U.S. patent application number 11/013223 was filed with the patent office on 2006-06-29 for modular flashing system.
Invention is credited to Jeff Casey.
Application Number | 20060137263 11/013223 |
Document ID | / |
Family ID | 36609756 |
Filed Date | 2006-06-29 |
United States Patent
Application |
20060137263 |
Kind Code |
A1 |
Casey; Jeff |
June 29, 2006 |
Modular flashing system
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.
Inventors: |
Casey; Jeff; (New Haven,
CT) |
Correspondence
Address: |
PROTEUS PATENT PRACTICE LLC
P.O. BOX 1867
NEW HAVEN
CT
06508
US
|
Family ID: |
36609756 |
Appl. No.: |
11/013223 |
Filed: |
December 14, 2004 |
Current U.S.
Class: |
52/58 |
Current CPC
Class: |
E06B 1/62 20130101; E06B
2001/628 20130101 |
Class at
Publication: |
052/058 |
International
Class: |
E04D 13/14 20060101
E04D013/14 |
Claims
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. 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. 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. 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. 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. 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. The modular flashing entity described in claim 1 wherein at
least the second surface is nonplanar.
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. 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. 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. 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. The modular trim flashing element described in claim 11 wherein
the first surface is approximately perpendicular to the second
surface.
13. A kit comprising a plurality of modular flashing entities
described in claim 1.
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. A kit comprising a plurality of modular flashing entities
described in claim 4.
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. A kit comprising a plurality of modular flashing entities
described in claim 6.
18. A kit comprising a plurality of modular flashing entities
described in claim 7.
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. 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. The method described in claim 19 wherein the one or more
modular flashing entities seal a portal that is generally a
rectilinear opening.
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. The method described in claim 19 wherein the one or more
modular flashing entities seal a portal that is at least partly
curvilinear.
24. The method described in claim 23 wherein the portal includes a
circular, elliptical, hyperbolic, parabolic or other curvilinear
segment.
25. The method described in claim 19 wherein the affixing comprises
at least one of gluing, bonding, nailing, screwing, or
riveting.
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.
Description
FIELD OF THE INVENTION
[0001] 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
[0002] 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).
[0003] 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
[0004] 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.
[0005] In a first aspect the invention provides a modular flashing
entity including [0006] a) a first surface, [0007] 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
[0008] 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 [0009] 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 [0010] 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.
[0011] 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.
[0012] 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 [0013] 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 [0014] 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.
[0015] 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 [0016] 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 [0017] b) there is neither a left
extension nor a right extension.
[0018] 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.
[0019] 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 [0020] i) the second surface of the flashing
entity contacts a portion of the portal framing, and [0021] ii) the
first surface of a flashing entity contacts an exterior surface of
the building adjacent to the portal.
[0022] 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
[0023] FIG. 1. Schematic representation of a rectilinear portal
including a drip cap modular flashing entity (top) and a pan
flashing modular flashing entity (bottom).
[0024] FIG. 2. Schematic representation of a rectilinear portal
including modular trim flashing elements along the vertical
portions.
[0025] FIG. 3. Schematic representation of a left pan flashing
modular flashing entity and a right pan flashing modular flashing
entity.
[0026] FIG. 4. Schematic representation of a left drip cap modular
flashing entity and a right drip cap modular flashing entity.
[0027] FIG. 5. Schematic representation of a modular flashing
entity showing optional left and/or right extensions.
[0028] FIG. 6. Schematic representation of a modular trim flashing
element showing optional left and/or right extensions.
[0029] FIG. 7. Schematic representation of a curvilinear portal
including modular flashing entities affixed therein.
DETAILED DESCRIPTION OF THE INVENTION
[0030] 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.
[0031] 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.
[0032] 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.
[0033] 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".
[0034] 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.
[0035] 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.
[0036] 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.
[0037] 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.
[0038] 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.
[0039] 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.
[0040] 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.
[0041] 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.
[0042] 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''.times.4'' studs, or
2''.times.6'' studs, and so forth.
[0043] 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.
[0044] 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.
[0045] 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".
[0046] 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.
[0047] 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.
[0048] 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).
[0049] 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).
[0050] 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.
[0051] 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.
[0052] 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.
[0053] 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
[0054] 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
[0055] b) there is neither a left extension nor a right
extension.
[0056] 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.
[0057] 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.
[0058] 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.
[0059] 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.
[0060] 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).
[0061] 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.
[0062] 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.
[0063] 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.
[0064] 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.
[0065] 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).
[0066] 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.
[0067] 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.
[0068] A nonlimiting example of a construction process for a
rectilinear door or window using the modular flashing systems of
the present invention includes: [0069] 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. [0070] 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. [0071] 3. Install exterior casement trim around the
installed door or window assembly. [0072] 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.
[0073] 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.
[0074] 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.
* * * * *