U.S. patent application number 12/067621 was filed with the patent office on 2009-02-05 for roof flashing connections.
This patent application is currently assigned to VIRIDIAN CONCEPTS LTD. Invention is credited to Martin Davies, Stuart Elmes, Kak Thong Tan.
Application Number | 20090031640 12/067621 |
Document ID | / |
Family ID | 35335221 |
Filed Date | 2009-02-05 |
United States Patent
Application |
20090031640 |
Kind Code |
A1 |
Elmes; Stuart ; et
al. |
February 5, 2009 |
Roof Flashing Connections
Abstract
A roof-penetrating structure for incorporating into a roof, the
structure including a portion extending along one or more sides of
the roof-penetrating structure for receiving an edge section of one
or more sheets of flashing to provide a weather-proof connection
therebetween; said portion including one or more resilient members
such that, in use, the insertion of flashing into said portion
automatically forces at least one of said one or more resilient
members into a configuration in which they are biased against the
flashing.
Inventors: |
Elmes; Stuart; (Cambridge,
GB) ; Tan; Kak Thong; (Cambridge, GB) ;
Davies; Martin; (Cambridge, GB) |
Correspondence
Address: |
SUGHRUE MION, PLLC
2100 PENNSYLVANIA AVENUE, N.W., SUITE 800
WASHINGTON
DC
20037
US
|
Assignee: |
VIRIDIAN CONCEPTS LTD
Herts
GB
|
Family ID: |
35335221 |
Appl. No.: |
12/067621 |
Filed: |
September 20, 2006 |
PCT Filed: |
September 20, 2006 |
PCT NO: |
PCT/GB2006/003487 |
371 Date: |
August 8, 2008 |
Current U.S.
Class: |
52/60 ;
52/200 |
Current CPC
Class: |
F24S 80/40 20180501;
E04D 13/1475 20130101; Y02E 10/44 20130101; F24S 80/70 20180501;
Y02E 10/40 20130101; F24S 80/30 20180501; E04D 13/02 20130101; Y02B
10/20 20130101; F24S 20/67 20180501; E04D 13/031 20130101 |
Class at
Publication: |
52/60 ;
52/200 |
International
Class: |
E04D 13/03 20060101
E04D013/03; E04B 7/18 20060101 E04B007/18 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 21, 2005 |
GB |
0159286.9 |
Claims
1-19. (canceled)
20. A roof-penetrating structure for incorporating into a roof, the
structure including a portion extending along one or more sides of
the roof-penetrating structure for receiving an edge section of one
or more sheets of flashing to provide a weather-proof connection
therebetween; said portion including one or more resilient members
such that, in use, the insertion of flashing into said portion
automatically forces at least one of said one or more resilient
members into a configuration in which they are biased against the
flashing.
21. A roof-penetrating structure according to claim 20, wherein the
resilient member(s) comprise at least one pair of resilient flap
members extending from opposing sides of said portion.
22. A roof-penetrating structure according to claim 21, wherein
said pair of resilient flap members overlap with each other in
their relaxed configuration.
23. A roof-penetrating structure according to claim 21, including a
plurality of said pairs of resilient flap members positioned at
increasing distances in the direction of insertion of the
flashing.
24. A roof-penetrating structure according to claim 21, wherein the
resilient flap members partially point in the direction of
insertion of the flashing in their relaxed configuration.
25. A roof-penetrating structure according to claim 20, wherein
said portion is a component fitted into a recess in a base
structure of said roof-penetrating structure.
26. A roof-penetrating structure according to claim 25, wherein
said component is provided with barbs which act to resist its
removal from said recess.
27. A roof-penetrating structure according to claim 25, wherein
said recess extends continuously around the roof-penetrating
structure, and said portion is a continuous component fitted about
said base structure and into said recess.
28. A roof-penetrating structure according to claim 25, wherein
said component is an extruded component.
29. A roof-penetrating structure according to claim 20, wherein the
resilient member(s) comprises bristles extending from opposing
sides of said portion.
30. A roof-penetrating structure according to claim 20, wherein
said portion defines a resilient convex end-stop, which, in use,
partially inverts when the edge of the flashing is forced against
it.
31. A roof-penetrating structure according to claim 20, which is a
solar panel or a roof window.
32. A roof-penetrating structure according to claim 20, which is
incorporated into a roof by inserting the edge of at least one
sheet of flashing into said portion, and creating a weather-proof
connection between said sheet of flashing and said roof.
33. A kit comprising a roof-penetrating structure for incorporating
into a roof and one or more sheets of flashing, the structure
including a portion extending along one or more sides of the
roof-penetrating structure for receiving an edge section of said
one or more sheets of flashing to provide a weather-proof
connection therebetween; said portion including one or more
resilient members such that, in use, the insertion of flashing into
said portion automatically forces at least one of said one or more
resilient members into a configuration in which they are biased
against the flashing.
34. A sheet of flashing for incorporating a roof-penetrating
structure in a roof, said sheet of flashing including an edge
section for inserting into a receiving portion of a
roof-penetrating structure to provide a weather-proof connection
therebetween; said edge section of said sheet of flashing being
provided with one or more resilient members such that, in use, the
insertion of the sheet of flashing into said receiving portion of
said roof-penetrating structure automatically forces at least one
of said one or more resilient members into a configuration in which
they are biased against the receiving portion.
35. A sheet of flashing according to claim 34, which is used to
incorporate a roof-penetrating structure into a roof by inserting
said edge section into a receiving portion of a roof-penetrating
structure, and creating a weather-proof connection between said
sheet of flashing and said roof.
36. A kit comprising a roof penetrating structure and one or more
sheets of flashing for incorporating said roof-penetrating
structure in a roof, said one or more sheets of flashing including
an edge section for inserting into a receiving portion of a
roof-penetrating structure to provide a weather-proof connection
therebetween; said edge section being provided with one or more
resilient members such that, in use, the insertion of said one or
more sheets of flashing into said receiving portion of said
roof-penetrating structure automatically forces at least one of
said one or more resilient members into a configuration in which
they are biased against the receiving portion.
Description
[0001] The present invention relates to a technique for connecting
a roof-penetrating structure to roof flashing, such as, for
example, that used to create a weathertight seal between a roof
window or solar panel and a roof covering such as tiles, slates or
shingles.
[0002] The use of pre-formed flashing kits is well known in roof
windows. The skilful and time-consuming job of forming lead sheet
on site to make a weathertight seal between the window and the roof
covering is replaced with a factory manufactured kit of parts,
often made by pressing or roll forming pre-painted aluminium sheet.
The kit is normally supplied in four parts--two side gutters and
sections to go around the top and bottom. This approach has also
been applied to solar panels.
[0003] Conventional approaches for joining roof flashing to the
upstand of a roof-penetrating body are illustrated in FIGS.
1-3.
[0004] One approach, shown in FIG. 1, is to provide side gutters,
and top and bottom flashing components as a continuous part of the
product--pre attached in the factory. The gutter (4) between the
upstand of the roof penetrating structure (2) and the tile (3) is
formed by a flashing (1) that is a continuous part of the cover
glass. A flexible seal (5) may be present to provide a conforming
fit with the shape of the tile. This approach has particularly been
adopted for roof windows and solar panels with thermoformed clear
plastic covers.
[0005] With this approach, the flashing needs to be made more
robust (for handling) than it needs to be for durability once
installed. Also, different types of flashing may be needed for
different roof coverings, requiring the manufacturer to produce
different versions of the roof-penetrating structure incorporating
the different types of flashing.
[0006] A second approach, shown in FIG. 2, provides a separate
flashing (1) that tucks up under a skirt (7) on the rooflight or
solar panel. The glazing (6) is now a separate part. Gravity keeps
water out, and a return fold (8) on the flashing prevents
wind-driven rain from entering.
[0007] With this approach, the flashing needs to be rotated into
position, which can limit the acceptable geometry for the flashing
and the skirt. Also, flashing corner pieces are particularly
difficult to fit in without significant distortion of the flashing
being required.
[0008] The skirt can be made a separate component that is removed
prior to pushing the flashing against the side of the roof window,
and then clipped back into place. Whilst this can alleviate the
difficulty mentioned above, it does add to the complexity of
fitment and manufacture.
[0009] A third approach, illustrated in FIG. 3, is to have a
removable cover (9) on the window or solar panel. This is removed
to allow the flashing to engage, and then reaffixed with nails or
screws (10) to cover the flashing.
[0010] This arrangement is cheap to produce, but requires the
roofing contractor to disassemble and reassemble components. This
can be time consuming, and there is also the risk of the
disassembled components being dropped before reassembly. This
approach has particularly been used with wooden frames, where nails
or screws can be used to attach the cover through the flashing.
[0011] It is an aim of the invention to provide a new technique of
connecting a roof flashing to a roof-light, solar panel or other
roof penetrating structure which is simple and quick whilst
providing a weather-tight and durable connection.
[0012] According to one aspect of the present invention, there is
provided a roof-penetrating structure for incorporating into a
roof, the structure including a portion extending along one or more
sides of the roof-penetrating structure for receiving an edge
section of one or more sheets of flashing to provide a
weather-proof connection therebetween; said portion including one
or more resilient members such that, in use, the insertion of
flashing into said portion automatically forces at least one of
said one or more resilient members into a configuration in which
they are biased against the flashing.
[0013] In one embodiment, the resilient member(s) comprise at least
one pair of resilient flap members extending from opposing sides of
said portion; said pair of resilient flap members overlap with each
other in their relaxed configuration; a plurality of said pairs of
resilient flap members are positioned at increasing distances in
the direction of insertion of the flashing; and the resilient flap
members partially point in the direction of insertion of the
flashing in their relaxed configuration.
[0014] In one embodiment, said portion is a component fitted into a
recess in a base structure of said roof-penetrating structure; said
component is provided with barbs which act to resist its removal
from said recess; and said recess extends continuously around the
roof-penetrating structure; said portion is a continuous component
fitted about said base structure and into said recess; and said
component is an extruded component.
[0015] In one embodiment, the resilient member(s) comprises
bristles extending from opposing sides of said portion.
[0016] In one embodiment, said portion defines a resilient convex
end-stop, which, in use, partially inverts when the edge of the
flashing is forced against it.
[0017] There is also provided a solar panel or roof window
comprising a roof-penetrating structure as described above.
[0018] The present invention also provides a method of
incorporating a roof-penetrating structure as described above into
a roof, the method comprising inserting the edge of at least one
sheet of flashing into said portion, and creating a weather-proof
connection between said sheet of flashing and said roof.
[0019] The present invention also provides a kit comprising a
roof-penetrating structure for incorporating into a roof and one or
more sheets of flashing, the structure including a portion
extending along one or more sides of the roof-penetrating structure
for receiving an edge section of said one or more sheets of
flashing to provide a weather-proof connection therebetween; said
portion including one or more resilient members such that, in use,
the insertion of flashing into said portion automatically forces at
least one of said one or more resilient members into a
configuration in which they are biased against the flashing.
[0020] According to another aspect of the present invention, there
is provided a sheet of flashing for incorporating a
roof-penetrating structure in a roof, said sheet of flashing
including an edge section for inserting into a receiving portion of
a roof-penetrating structure to provide a weather-proof connection
therebetween; said edge section of said sheet of flashing being
provided with one or more resilient members such that, in use, the
insertion of the sheet of flashing into said receiving portion of
said roof-penetrating structure automatically forces at least one
of said one or more resilient members into a configuration in which
they are biased against the receiving portion.
[0021] The present invention also provides a method of
incorporating a roof-penetrating structure into a roof, the method
comprising inserting said edge section of a sheet of flashing
described in the preceding paragraph into a receiving portion of a
roof-penetrating structure, and creating a weather-proof connection
between said sheet of flashing and said roof.
[0022] The present invention also provides a kit comprising a roof
penetrating structure and one or more sheets of flashing for
incorporating said roof-penetrating structure in a roof, said one
or more sheets of flashing including an edge section for inserting
into a receiving portion of a roof-penetrating structure to provide
a weather-proof connection therebetween; said edge section being
provided with one or more resilient members such that, in use, the
insertion of said one or more sheets of flashing into said
receiving portion of said roof-penetrating structure automatically
forces at least one of said one or more resilient members into a
configuration in which they are biased against the receiving
portion.
[0023] Hereunder follows a detailed description of embodiments of
the invention, by way of example only, with reference to the
accompanying drawings, in which:
[0024] FIGS. 1-3 are cross-sectional views of the gutter formed by
the flashing between the roof penetrating structure and the roof
covering according to the above-described conventional
approaches.
[0025] FIG. 4 is a cross-sectional view similar to FIGS. 1-3 for an
embodiment of the present invention.
[0026] FIG. 5 is a cross-sectional view of an example of the
flashing gasket of FIG. 4.
[0027] FIG. 6 shows the flashing gasket of FIG. 5 with the flashing
inserted.
[0028] FIG. 7 is a cross-sectional view of another example of the
flashing gasket of FIG. 4.
[0029] FIG. 8 shows the flashing gasket of FIG. 7 with the flashing
inserted.
[0030] FIG. 9 is a cross-sectional view of a third example of the
flashing gasket of FIG. 4 with inward facing bristles.
[0031] FIG. 10 is a cross sectional view similar to FIGS. 1-3 for
an alternative embodiment of the present invention.
[0032] In one embodiment of the invention, shown in cross-section
in FIG. 4, a weather tight seal is made between the upstand of a
solar panel, rooflight, or other roof penetrating structure (2),
and a roof covering such as a tiles (3) by forming a gutter (4)
with a flashing (1). The roof penetrating structure is provided
with a continuous slot (11) around the outside face of its upstand
(2). The slot is shaped to receive a flexible gasket (12). To
secure the gasket into the slot, a barb (13) on the outside face of
the gasket mates with a corresponding rebate in the slot.
[0033] The gasket plug is of a generally U-shaped section formed
with a series of lips (14) extending into the centre, such that
when a thin sheet of flashing material (1) is pushed into it, they
are deflected to form a series of seals against the upper and lower
faces of the sheet.
[0034] If the lips are made to extend beyond the centre line of the
gasket, then discrepancies in the height of the flashing can be
accommodated. The use of a spaced apart series of lips disrupts the
path of capillarity, so water will not penetrate beyond the end of
the contact face of the first lip by this mechanism. If the lips
are angled towards the closed end of the gasket they deform easily
by bending when the flashing is pushed in, but resist pull out.
[0035] It can be seen that the advantage of this design is the ease
with which the flashing is fitted. The flashing is simply pushed
into the slot in the gasket until it stops against the side of the
upstand, thus providing clear feedback to the fitter that it is
properly in place.
[0036] An alternative design of gasket has an inlet cover that
hangs down below the top edge of the flashing (16). The inlet cover
is shaped so that as the flashing is pushed past it, a protrusion
prevents its further rotation by interfering with the first lip.
Once the flashing is pushed to its maximum extent, the inlet cover
springs down against the flashing. This feature is useful to
prevent against wind pressure opening the lips. Positive pressure
on the outside acts to press the inlet cover harder against the
flashing.
[0037] In places the flashing sections overlap each other, and
there is a double thickness of flashing material pushed into the
gasket. The gasket cannot perfectly conform to the change in
thickness at each end of the overlap section. Consequently there
will be a small gap between the flexible lips and the top and
bottom faces of the flashing at these points (although the gap and
the top and the gap at the bottom will be offset by the distance of
the overlap). A compressible convex shape (15) at the end of the
recess in the gasket seals against the edge of the flashing and
provides a continuous seal at all points.
[0038] One variation of this embodiment would have the inside faces
of the gasket made up of bristles (17), with their free end facing
towards the centre. This variation could better conform to step
changes in the flashing material, such as those described
above.
[0039] Examples of suitable materials for the gasket plug are
rubber and EPDM (ethylene propylene diene monomer) synthetic
rubber. It can be formed by extrusion, and joined with moulded
mitred corners to form a continuous loop. The design is
particularly well suited to connecting the flashing to a frame
formed by extrusion, for example one of aluminium. However, the
slot could also be formed by routing in wood, or forming steel or
aluminium sheet by roll forming.
[0040] An alternative embodiment of the invention, shown in FIG.
10, includes a flashing with a gasket attached to its edge (18).
The fitment procedure would then be to push the flashing and gasket
into a receiving slot (11) in the upstand of the roof penetrating
structure.
[0041] With the techniques described above, a standardised roof
window or solar panel can be produced that can be used with a
variety of different flashing kits.
[0042] The above detailed description of embodiments of the present
invention is provided by way of example only, and various
modifications can be made to these embodiments without departing
from the scope of the invention
[0043] The applicant draws attention to the fact that the present
invention may include any feature or combination of features
disclosed herein either implicitly or explicitly or any
generalisation thereof, without limitation to the scope of any
definitions set out above.
* * * * *