U.S. patent application number 11/104472 was filed with the patent office on 2006-11-23 for pan flashing with sill wedge.
Invention is credited to Mark F. Williams.
Application Number | 20060260213 11/104472 |
Document ID | / |
Family ID | 37101463 |
Filed Date | 2006-11-23 |
United States Patent
Application |
20060260213 |
Kind Code |
A1 |
Williams; Mark F. |
November 23, 2006 |
Pan flashing with sill wedge
Abstract
The subject invention provides a component which improves upon
the overall function of sill pan flashing, specifically the use of
a novel sill wedge that promotes drainage of water from the sill
pan. The novel sill wedge is made from polyethylene foam, a
flexible material in a unique configuration, which also provides
support for the bottom of the sill pan. Accordingly, the sill wedge
can be effectively extruded into a double wedge, continuous roll,
shrink wrapped and shipped in rolls thus allowing for easy cutting
to length in the field, improving performance of the pan flashing
while also addressing shipping, storage and installation
issues.
Inventors: |
Williams; Mark F.; (Maple
Glen, PA) |
Correspondence
Address: |
Cornelius J. Husar
12901 Penecrest Road
Herndon
VA
20171
US
|
Family ID: |
37101463 |
Appl. No.: |
11/104472 |
Filed: |
April 13, 2005 |
Current U.S.
Class: |
52/60 |
Current CPC
Class: |
E06B 2001/628 20130101;
E06B 1/70 20130101; E06B 1/702 20130101 |
Class at
Publication: |
052/060 |
International
Class: |
E04D 13/14 20060101
E04D013/14; E04D 1/36 20060101 E04D001/36 |
Claims
1. A combination of flashing elements for reducing the penetration
of water around a rough opening with a window, door or louver
installed therein, said combination comprising: a rough opening
including a header, side jambs and a rough opening sill plate; a
sill wedge member installed across said sill plate; a pan flashing
member installed across the width of the opening above said sill
plate with said sill wedge member therebeneath; said pan flashing
member comprising a self-adhesive backed flashing installed across
the rough opening with vertical slits at the jamb studs folded into
the rough opening over said sill wedge and terminating in a back
dam; a pair of preformed corner accessory pieces having a pair of
legs installed in the lower corners of the rough window opening
with one leg installed over said pan flashing member and the other
leg in abutting relation with said window side jambs; self-adhesive
strip seals are placed over the sill edge of each of the corner
accessory pieces which effectively combines to prevent moisture
leakage into the building at this locale.
2. A combination of flashing components as defined in claim 1
wherein said sill wedge is an extruded polyethylene foam shape that
is tapered across its width to promote drainage of water from the
interior portion of the pan flashing towards the building's
exterior.
3. A combination of flashing elements as defined in claim 2 wherein
said polyethylene foam sill wedge is of a density that is flexible
enough to be coiled into a roll.
4. A combination of flashing elements as defined In claim 3 wherein
said polyethylene foam sill wedge is of a density that is firm
enough to support the sill pan.
5. A combination of flashing elements as defined in claim 4 wherein
the polyethylene foam sill wedge can be easily cut and trimmed with
scissors or a utility knife.
6. A combination of flashing components as defined in claim 5
wherein said polyethylene foam sill wedge is extruded in a single
width.
7. A combination of flashing components as defined in claim 5
wherein said polyethylene foam sill wedge is extruded in a double
width to facilitate coiling, shipping and reduce manufacturing
costs.
8. A sill wedge for supporting a rough opening pan flashing
comprising extruded polyethylene foam that is sloped across its
width to create a wedge shape.
9. A sill wedge for supporting a pan flashing as defined in claim 8
wherein said wedge shape is extruded as a single width.
10. A sill wedge for supporting a pan flashing as defined in claim
8 wherein said wedge shape is extruded in a double width form for
ease of shipping and storage.
11. A sill wedge made of extruded polyethylene foam into a double
wedge; each wedge of said double wedge having a high rear end and a
forward extending taper ending in a forward tip of diminished
height; said double wedge extruded with said forward tip of each
wedge in contact with the forward tip of the opposite wedge thus
forming said double wedge of substantial width allowing the
free-standing of a roll of said double wedge.
12. A sill wedge as defined in claim 11 wherein said extruded
double wedge has an imaginary centerline whereby said double wedge
may be cut along said imaginary centerline into a pair of single
sill wedge members.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is closely related to Ser. No. 09/692,226,
filed on Oct. 26, 2000 entitled, Multi-Component Flashing Systems,
now U.S. Pat. No. 6,401,401 and Ser. No. 09/777,844, filed on Feb.
07, 2001, entitled, Pre-Folded Flashing This application is closely
related to Ser. No. 09/692,226, filed on Oct. 26, 2000, Systems and
Method, now U.S. Pat. No. 6,401,402, both by the same inventor as
the subject application and also another earlier patent entitled
Multi-Component Elastomeric Materials For A Building Flashing
System issued to Williams et al, as U.S. Pat. No. 5,899,026 on May
4, 1999, pending application Ser. No. 10/200,259 filed on Jul. 23,
2002 entitled, Integrated System For Controlling Water Intrusion
and Air Movement Through Exterior Wall Construction by Mark F.
Williams and pending applications Ser. No. 10/670,318 filed on Sep.
26, 2003, entitled MULTI-UNIT TERMINATION ACCESSORY FLASHING and
pending application Ser. No. ______, filed on ______, entitled Pan
Flashing With Sill Wedge and Window Clip, both pending applications
invented by the same inventor, Mark F. Williams.
BACKGROUND OF THE INVENTION
[0002] As has been pointed out in several of the above noted patent
applications, air and moisture penetration in and around window,
door and louver rough openings, is one of the construction
industry's most serious problems. Damage caused by infiltration of
air and moisture at rough openings, and the problem of mold and
fungi with their own special set of consequences, has been
increasingly recognized over the past several years.
[0003] As a result of these problems, there is an aggressive effort
by many to improve upon the products and installation techniques
that are currently in use. Several of the above-noted related
applications deal with the flashing of rough window openings using
a special formulated silicone sealing adhesive in combination with
a particular sheet flashing material that the silicone sealing
adhesive readily bonded to form watertight joints in and around
rough window openings and other openings such as rough door
openings.
[0004] The Williams, '401 patent noted above deals primarily with a
preformed termination accessory that can be used in any one of the
four corners of a rough opening. However, its use would most
commonly be used at the lower bottom corners where the same
accessory can be used in any of the lower or upper corners merely
by rotating the accessory unit ninety degrees. The Williams '401
patent also discloses the use a clay coated flashing material that
is used in conjunction with an elastomeric adhesive sealant that
readily bonds with the clay coated flashing material.
[0005] The Williams '402 patent discloses a pre-folded flashing
system and Williams et al, '026 discloses the use of both liquid
and solid forms of flashing material. Pending Williams application
Ser. No. 10/200,259 discloses an integrated system wherein a
variety of exterior sheathing panels, i.e. foam boards, foil-faced
board, cementitious based boards, are exteriorly treated with an
elastomeric membrane-like material and the joints therebetween are
taped with clay coated adhesive backed taped. Williams pending
application Ser. No. 10/670,318 deals primarily with a multi-unit
termination accessory flashing that is manufactured in molded units
of four that are separable and individually used in rough opening
corners similar to the termination accessory units of the Williams,
'401 patent.
[0006] As can be seen from a review of the above noted patents and
pending applications, solving the problems associated with air and
moisture penetration continues to be a work in progress. The
subject invention is an extension of the prior attempts to resolve
this serious problem. In the present application there is disclosed
a sill wedge that is installed beneath the sill pan flashing.
Previous to this invention, when a sill wedge was used, it was
constructed from rigid plastic or wood. Both of these materials had
many drawbacks; consequently, the usage of sill wedges has been
limited. Pan flashings are a proven method of managing unwanted
water at rough openings in the building enclosure. However,
providing slope for the pan flashing can pose certain unique
challenges. These challenges are solved by using WillFlash.RTM.
Sill Wedge which is flexible enough to be coiled on a roll to
facilitate shipping, yet is firm enough to provide a base for the
sill pan itself. This wedge solves many problems by supporting a
sill pan self-adhering membrane and directing water from the sill
pan towards the building exterior; yet because it is not rigid, it
may be conveniently coiled for storage and/or shipment.
Furthermore, the sill wedge material itself may be easily cut and
trimmed with scissors or a utility knife, which helps to speed
installations. Additionally, it has been found that the sill wedge
may be most efficiently manufactured by extruding two polyethylene
sill wedges simultaneously, in a "tip to tip" configuration. This
reduces the manufacturing costs because two wedges are
simultaneously fabricated. Furthermore, the two wedge profile is
symmetrical, which also benefits the coiling of sill wedge on a
roll. The symmetrical profile will roll consistently; whereas, a
single wedge profile rolls unevenly onto the shipping spool.
Therefore, the "two wedge profile" may be rolled upon itself
without the need for a spool, further reducing the cost of
packaging and transport.
SUMMARY OF THE INVENTION
[0007] As indicated above, the subject invention provides a
component which improves upon the overall function of sill pan
flashing, specifically the use of a novel sill wedge that promotes
drainage of water from the sill pan. The novel sill wedge is made
from polyethylene foam, a flexible material in a unique
configuration, which also provides support for the bottom of the
sill pan. Accordingly, the sill wedge can be effectively extruded
into a double wedge, continuous roll, shrink wrapped and shipped in
rolls thus allowing for easy cutting to length in the field,
improving performance of the pan flashing while also addressing
shipping and installation issues.
DISCUSSION OF THE PRIOR ART
[0008] A recent search of the Patent Office files in the
appropriate Classes and subclasses revealed the following prior art
documents. [0009] U.S. Pat. No. 2,472,216--issued to Kasik on Jun.
7, 1949--discloses a window stop 20 in the shape of a wedge. Stop
20 is used to on a window sash to permit opening the window any
desired amount. [0010] U.S. Pat. No. 5,340,176--issued to Cresci on
Aug. 23, 1994--discloses a window wedge that is used as a stop for
a sliding type window such as a double hung window. [0011] U.S.
Pat. No. 5,491,940--issued to Bruchu on Feb. 20, 1996--discloses a
variable angle wedge that supports a replacement window and
compensates for whatever sill angle exists on the previous window
frame [0012] US 2002/0146539--application of Dwinell published on
Oct. 10, 2002--discloses a window stabilizing device including a
wedge portion dimensioned for being positioned between a lower edge
of a window and a corresponding window frame or sill.
[0013] In addition to this known patent prior art, there has also
been activity in the field by a company entitled Vinyl Corp.that
published a 2004 PRODUCT DATA CATALOG, 3 pages, that includes a
product called PB SLOPED SILL WEDGE and contains a statement,
"Sloped Sill Wedge--Trim component used to provide a positive slope
over the sill to direct intruding water to the outside face of
weather-resistive barrier for drainage out of the system. This is
not a flashing use in combination with a water-managed system."
Additionally, there is a second publication, a one page article
entitled, CANT LEAK SILL GUARD TM WINDOW DRAINAGE SYSTEM by
Protecto Wrap Company that refers to a patent pending window sill
drainage system for use in new and remodeling construction. This
publication is rather weak in its description of the product and
serves more or less as an advertising brochure for the product
without much detail as to the product per se and its manner of
use.
[0014] As can be seen from a review of this known prior art, i.e.
patent documents, there are a variety of wedge devices that are
used in their customary manner, i.e. the tapered end of the wedge
is inserted between a pair of elements to provide a bias
therebetween and prevent "rattling" or serve as a "stop" between
two relatively moveable members. However, none of the known prior
art "wedges" are used in combination with a "pan flashing" member
to provide sufficient elevation to the rear end of the pan flashing
member thus allowing gravitational flow of any moisture in the area
to move forward and exit the building structure. The two known
non-patent publications, both indicate an awareness of the problems
in this particular area, however, they both attempt to solve the
problem in a different manner.
OBJECTS OF THE INVENTION
[0015] An object of the invention is to improve the drainage
performance of pan flashing that is utilized to control the
intrusion of water below a window, door or louver in the sill
area.
[0016] Another object of the invention is to provide a sill wedge
that is made of a suitable density polyethylene foam which is
flexible enough to be coiled on a roll to facilitate shipping.
[0017] A further object of the invention is to provide a suitable
density polyethylene foam that is firm enough to provide a base for
the sill pan itself.
[0018] A still further object of the invention is to provide a
suitable density polyethylene foam that may be cut and trimmed with
scissors or a utility knife to improve the speed of
installation.
[0019] Yet another object of the invention is to provide a unique
double width configuration for the sill wedge to reduce
manufacturing costs and aid coiling of the sill wedge material onto
a consistent roll.
[0020] These and other objects of the invention will become more
apparent hereinafter. The instant invention will now be described
with reference to the accompanying drawings wherein like reference
characters designate the corresponding parts throughout the several
views.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is an exploded view of a window rough opening
illustrating the components and sequence of their installation in
flashing a window rough opening.
[0022] FIG. 2 is an illustration of a coil of sill wedge material
as shipped from the factory.
[0023] FIG. 3 is a cross-sectional view taken along the plane 3-3
of FIG. 2, prior to severing into useful individual sill wedge
components.
[0024] FIG. 4 is portion of sill wedge material after it has been
severed from the roll followed by a central split to form an
individual sill wedge member.
DETAILED DESCRIPTION OF THE DRAWINGS
[0025] Referring now to FIG. 1, there is illustrated an exploded
view of a rough opening 25 comprised of the usual header 26, side
jambs 27 and sill portion 28. As illustrated, sill wedge 29 is
about to be placed over rough opening sill portion 28 to provide
some elevation to the rear end of rough opening sill portion 28 to
allow easy outward draining of any moisture that might collect on
pan flashing member 30 when installed over sill wedge 29. Pan
flashing member is comprised of a sill portion 32 with an
upstanding rear lip portion or back darn 33 that extends the full
width of window rough opening 28. Additionally, pan flashing 30
includes a forward apron portion 30A that extends downward across
the frontal face of the building structure and a pair of oppositely
disposed panel portions 34 that would extend across the frontal
face of the jamb portions (not shown). Inasmuch as the pan flashing
30 is made of self-adhering material, once the release paper
material is removed, it can readily be affixed to the rough opening
over the sill wedge 29. Upon completion of the installation of pan
flashing member 30, a pair of pre-molded Comer Accessory Pieces 35
(CAPs) are installed in the lower left and right-hand corners over
the pan flashing member 30. These CAPs 35 in combination with rear
lip portion 33 cooperate to form the side and end dams for sill pan
30. After installation of CAPs 35 in their respective corners, a
strip seal 36 (a self-adhering flashing) is placed over the
right-most edge of the CAP 35 overlying a portion of CAP 35 and
also pan flashing sill portion 32 to seal the edge therebeneath. It
is to be noted that the rear end of strip seal 36 (a self-adhering
flashing) extends rearward to the point where it wraps over the
back dam giving it added strength in that area. Next, outer seal
37, (a self-adhering flashing) is placed over strip seal 36 and
also the horizontal leg portion of CAP 35 to complete the sealing
of the rough window opening 25.
[0026] Turning now to FIG. 2, there is shown a roll of sill wedge
50, as shown, the sill wedge material 29 has been rolled into a
reasonably sized roll of material for shipping purposes after it
has come out of the extruder and cooled sufficiently. As shown the
polyethylene foam has been extruded into a double wedge
configuration 29A and 29B, with their tapered tips meeting along
the imaginary centerline 29CL. As pointed out earlier, the main
advantage of this "double wedge configuration" is that it provides
symmetry relative to centerline 29CL and provides balance to the
product allowing it to become free-standing when rolled as shown in
FIG. 2.
[0027] Referring now to FIG. 3, there is shown a sectional view
taken along the plane 3-3 of FIG. 2 illustrating the "double wedge"
configuration referred to above. As indicated earlier, this "double
wedge" provides balance during the extrusion process and also
during shipment of the finished product. The second wedge provides
an equalizing or stabilizing force when combined with the first
wedge and permits unsupported standing of a roll. As one can
imagine, these features greatly enhance the shipping and handling
features of the product.
[0028] FIG. 4 is an illustration of the sill wedge material 29
shown in FIG. 3, however, in this view, the material has been cut
along the centerline 29CL and in preparation for insertion into a
rough window opening as illustrated in FIG. 1.
[0029] While the invention has been described in its preferred
embodiment, it is to be understood that the words which have been
used are words of description rather than words of limitation and
that changes may be made within the purview of the appended claims
without departing from the full scope or spirit of the invention.
Accordingly, the present invention is to be limited only by the
appended claims, and not by the foregoing specification.
* * * * *