flashing membrane and provides an economical, simple to install and easy to use corner guard to waterproof and flash corner intersections in window, door or other openings.

[0033] While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. For example, while the preferred use of the corner guard of the present invention is along the lower ledge of windows or doors, it can equally be used along other parts of windows, doors or openings, wherever protection from drafts and water leaks is of value. Likewise, while the corner guard is preferably used prior to casement of a window, door or other opening, the present invention may be used in the absence of opening casements. In addition, while the base and end pieces of the corner guard are preferably formed as part of a unitary construction, the same elements could be connected in a variety of way to achieve the desired shape and function, for example, by tacks, staples, pins, screws, adhesives or other equivalent securing options. Also, while the preferred first and second members of the base and end piece were described as generally flat, the material sheets need not be flat, but could include shape, for example, curvature or designs. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow.

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A corner guard for corner joints or intersections in building construction, comprising: a base comprised of first and second members joined together, the base having first and second ends, wherein the first and second members of the base are joined at an angle with respect to each other between the first and second ends; and an end piece joined at the first end of the base adjacent the first and second members of the base, wherein the end piece and the first and second members of the base are joined at an angle as between the end piece and each member, respectively.

2. The corner guard of claim 1, wherein the angle between the first and second members is substantially between 85 and 135 degrees.

3. The corner guard of claim 1, wherein the angel between the end piece and each member, respectively, is substantially between 85 and 135 degrees.

4. A system for corner joints or intersections in building construction, comprising: an opening defined by a surface, at least two interior ledges and at least one corner joint at the intersection of the at least two interior ledges, wherein a corner joint angle is defined by the intersection of the at least two interior ledges forming the corner joint and a surface ledge angle is defined by the intersection of at least one of the ledges and the surface; and a corner guard for waterproofing or flashing the at least one corner intersection, comprising: a base comprised of first and second members joined together, the base having first and second ends, wherein the first and second members of the base are joined between the first and second ends at an angle with respect to each other substantially the same as the corner joint angle; and an end piece joined at the first end of the base adjacent the first and second members of the base, wherein the end piece and the first and second members of the base are joined at an angle as between the end piece and the first member substantially the same as the surface ledge angle.

5. The system of claim 4, wherein one of the at least two interior ledges of the opening has a depth and the length of at least one of the first and second members of the base is substantially the same as the depth of the one of the at least two interior ledges.

6. The system of claim 4, wherein the corner joint angle defined by the intersection of the at least two interior ledges forming the corner joint is substantially between 85 and 135 degrees.

7. The system of claim 4, wherein the surface ledge angle is defined by the intersection of at least one of the ledges and the surface is substantially between 85 and 135 degrees.

8. A system for corner joints or intersections in building construction, comprising: an intersection wherein a first and second surface intersect to form a first joint defining a corner joint angle and the first surface intersects with a third surface to form a second joint defining a surface angle; and a corner guard for waterproofing or flashing the intersection, comprising: a base comprised of first and second members joined together, the base having first and second ends, wherein the first and second members of the base are joined between the first and second ends at an angle with respect to each other substantially the same as the corner joint angle; and an end piece joined at the first end of the base adjacent the first member of the base, wherein the end piece and the first member of the base are joined at an angle as between the end piece and the first member substantially the same as the surface angle.

9. The system of claim 8: wherein the surface intersects with a fourth surface to form a third joint defining a second surface angle; and further comprising an end piece joined at the first end of the base adjacent the second member of the base, wherein the end piece and the second member of the base are joined at an angle as between the end piece and the second member substantially the same as the second surface angle.

10. A system for waterproofing or flashing corner intersections in windows, doors or other openings, comprising: an opening defined by a surface, at least two interior ledges and at least one corner joint at the intersection of the at least two interior ledges, wherein a corner joint angle is defined by the intersection of the at least two interior ledges forming the corner joint and a surface ledge angle is defined by the intersection of at least one of the ledges and the surface; and a first membrane strip; means for securing the first membrane strip to the surface; a corner guard for waterproofing or flashing the at least one corner intersection, comprising: a base comprised of first and second members joined together, the base having first and second ends, wherein the first and second members of the base are joined between the first and second ends at an angle with respect to each other substantially the same as the corner joint angle; and an end piece joined at the first end of the base adjacent the first and second members of the base, wherein the end piece and the first and second members of the base are joined at an angle as between the end piece and the first member substantially the same as the surface ledge angle; means for securing the corner guard along the intersection of the at least two interior ledges at the corner joint; a second membrane strip; and means for securing the second membrane strip along one of the at least two interior ledges and the surface and overlapping at least part of the base and end piece of the corner guard.

11. The system of claim 10, wherein one of the at least two interior ledges of the opening has a depth and the length of at least one of the first and second members of the base is substantially the same as the depth of the one of the at least two interior ledges.

12. The system of claim 10, wherein the corner joint angle defined by the intersection of the at least two interior ledges forming the corner joint is substantially between 85 and 135 degrees.

13. The system of claim 10, wherein the surface ledge angle is defined by the intersection of at least one of the ledges and the surface is substantially between 85 and 135 degrees.

14. A method for waterproofing or flashing a corner intersection in a window, door or other opening defined by a surface, at least two interior ledges and at least one corner joint at the intersection of the at least two interior ledges, comprising: placing a first membrane strip against the surface; securing the membrane strip to the surface; placing a corner guard along the intersection of the at least two interior ledges at the corner joint, wherein the corner guard comprises: a base comprised of first and second members joined together, the base having first and second ends, wherein the first and second members of the base are joined between the first and second ends at an angle with respect to each other; and an end piece joined at the first end of the base adjacent the first and second members of the base, wherein the end piece and the first and second members of the base are joined at an angle as between the end piece and the first and second members, respectively; securing the corner guard along the corner joint; placing a second membrane strip along one of the at least two interior ledges and the surface and overlapping at least part of the base and end piece of the corner guard; and securing the second membrane strip to the at least two interior ledges and the surface.

15. The system of claim 14, wherein the corner guard is placed along the corner joint such that the first member of the base is adjacent one of the at least two ledges of the opening and the second member of the base is adjacent the other one of the at least two ledges of the opening.

16. The system of claim 14, wherein one of the at least two interior ledges of the opening has a depth and the length of at least one of the first and second members of the base is cut along the edge opposite the end piece to fit the depth of the one of the at least two interior ledges.

17. The system of claim 14, wherein the first and second members of the base are joined along a ridge so as to form an angle between the first and second members of substantially between 85 and 135 degrees.

18. The system of claim 14, wherein the end piece and the first and second members of the base are joined as between the end piece and each member, respectively, at an angle of substantially between 85 and 135 degrees.

19. A corner guard for flashing a corner joint or intersection of a building structure, comprising: a first sheet of material; a second sheet of material fixed to and substantially transversely intersecting the first sheet of material; and a third sheet of material fixed to and substantially transversely intersecting the first and second sheets of material, wherein the first and second sheets of material do not extend beyond the intersection with the third sheet of material.

20. The corner guard of claim 19, wherein the intersection between the first and second sheets form an angle substantially between 85 and 135 degrees.

21. The corner guard of claim 19, wherein the intersection between each of the first and second sheets and the third sheet, respectively, forms an angle substantially between 85 and 135 degrees.

22. The corner guard of claim 19, wherein the sheets of material are substantially flat.