U.S. patent application number 12/478419 was filed with the patent office on 2010-05-06 for zinc flashing for roof penetrations.
This patent application is currently assigned to The Garland Company, Inc.. Invention is credited to JAY EUGENE MULLIGAN.
Application Number | 20100109318 12/478419 |
Document ID | / |
Family ID | 42130465 |
Filed Date | 2010-05-06 |
United States Patent
Application |
20100109318 |
Kind Code |
A1 |
MULLIGAN; JAY EUGENE |
May 6, 2010 |
ZINC FLASHING FOR ROOF PENETRATIONS
Abstract
An improved zinc flashing system for use with metal and
non-metal roof systems. The improved zinc flashing system includes
a base plate that includes an aperture and vertical tube that is
attached to the base plate. The vertical tube form extends upwardly
from the upper surface of the base plate or downwardly from the
bottom surface of the base plate. The zinc flashing system is
designed to form a water-tight seal about a roof penetration and/or
a roof drain. A protective layer can be used to inhibit or prevent
contact of the zinc material of the zinc flashing with a roofing
structure. The protective layer can be connected and/or coated to
the zinc flashing.
Inventors: |
MULLIGAN; JAY EUGENE;
(Novato, CA) |
Correspondence
Address: |
FAY SHARPE LLP
1228 Euclid Avenue, 5th Floor, The Halle Building
Cleveland
OH
44115
US
|
Assignee: |
The Garland Company, Inc.
|
Family ID: |
42130465 |
Appl. No.: |
12/478419 |
Filed: |
June 4, 2009 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
61109641 |
Oct 30, 2008 |
|
|
|
Current U.S.
Class: |
285/42 ; 428/596;
52/741.4 |
Current CPC
Class: |
Y10T 428/12361 20150115;
E04D 13/0409 20130101; E04D 13/1475 20130101; E04D 13/1476
20130101; E04D 2013/0436 20130101 |
Class at
Publication: |
285/42 ; 428/596;
52/741.4 |
International
Class: |
E04D 13/14 20060101
E04D013/14; E04B 1/68 20060101 E04B001/68 |
Claims
1. A flashing for use on a roofing system, said flashing including
a base plate having an aperture at least partially spaced from a
peripheral edge of said base plate, said base plate having an
average thickness of less than 0.25 inch, said base plate formed of
pure zinc or a zinc alloy.
2. The flashing material as defined in claim 1, wherein said base
plate is formed of a zinc alloy, said zinc alloy including over 99
weight percent zinc and 0.005-0.9 weight percent alloying metal,
said alloying metal including one or more metals selected from the
group consisting of aluminum, cadmium, chromium, copper, iron,
lead, magnesium, nickel, tin, and titanium, said zinc alloy
including less than 0.75 weight percent copper and less than 0.13
weight percent titanium.
3. The flashing material as defined in claim 1, including a
vertical tube connected to said base plate, said vertical tube at
least partially encircling said aperture.
4. The flashing material as defined in claim 2, including a
vertical tube connected to said base plate, said vertical tube at
least partially encircling said aperture.
5. The flashing material as defined in claim 3, wherein said
vertical tube is formed of the same material as said base
plate.
6. The flashing material as defined in claim 3, wherein said
vertical tube is formed of the same material as said base
plate.
7. The flashing material as defined in claim 1, wherein said base
plate includes a coating material that inhibits or prevents
corrosion of said pure zinc or a zinc alloy when exposed to an
oxygen containing environment.
8. The flashing material as defined in claim 6, wherein said base
plate includes a coating material that inhibits or prevents
corrosion of said pure zinc or a zinc alloy when exposed to an
oxygen containing environment.
9. The flashing material as defined in claim 1, wherein said base
plate includes an adhesive on an upper surface, a bottom surface,
and combinations thereof, said adhesive designed to at least
partially secure said baseplate to the roofing system.
10. The flashing material as defined in claim 6, wherein said base
plate includes an adhesive on an upper surface, a bottom surface,
and combinations thereof, said adhesive designed to at least
partially secure said baseplate to the roofing system.
11. The flashing material as defined in claim 8, wherein said base
plate includes an adhesive on an upper surface, a bottom surface,
and combinations thereof, said adhesive designed to at least
partially secure said baseplate to the roofing system.
12. The flashing material as defined in claim 1, wherein said base
plate includes a protective barrier, said protective barrier
preventing direct contact of said pure zinc or a zinc alloy with a
metal structure roofing system.
13. The flashing material as defined in claim 3, wherein said base
plate, said vertical tube, and combinations thereof include a
protective barrier, said protective barrier preventing direct
contact of said pure zinc or a zinc alloy with a metal structure
roofing system.
14. The flashing material as defined in claim 6, wherein said base
plate, said vertical tube, and combinations thereof includes a
protective barrier, said protective barrier preventing direct
contact of said pure zinc or a zinc alloy with a metal structure
roofing system.
15. The flashing material as defined in claim 10, wherein said base
plate, said vertical tube, and combinations thereof include a
protective barrier, said protective barrier preventing direct
contact of said pure zinc or a zinc alloy with a metal structure
roofing system.
16. The flashing material as defined in claim 11, wherein said base
plate, said vertical tube, and combinations thereof include a
protective barrier, said protective barrier preventing direct
contact of said pure zinc or a zinc alloy with a metal structure
roofing system.
17. The flashing material as defined in claim 3, wherein said base
plate, said vertical tube, and combinations thereof include a
split.
18. The flashing material as defined in claim 16, wherein said base
plate, said vertical tube, and combinations thereof include a
split.
19. The flashing material as defined in claim 3, wherein said
vertical tube includes a fluted portion that enables adjustment of
a longitudinal length of said vertical tube.
20. The flashing material as defined in claim 16, wherein said
vertical tube includes a fluted portion that enables adjustment of
a longitudinal length of said vertical tube.
21. The flashing material as defined in claim 3, including a
sealing gasket connected to said vertical tube, said sealing gasket
including an aperture designed to at least partially encircle a
roof penetration.
22. The flashing material as defined in claim 20, including a
sealing gasket connected to said vertical tube, said sealing gasket
including an aperture designed to at least partially encircle a
roof penetration.
23. A method for forming a water-tight seal about a roof
penetration that extends above a surface of a roof deck, said
method comprising the steps of: providing flashing, said flashing
including a base plate and a vertical tube connected to the
baseplate, said base plate having an aperture at least partially
spaced from a peripheral edge of said base plate, said vertical
tube at least partially encircling said aperture, said vertical
tube having a cavity extending through said vertical tube and which
one end of said cavity is at least partially aligned with said
aperture of said base plate, said base plate and said vertical tube
having an average thickness of less than 0.25 inch, said base plate
and said vertical tube formed of pure zinc or a zinc alloy;
inserting said flashing on said roof penetration so that said
aperture and said cavity telescopically receive at least a top
portion of said roof penetration; positioning said base plate at
least partially on said roof deck; forming a seal between a top
portion of said vertical tube and an exterior surface of said roof
penetration; and, forming a seal between said base plate and said
roof deck.
24. The method as defined in claim 23, wherein said base plate and
said vertical tube is formed of a zinc alloy, said zinc alloy
including over 99 weight percent zinc and 0.005-0.9 weight percent
alloying metal, said alloying metal including one or more metals
selected from the group consisting of aluminum, cadmium, chromium,
copper, iron, lead, magnesium, nickel, tin, and titanium, said zinc
alloy including less than 0.75 weight percent copper and less than
0.13 weight percent titanium.
25. The method as defined in claim 23, wherein said step of forming
said seal between said top portion of said vertical tube and said
exterior surface of said roof penetration includes the steps of a)
bending at least part of said top portion of said vertical tube
into at least a portion of a top opening of said roof penetration,
b) applying a sealant between said top portion of said vertical
tube and said exterior surface of said roof penetration, c)
inserting a sealing gasket between said top portion of said
vertical tube and said exterior surface of said roof penetration,
and combinations thereof.
26. The method as defined in claim 24, wherein said step of forming
a seal between said top portion of said vertical tube and said
exterior surface of said roof penetration includes the steps of a)
bending at least part of said top portion of said vertical tube
into at least a portion of a top opening of said roof penetration,
b) applying a sealant between said top portion of said vertical
tube and said exterior surface of said roof penetration, c)
inserting a sealing gasket between said top portion of said
vertical tube and said exterior surface of said roof penetration,
and combinations thereof.
27. The method as defined in claim 23, including the step of
applying a protective barrier between an interior surface of said
cavity of said vertical tube and an exterior surface of said roof
penetration, said protective barrier designed to inhibit or prevent
corrosive contact between said flashing and said roof penetration
by limiting direct contact of said pure zinc or zinc alloy of said
flashing with said roof penetration, said protective barrier
including a) a non-zinc coating material on said flashing, b) a
non-zinc coating material on said roof penetration, c) a non-zinc
material connected to said flashing, d) a non-zinc material
connected to said roof penetration, e) a non-zinc material
unconnected to said flashing and said roof penetration, and
combinations thereof.
28. The method as defined in claim 26, including the step of
applying a protective barrier between an interior surface of said
cavity of said vertical tube and an exterior surface of said roof
penetration, said protective barrier designed to inhibit or prevent
corrosive contact between said flashing and said roof penetration
by limiting direct contact of said pure zinc or zinc alloy of said
flashing with said roof penetration, said protective barrier
including a) a non-zinc coating material on said flashing, b) a
non-zinc coating material on said roof penetration, c) a non-zinc
material connected to said flashing, d) a non-zinc material
connected to said roof penetration, e) a non-zinc material
unconnected to said flashing and said roof penetration, and
combinations thereof.
29. A method for forming a water-tight seal about a roof drain that
extends into a surface of a roof deck, said method comprising the
steps of: providing flashing, said flashing including a base plate
and a vertical tube connected to the baseplate, said base plate
having an aperture at least partially spaced from a peripheral edge
of said base plate, said vertical tube at least partially
encircling said aperture, said vertical tube having a cavity
extending through said vertical tube and which one end of said
cavity is at least partially aligned with said aperture of said
base plate, said base plate and said vertical tube having an
average thickness of less than 0.25 inch, said base plate and said
vertical tube formed of pure zinc or a zinc alloy; at least
partially inserting said vertical tube into an opening in said roof
drain; positioning said base plate at least partially on said roof
deck; and, forming a seal between said base plate and said roof
deck.
30. The method as defined in claim 29, wherein said base plate and
said vertical tube is formed of a zinc alloy, said zinc alloy
including over 99 weight percent zinc and 0.005-0.9 weight percent
alloying metal, said alloying metal including one or more metals
selected from the group consisting of aluminum, cadmium, chromium,
copper, iron, lead, magnesium, nickel, tin, and titanium, said zinc
alloy including less than 0.75 weight percent copper and less than
0.13 weight percent titanium.
31. The method as defined in claim 29, including the step of
applying a protective barrier between an exterior surface of said
vertical tube and an interior surface of said opening of said roof
drain, said protective barrier designed to inhibit or prevent
corrosive contact between said flashing and said roof drain by
limiting direct contact of said pure zinc or zinc alloy of said
flashing with said roof drain, said protective barrier including a)
a non-zinc coating material on said flashing, b) a non-zinc coating
material on said roof drain, c) a non-zinc material connected to
said flashing, d) a non-zinc material connected to said roof drain,
e) a non-zinc material unconnected to said flashing and said roof
drain, and combinations thereof.
32. The method as defined in claim 30, including the step of
applying a protective barrier between an exterior surface of said
vertical tube and an interior surface of said opening of said roof
drain, said protective barrier designed to inhibit or prevent
corrosive contact between said flashing and said roof drain by
limiting direct contact of said pure zinc or zinc alloy of said
flashing with said roof drain, said protective barrier including a)
a non-zinc coating material on said flashing, b) a non-zinc coating
material on said roof drain, c) a non-zinc material connected to
said flashing, d) a non-zinc material connected to said roof drain,
e) a non-zinc material unconnected to said flashing and said roof
drain, and combinations thereof.
Description
[0001] The present invention claims priority on U.S. Provisional
Application Ser. No. 61/109,641 filed Oct. 30, 2008 entitled "Zinc
Flashing for Roof Penetrations," which is incorporated fully herein
by reference.
[0002] The present invention is generally directed to flashing for
roofing systems, more particularly to flashing that is used about
roof penetrations, and even more particularly to zinc flashing that
is used about roof penetrations.
BACKGROUND OF THE INVENTION
[0003] Currently, soft lead flashing is the common choice for
flashing materials. Lead flashing is used because it is malleable,
thus is easy to form the lead flashing to the surface of a roofing
system and about various structures on the surface of the roofing
system. As such, lead flashing is relatively easy to integrate
between layers of roofing material and the lead flashing also
easily conforms to irregular shapes on the surface of the roofing
system. Roof flashing can also be formed by other materials such as
stainless steel or galvanized sheet metal. This non-lead flashing
is much more rigid than lead flashing, thus typically requiring the
flashing to be anchored (e.g., nailed, riveted, screwed, etc.) to
the surface of the roofing system. The anchoring of such flashing
to a roofing system typically adds to the cost and time for
assembling the roofing system. Furthermore, the arrangements
required to anchor such non-lead roof flashing to the roofing
system can adversely affect the sealing properties of the roofing
system. As such, lead flashing is the preferred choice of flashing
in the roofing industry. Lead flashing generally does not require
special anchoring arrangements on the roofing system, and lead
flashing is easy to bend. Lead flashing also is slow to corrode and
does not form unsightly oxides and discoloration during
corrosion.
[0004] Although lead flashing is a desirable roof flashing for
purposes of installation on roofing systems, lead materials are of
a health concern in many countries since lead can leach into water
that contacts the lead material. As such, lead materials have
fallen out of favor in many communities. Consequently, stainless
steel flashing and galvanized flashing have grown in popularity in
the roofing industry, even though such materials are more costly
and expensive to use, and can result in an inferior roofing
system.
[0005] In view of the current problems in the roofing industry,
there is a need for a flashing product that has similar
malleability properties as lead, has corrosion resistant
properties, is not considered harmful to humans and the
environment, and which can be effectively used as flashing on a
roofing system.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to flashing, and more
particularly to flashing that can be used on roofing systems, and
more particularly to flashing that can be used to seal the area
about penetrations in a roofing system. In accordance with one
non-limiting embodiment of the invention, the flashing is formed of
a metal material that primarily constitutes zinc. In one
non-limiting aspect of this embodiment, the zinc content of the
metal material is over 95 weight percent. In another and/or
alternative non-limiting aspect of this embodiment, the zinc
content of the metal material is over 99 weight percent. In still
another and/or alternative non-limiting aspect of this embodiment,
the zinc content of the metal material is over 99.1 weight percent
and has about 0-0.9 weight percent alloying metals and impurities.
In still yet another and/or alternative non-limiting aspect of this
embodiment, the zinc content of the metal material is over 99.2
weight percent and has about 0-0.8 weight percent alloying metals
and impurities. In another and/or alternative non-limiting aspect
of this embodiment, the zinc content of the metal material is over
99.3 weight percent and has about 0-0.7 weight percent alloying
metals and impurities. In still another and/or alternative
non-limiting aspect of this embodiment, the zinc content of the
metal material is over 99.4 weight percent and has about 0-0.6
weight percent alloying metals and impurities. In yet another
and/or alternative non-limiting aspect of this embodiment, the zinc
content of the metal material is over 99.5 weight percent and has
about 0-0.5 weight percent alloying metals and impurities. In yet
another and/or alternative non-limiting aspect of this embodiment,
the zinc content of the metal material is over 99.6 weight percent
and has about 0-0.4 weight percent alloying metals and impurities.
In another and/or alternative non-limiting aspect of this
embodiment, metal material is not formed of a titanium zinc alloy.
Titanium zinc alloys are known as zinc alloys that certain amounts
of copper and titanium. Typically, titanium zinc alloys include
about 0.75-1.1 weight percent copper and about 0.13-1.7 weight
percent titanium and the balance zinc with minor impurities of no
more than 0.05 weight percent. Titanium zinc alloys are not
suitable for the zinc flashing of the present invention since such
zinc alloys are too rigid. Titanium zinc are less malleable than
the zinc alloy used in the present invention, thus flashing formed
of titanium zinc alloy will not easily conform to roof surfaces in
a manner similar to lead flashing. Indeed, flashing formed of
titanium zinc alloy exhibits the same malleability problems as
flashing formed of stainless steel and galvanized steel. In still
another and/or alternative non-limiting aspect of this embodiment,
the zinc content of the metal material is over 91.1 weight percent
and the copper content of the metal material is less than 0.75
weight percent and the titanium content is less than 0.13 weight
percent. In yet another and/or alternative non-limiting aspect of
this embodiment, the zinc content of the metal material is over
91.2 weight percent and the copper content of the metal material is
less than 0.7 weight percent and the titanium content is less than
0.1 weight percent. In still yet another and/or alternative
non-limiting aspect of this embodiment, the zinc content of the
metal material is over 91.2 weight percent and the copper content
of the metal material is less than 0.6 weight percent and the
titanium content is less than 0.075 weight percent. In another
and/or alternative non-limiting aspect of this embodiment, the zinc
content of the metal material is over 91.2 weight percent and the
copper content of the metal material is less than 0.5 weight
percent and the titanium content is less than 0.05 weight percent.
In still yet another and/or alternative non-limiting aspect of this
embodiment, the metal material of the present invention is not pure
zinc. As such, limited amounts of alloying agents are included in
the metal material to improve the physical characteristics of the
metal material; however, it can be appreciated that the metal
material can be formed of pure zinc. Generally, the alloy content
of the metal material is at least about 0.005 weight percent,
typically at least about 0.01 weight percent, more typically at
least about 0.05 weight percent. Furthermore, the alloy content of
the metal material is generally less than about 1 weight percent,
typically less than about 0.9 weight percent, and even more
typically less than about 0.8 weight percent. Typically alloy metal
content of the metal material is about 0 01-0.9 weight percent,
more typically about 0.05-0.85 weight percent, and even more
typically about 0.05-0.8 weight percent. The alloying components
that can be used in the metal material include aluminum, cadmium,
chromium, copper, iron, lead, magnesium, nickel, tin, titanium, and
any combination thereof. Generally the alloying metals include
copper, cadmium, iron and/or titanium. The metal material can
include various impurities (e.g., carbon, oxygen, nitrogen, etc.).
Generally the impurity content of the metal material is less than
about 0.05 weight percent, typically less than about 0.01 weight
percent, and more typically less than about 0.005 weight
percent.
[0007] It has been found that relatively pure zinc and certain zinc
alloys form a durable and malleable material that can be easily
formed into various shapes. As such, when these types of metals are
formed into flashing, the zinc flashing does not require special
attachment arrangements as is require for stainless and galvanized
flashing materials. The average thickness of the metal material
that forms the zinc flashing of the present invention is generally
less than 0.25 inches, typically less than about 0.125 inches, more
typically less than about 0.1 inches, even more typically about
0.005-0.05 inches, and still even more typically about 0.01-0.03
inches. The zinc flashing in accordance with the present invention
provides a flash system that is compatible in utility to the
current standard roof flashing products, such as lead flashing
products. The zinc flashing of the present invention can be used to
waterproof roof penetrations through a roof system that cannot be
sealed using the primary roofing material. For instance, primary
roofing materials may be too rigid (e.g., concrete, tile, sheet
metal, etc.) and/or experience significant shrinkage (e.g., asphalt
built up roofing, etc.) during the useful life of the roofing
materials, thus cannot be used in-of-themselves to waterproof the
region about a roof penetration (e.g., round cast iron plumbing
vent pipe, round PVC plumbing vent pipe, etc.). In such instances,
flashing is typically used to form the waterproof seal about the
roof penetration. Lead flashing is typically used since such
material is soft and easily conforms to the shape of the roof
penetration and has a life that is generally longer than the life
of the primary roofing materials. The zinc flashing of the present
invention can be used to replace standard lead flashing without
requiring increased costs or labor. The malleability properties of
the zinc material of the present invention are similar to lead
materials and the life of the zinc material is generally the same
as or longer than the life of the primary roofing materials.
Flashing that is made of soft and/or malleable materials is
important as a waterproofing component of roofing systems. The
flexibility of the of the zinc material of the present invention
enables the flashing made from such zinc material to facilitate in
waterproofing roofing systems, especially around penetrations in a
roofing system. As such, the zinc flashing of the present invention
can be used on standard roofing systems, can be conformed to roof
penetrations, and can be conformed to the shape of the roofing
system layers.
[0008] In another and/or alternative non-limiting aspect of the
present invention, the zinc flashing of the present invention can
have a specific configuration for use with roof penetrations. In
one non-limiting embodiment, the zinc flashing includes a generally
flat planar base plate with an aperture in the base plate. As can
be appreciated, the base plate is not required to be flat and
planar. A vertical tube structure extends upwardly from the base
plate and at least partially encircles the aperture in the base
plate. The vertical tube structure can extend upwardly at an angle
perpendicular to the upper surface of the base plate; however, the
vertical tube structure can extend upwardly at an angle of
30.degree.-90.degree. from the upper surface of the base plate. The
non-perpendicular angle of the upwardly extending vertical tube is
generally used on sloped roof surfaces. The vertical tube structure
can be a separate piece of material from the base plate, thus
requiring the vertical tube to be connected to the base plate by 1)
a mechanical attachment arrangement (e.g., rivets, clamps,
mechanical seam, etc.), 2) use of solder, 3) use of a weld bead,
and/or 4) use of an adhesive. Alternatively, the vertical tube
structure and base plate can be formed from a single piece of
material. The vertical tube structure is designed to fit about
vertical penetrations that are extending upwardly from the roofing
surface. In another and/or alternative non-limiting embodiment, the
aperture in the base plate has a generally circular cross-sectional
shape; however, other cross-sectional shapes such as a polygonal
shape (e.g., square-shaped, rectangular-shaped, etc.), oval shaped
and the like can be used. In yet another and/or alternative
non-limiting embodiment, the vertical tube can have a constant
cross-sectional shape and/or constant cross-sectional area along
the longitudinal length of the vertical tube; however, this is not
required. In one non-limiting aspect of this embodiment, the
vertical tube has a circular cross-sectional shape along the
complete longitudinal length of the vertical tube. In another
and/or alternative non-limiting aspect of this embodiment, the
vertical tube has a circular cross-sectional shape along the
complete longitudinal length of the vertical tube and the
cross-sectional area remains generally constant along the complete
longitudinal length of the vertical tube. In still another and/or
alternative non-limiting aspect of this embodiment, the vertical
tube has a circular cross-sectional shape along the complete
longitudinal length of the vertical tube and the cross-sectional
area changes along at least a portion of the longitudinal length of
the vertical tube (e.g., cone-shaped vertical tube, etc.). In yet
another and/or alternative non-limiting aspect of this embodiment,
the vertical tube has a polygonal cross-sectional shape along the
complete longitudinal length of the vertical tube. In still yet
another and/or alternative non-limiting aspect of this embodiment,
the vertical tube has a polygonal shape along the complete
longitudinal length of the vertical tube and the cross-sectional
area remains generally constant along the complete longitudinal
length of the vertical tube. In still yet another and/or
alternative non-limiting aspect of this embodiment, the vertical
tube has a polygonal shape along the complete longitudinal length
of the vertical tube and the cross-sectional changes along at least
a portion of the longitudinal length of the vertical tube (e.g.,
pyramid-shaped vertical tube, etc.).
[0009] As described above, the zinc flashing of the present
invention can be used as a substitute for prior art lead flashing
and create water-proofing about roof penetrations. For example, in
asphalt built-up roofing systems, the roof is built-up through the
application of layers of felt material and liquid asphalt. The
solidified asphalt does not have the flexibility over time that is
required to maintain a seal about a roof penetration (e.g, a cast
iron plumbing vent pipe, etc.) for more than a few years. The roof
penetration generally expands and contracts as the ambient
temperature changes. Over time, this expansion and contraction will
cause the seal between the asphalt and the roof penetration to
break, thereby compromising the water-proofing of the roofing
system. Typically, the watertight warranty for built-up asphalt
roofing systems is at least 10 years. As such, metal flashing has
been used to form a water-proof seal about roof penetrations. In
practice, roofers lay down two or three plys of felt up to the
region of the roof penetration and then apply the metal flashing
about the roof penetration. The metal flashing is then set in a bed
of asphalt mastic and subsequently pressed down onto the roof to
then be sealed by the first few layers of roofing. The top side of
the flashing is then generally primed and two additional layers of
roofing felt and liquid asphalt are applied over the felt layers on
the metal flashing. After application of the felt layers and the
asphalt, the base plate of the metal flashing is sandwiched between
the layers of the built-up roofing system. The vertical tube that
extends upwardly from the base plate of the metal flashing can then
be sealed at the top region of the roof penetration by compressing
the top portion of the vertical tube with a mechanical drawband or
the like and then applying a sealant to the drawn portion of the
vertical tube and the roof penetration. Alternatively, the top
portion of the vertical tube can be bent down into the roof
penetration and/or a roof cap can be installed over the top of the
vertical penetration to create a watertight condition. In the past,
lead flashing has been used as the metal flashing to form the
water-tight seals for roof penetrations as set forth above. The
zinc flashing of the present invention is designed to be a
replacement of the lead flashing that is used to seal roof
penetrations. The zinc flashing can also have additional uses and
can be used in flashing applications that are illustrated in U.S.
Pat. No. 7,114,301; U.S. Pat. No. 7,059,086; U.S. Pat. No.
6,503,601; U.S. Pat. No. 5,913,779; U.S. Pat. No. 5,605,020; U.S.
Pat. No. 5,344,062; U.S. Pat. No. 5,317,845; U.S. Pat. No.
4,977,721; U.S. Pat. No. 4,700,512; U.S. Pat. No. 4,102,090; US
2007/0101664; US 2005/0252111; US 2005/0055889; US 2004/0255523; EP
1424455; GB 2,386,135; GB 2,355,471; GB 1,429,022; WO 2006/02629;
WO 2004/051026; WO 2004/007864; and WO 2003/074812; all of which
are fully incorporated herein by reference. The zinc flashing of
the present invention has been designed to be substituted for prior
lead flashing materials without sacrificing ease of installation
and durability and longevity of the life of the flashing. Indeed,
the zinc flashing will far outlast the useful life of a built-up
roofing system and many other types of roofing systems.
[0010] In still another and/or alternative non-limiting aspect of
the present invention, the zinc flashing of the present invention
has an important advantage over current lead flashing in that zinc
and zinc alloys are considered to be a much safer material to
handle than lead. Zinc can be handled by humans without skin
protection. Lead, on the other hand, can be dangerous for humans to
directly contact. Indeed, many government agencies are attempting
to reduce the amount of lead and lead exposure in workplaces.
Roofing work is considered by many a low skill trade wherein
workers may have minimal education and may not speak or read
English, therefore, exposing workers to the harmful effects of
lead. Lead flashing is commonly handled without any protection to
the skin. Furthermore, respirators are generally not used when lead
based solders (60% lead) are used. The use of zinc flashing in
accordance with the present invention overcomes such problems
associated with the handling and soldering of lead flashing. The
zinc flashing of the present invention also can be used on a
variety of types of roof systems such as, but not limited to,
asphalt built up roof, modified bitumen roofing, single ply
membrane roofing, fluid applied roofing, asphalt shingles, clay
tiles, concrete tiles, slate, galvanized steel sheet metal roofing,
aluminum sheet metal roofing, zinc sheet metal roofing, and the
like. The zinc alloy used on the zinc flashing of the present
invention is formulated to be soft enough and malleable enough to
conform to the surface of many types of roofing systems and/or
roofing structures on the roofing system (e.g., roof penetrations,
roof vents, etc.) and the zinc flashing can be integrated into such
roofing systems without the use of mechanical fasteners, thus such
zinc flashing has significant advantages over stainless steel,
galvanized, and tin flashing.
[0011] In yet another and/or alternative non-limiting aspect of the
present invention, the bottom surface and/or upper surface of the
base plate can include an adhesive that can be used to secure to
the bottom surface and/or upper surface of the base plate to a
roofing surface; however, this is not required. Various types of
adhesives can be used (e.g., urethane adhesive, epoxy adhesive,
methacrylate adhesive, methacrylate adhesive, isocyanate adhesive,
cyanoacrylate adhesive, etc.). In one non-limiting embodiment of
the invention, the adhesive can be a pre-applied adhesive layer
that includes a removable protective film. The removable protective
film, when used, can be designed to be removable so as to expose
the layer of adhesive prior to contacting the bottom face of the
adhesive to a roofing surface; however, this is not required. The
adhesive, when used, is designed to at least partially maintain the
zinc flashing in position on the surface of the roofing system. The
type of adhesive and thickness of the adhesive layer is
non-limiting.
[0012] In still yet another and/or alternative non-limiting aspect
of the present invention, at least a portion of the zinc flashing
can be coated with a material that inhibits or prevents oxidation
of the zinc material that can form on the zinc flashing when
exposed to the environment; however, this is not required. In one
non-limiting embodiment, the complete zinc flashing is coated with
a material that inhibits or prevents oxidation of the zinc
material. The type and thickness of the material coated on the zinc
material is non-limiting.
[0013] In another and/or alternative non-limiting aspect of the
present invention, a portion of the zinc flashing includes a
protective layer that creates a barrier layer between the zinc
flashing and one or more components of a roofing system; however,
this is not required. It has been found that when zinc metal
directly contacts certain metals (e.g., iron, iron alloys, etc.),
the contact point can result in accelerated corrosion of the
contacted metal and/or zinc flashing. The protective layer is
designed to inhibit or prevent the direct contact of the zinc
flashing with a potentially reactive metal material. The protective
layer can be in the form of a coating and/or a material that is
inserted between the zinc flashing and the potentially reactive
metal material. In one non-limiting embodiment, the protective
layer is a coating material that is applied to one or more regions
of the zinc flashing. In one non-limiting aspect of this
embodiment, the coating material is a polymer coating, bitumen
coating and the like. In still another and/or alternative
non-limiting aspect of this embodiment, the coating material has a
thickness of less than 0.25 inches, typically less than about 0.1
inches, and more typically greater than about 0.0001 inches. In
still yet another and/or alternative non-limiting aspect of this
embodiment, the coating material is coated on the complete surface
of the zinc flashing. In another and/or alternative non-limiting
aspect of this embodiment, the coating material is coated only on
the bottom surface of the base plate of the zinc flashing. In still
another and/or alternative aspect of this embodiment, the coating
material is coated only on the interior surface of the vertical
tube that extends upwardly from the base plate of the zinc
flashing. In yet another and/or alternative non-limiting aspect of
this embodiment, the coating material is coated only on the
exterior surface of the vertical tube that extends upwardly and/or
downwardly from the base plate of the zinc flashing. In yet another
and/or alternative non-limiting aspect of this embodiment, the
coating material is coated only on the bottom surface of the base
plate of the zinc flashing and the interior and/or exterior surface
of the vertical tube that extends upwardly and/or downwardly from
the base plate of the zinc flashing. In another and/or alternative
non-limiting embodiment, the protective barrier is a material that
is positioned between the zinc flashing and one or more components
of a roofing system. In one non-limiting aspect of this embodiment,
the protective barrier is a material that is adhesively or
mechanically connected to the zinc flashing. In another and/or
alternative non-limiting aspect of this embodiment, the protective
barrier is a natural or man-made rubber material, a polymer
material, a bitumen material and the like. In still another and/or
alternative non-limiting aspect of this embodiment, the protective
barrier has a thickness of at least 0.02 inches and generally less
than about 0.5 inches; however, it can be appreciated that thicker
protective barriers can be used. In yet another and/or alternative
non-limiting aspect of this embodiment, the protective barrier is
only positioned on the bottom surface of the base plate of the zinc
flashing. In still yet another and/or alternative non-limiting
aspect of this embodiment, the protective barrier is only
positioned on the interior surface of the vertical tube that
extends upwardly from the base plate of the zinc flashing. In
another and/or alternative non-limiting aspect of this embodiment,
the protective barrier is positioned only on the exterior surface
of the vertical tube that extends upwardly and/or downwardly from
the base plate of the zinc flashing. In another and/or alternative
non-limiting aspect of this embodiment, the protective barrier is
only positioned on the bottom surface of the base plate of the zinc
flashing and the interior and/or exterior surface of the vertical
tube that extends upwardly and/or downwardly from the base plate of
the zinc flashing. In this arrangement, the protective barrier can
be a single piece of material or multiple pieces of material that
can be formed of the same type or different types of materials and
can have the same or differing thicknesses.
[0014] In still yet another and/or alternative non-limiting aspect
of the present invention, the zinc flashing can include a sealing
gasket used to facilitate in forming a water-tight seal between the
zinc flashing and the roofing system; however, this is not
required. The sealing gasket, when used, is generally positioned at
least partially about the outer surface of the vertical tube. In
one non-limiting embodiment, the sealing gasket, when used, is
positioned at least partially about the outer surface of the
vertical tube and at or near the base of the vertical tube that is
connected to the base plate. In still another and/or alternative
non-limiting embodiment, the sealing gasket, when used, is
positioned at least partially about the outer surface of the
vertical tube and at or near the top end of the vertical tube. In
yet another and/or alternative non-limiting embodiment, the sealing
gasket can be formed of a variety of materials such as, but not
limited to, a polymer material, rubber material, and the like. In
still yet another and/or alternative non-limiting embodiment, the
gasket material is generally a flexible and/or stretchable
material; however, this is not required. In another and/or
alternative non-limiting embodiment, the sealing gasket can be
secured to the zinc flashing by the use of a friction connection,
mechanical connection, hot melt connection, and/or adhesive
connection. In another and/or alternative non-limiting embodiment,
the sealing gasket can including an aperture that is designed to at
least partially fit about a roof penetration and at least partially
form a water-tight seal with the roof penetration.
[0015] In another and/or alternative non-limiting aspect of the
present invention, the zinc flashing can include a split to enable
the zinc flashing to be fitted about a structure on a roofing
system such as a roof penetration; however, this is not required.
When the zinc flashing includes a split, the split can be closed
and/or sealed by one or more of the following arrangements: use of
mechanical devices (e.g., rivets, clamping bands, clips, latches,
etc.), by use of a mechanically formed seal (e.g, bending together
of the edges, etc.), by use of a solder, by use of a weld bead, by
use of an adhesive, by use of a sealing gasket, by use of a sealing
sleeve, etc.
[0016] In still another and/or alternative non-limiting aspect of
the present invention, the zinc flashing can be used to facilitate
in forming a water-tight seal about a roof drain; however, this is
not required. The zinc flashing includes a base plate that has an
aperture. The base plate can be a generally flat planar plate;
however, this is not required. The bottom surface of the base plate
can include a downwardly extending vertical tube; however, this is
not required. The downwardly extending vertical tube, when used, is
designed to fit at least partially in the roof drain so as to
facilitate in the formation of a water-tight seal. As can be
appreciated, the edges of aperture can be bent down to form the
downwardly extending vertical tube or a preformed downwardly
extending vertical tube can be included on the base plate. The
vertical tube structure at least partially encircles the aperture
in the base plate. The vertical tube structure can extend
downwardly at an angle perpendicular to the bottom surface of the
base plate; however, the vertical tube structure can extend at an
angle of 30.degree.-90.degree. from the bottom surface of the base
plate. The non-perpendicular angle is generally used on sloped roof
surfaces. The vertical tube structure can be a separate piece of
material from the base plate, thus requiring the vertical tube to
be connected to the base plate by 1) a mechanical attachment
arrangement (e.g., rivets, clamps, mechanical seam, etc.), 2) use
of solder, 3) use of a weld bead, and/or 4) use of an adhesive.
Alternatively, the vertical tube structure and base plate can be
formed from a single piece of material. In another and/or
alternative non-limiting embodiment, the aperture in the base plate
has a generally circular cross-sectional shape; however, other
cross-sectional shapes such as a polygonal shape (e.g.,
square-shaped, rectangular-shaped, etc.) can be used. In yet
another and/or alternative non-limiting embodiment, the vertical
tube can have a constant cross-sectional shape and/or constant
cross-sectional area along the longitudinal length of the vertical
tube; however, this is not required. In one non-limiting aspect of
this embodiment, the vertical tube has a circular cross-sectional
shape along the complete longitudinal length of the vertical tube.
In another and/or alternative non-limiting aspect of this
embodiment, the vertical tube has a circular cross-sectional shape
along the complete longitudinal length of the vertical tube and the
cross-sectional area remains generally constant along the complete
longitudinal length of the vertical tube. In still another and/or
alternative non-limiting aspect of this embodiment, the vertical
tube has a circular cross-sectional shape along the complete
longitudinal length of the vertical tube and the cross-sectional
area changes along at least a portion of the longitudinal length of
the vertical tube (e.g., cone-shaped vertical tube, etc.). In yet
another and/or alternative non-limiting aspect of this embodiment,
the vertical tube has a polygonal cross-sectional shape along the
complete longitudinal length of the vertical tube. In still yet
another and/or alternative non-limiting aspect of this embodiment,
the vertical tube has a polygonal shape along the complete
longitudinal length of the vertical tube and the cross-sectional
area remains generally constant along the complete longitudinal
length of the vertical tube. In still yet another and/or
alternative non-limiting aspect of this embodiment, the vertical
tube has a polygonal shape along the complete longitudinal length
of the vertical tube and the cross-sectional changes along at least
a portion of the longitudinal length of the vertical tube (e.g.,
pyramid-shaped vertical tube, etc.).
[0017] In still another and/or alternative non-limiting aspect of
the present invention, the zinc flashing can at least partially
form a pitch pocket about a roof penetration; however, this is not
required. In such an arrangement, the vertical tube has a
cross-sectional area that is greater than the cross-sectional area
of the roof penetration. A water-tight seal is formed between the
vertical tube and the roof penetration by inserting a sealant
(e.g., asphalt, polymer, pitch, etc.) into the space between the
inner surface of the vertical tube and the outer surface of the
roof penetration. In common practice, grout can be first inserted
into the space between the inner surface of the vertical tube and
the outer surface of the roof penetration prior to adding the
sealant; however, this is not required. When a grout is used, the
grout is generally a non-shrinkable grout; however, this is not
required.
[0018] In yet another and/or alternative non-limiting aspect of the
present invention, the zinc flashing can be used in conjunction
with a cap, which cap is used to prevent liquids from entering the
top opening of a roof penetration; however, this is not required.
The cap can be formed of the same or similar material as the zinc
flashing, however, this is not required. The cap, when used, can be
connected to the exterior surface of the vertical tube of the zinc
flashing; however, this is not required. When the cap is connected
to the exterior surface of the vertical tube of the zinc flashing,
the connection can be formed by use of 1) a mechanical attachment
arrangement (e.g., rivets, clamps, mechanical seam, etc.), 2) a
solder, 3) a weld bead, and/or 4) an adhesive; however, this is not
required.
[0019] In still yet another and/or alternative non-limiting aspect
of the present invention, the vertical tube of the zinc flashing
can include a fluted portion or corrugated portion; however, this
is not required. The fluted portion or corrugated portion, when
used, can be used to adjust the longitudinal length of the vertical
tube to accommodate differing lengths of roof penetrations;
however, this is not required.
[0020] In one non-limiting object of the present invention, there
is provided a zinc flashing material that can be used to replace
standard types of flashing materials formed of lead, tin,
galvanized steel and stainless steel.
[0021] In another and/or alternative non-limiting object of the
present invention, there is provided a zinc flashing material that
has the same or similar malleability as lead flashing.
[0022] In still another and/or alternative non-limiting object of
the present invention, there is provided a zinc flashing material
that is formed of pure zinc or a certain type of zinc alloy.
[0023] In still another and/or alternative non-limiting object of
the present invention, there is provided a zinc flashing material
that is coated with a protective layer to inhibit or prevent
reaction of the zinc flashing with other components of a roofing
system.
[0024] In yet another and/or alternative non-limiting object of the
present invention, there is provided a zinc flashing material that
is used with a protective barrier to inhibit or prevent reaction of
the zinc flashing with other components of a roofing system.
[0025] In still yet another and/or alternative non-limiting object
of the present invention, there is provided a zinc flashing
material that includes an adhesive layer to facilitate in securing
the zinc flashing to a roofing system.
[0026] In another and/or alternative non-limiting object of the
present invention, there is provided a zinc flashing material that
is coated with a material that inhibits or prevents corrosion of
the zinc flashing material.
[0027] In still another and/or alternative non-limiting object of
the present invention, there is provided a zinc flashing material
that includes a vertical portion that is fluted or corrugated so
that the zinc flashing can be adjusted relative to roof
penetrations.
[0028] In still yet another and/or alternative non-limiting object
of the present invention, there is provided a zinc flashing
material that includes a sealing gasket used to at least partially
form a seal with a roof penetration.
[0029] In another and/or alternative non-limiting object of the
present invention, there is provided a zinc flashing material that
can be used to least partially form a pitch pocket about a roof
penetration.
[0030] In still another and/or alternative non-limiting object of
the present invention, there is provided a zinc flashing material
that can be used to form water-tight seals about roof drains and/or
roof penetrations.
[0031] These and other objects and advantages will become apparent
from the following description taken together with the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] Reference may now be made to the drawings, which illustrate
several non-limiting embodiments that the invention may take in
physical form and in certain parts and arrangements of parts
wherein;
[0033] FIG. 1 illustrates a zinc flashing in accordance with the
present invention that includes a zinc base plate and a vertical
tube extending upwardly form the top surface of the zinc base
plate;
[0034] FIG. 2 is a modification of FIG. 1 wherein the zinc flashing
includes a split in the base plate and the vertical tube;
[0035] FIG. 3 illustrates the installation of the zinc flashing of
FIG. 1 on a roof membrane and which zinc flashing includes the use
of a cap;
[0036] FIG. 4 is a cross-sectional view of the zinc flashing of
FIG. 1 that includes a protective layer in the form of a coating on
the bottom surface of the zinc base plate and the inside surface of
the vertical tube;
[0037] FIG. 5 is a cross-sectional view of the zinc flashing of
FIG. 1 that includes a protective layer in the form of the coating
on the bottom and top surface of the zinc base plate and the inside
and outside surface of the vertical tube;
[0038] FIG. 6 is a cross-sectional view of the zinc flashing of
FIG. 1 that includes a protective layer in the form of a sleeve on
the inside surface of the vertical tube;
[0039] FIG. 7 is another modification of FIG. 1 wherein the
vertical tube includes a fluted portion to adjust a longitudinal
length of the vertical portion;
[0040] FIG. 8 illustrates the installation of the zinc flashing of
FIG. 7 on a roof membrane and which zinc flashing includes the use
of a cap;
[0041] FIG. 9 is another modification of FIG. 1 wherein the
vertical tube is connected to the baseplate at a non-perpendicular
angle;
[0042] FIG. 10 illustrates the installation of the zinc flashing of
FIG. 7 on a roof membrane;
[0043] FIG. 11 is another modification of FIG. 1 wherein the
vertical tube is connected to the baseplate at a non-perpendicular
angle and the vertical tube is generally cone-shaped;
[0044] FIG. 12 illustrates the installation of the zinc flashing of
FIG. 11 on a roof membrane;
[0045] FIG. 13 is a modification of FIG. 1 wherein a rubber sealing
sleeve is positioned on the top portion of the vertical tube;
[0046] FIG. 14 illustrates the installation of the zinc flashing of
FIG. 13 on a roof membrane;
[0047] FIG. 15 is another modification of FIG. 1 wherein the
vertical tube has a polygonal cross-section shape along a
longitudinal length of the vertical portion;
[0048] FIG. 16 is a modification of FIG. 15 wherein the zinc
flashing includes a split in the base plate and the vertical
tube;
[0049] FIG. 17 illustrates the installation of the zinc flashing of
FIG. 15 on a roof membrane;
[0050] FIG. 18 illustrates a zinc flashing in accordance with the
present invention that includes a zinc blase plate and a vertical
tube extending downwardly from the bottom surface of the zinc base
plate; and,
[0051] FIG. 19 illustrates the installation of the zinc flashing of
FIG. 18 on a roof membrane.
NON-LIMITING EMBODIMENTS OF THE INVENTION
[0052] Referring now to the drawings wherein the showings are for
the purpose of illustrating non-limiting embodiments of the
invention only and not for the purpose of limiting same, FIGS. 1-19
illustrate several non-limiting configurations of the zinc flashing
in accordance with the present invention. The zinc flashing is
formed of a malleable zinc alloy that includes over 99 weight
percent zinc. The zinc flashing can be formed of pure zinc or a
special zinc alloy The zinc alloy generally contains at least about
0.01 weight percent alloying agent and less than about 0.7 weight
percent alloying agents. The alloying agents typically include one
or more metal alloy agents selected from the group of aluminum,
cadmium, chromium, copper, iron, lead, magnesium, nickel, tin, and
titanium. The alloying agent content in the zinc alloy is
maintained at small quantities so that the malleability of the zinc
alloy is not adversely affected. Non limiting examples of zinc
alloys that can be used in the present invention are set forth
below in the following examples:
EXAMPLE A
TABLE-US-00001 [0053] Component Weight Percent zinc 91.1-99.99%
aluminum up to 0.9% cadmium up to 0.9% chromium up to 0.9% copper
up to <0.75% iron up to 0.9% lead up to 0.9% magnesium up to
0.9% nickel up to 0.9% tin up to 0.9% titanium <0.13% Impurities
<0.05%
EXAMPLE B
TABLE-US-00002 [0054] Component Weight Percent zinc 91.1-99.9%
aluminum up to 0.7% cadmium up to 0.7% chromium up to 0.5% copper
up to 0.7% iron up to 0.5% lead up to 0.7% magnesium up to 0.5%
nickel up to 0.5% tin up to 0.7% titanium up to 0.12% Impurities
<0.05%
EXAMPLE C
TABLE-US-00003 [0055] Component Weight Percent zinc 91.2-99.9%
aluminum up to 0.5% cadmium up to 0.5% chromium up to 0.3% copper
up to 0.5% iron up to 0.3% lead up to 0.5% magnesium up to 0.3%
nickel up to 0.3% tin up to 0.5% titanium up to 0.1% Impurities
<0.05%
EXAMPLE D
TABLE-US-00004 [0056] Component Weight Percent zinc 92-99.9%
aluminum up to 0.2% cadmium up to 0.2% chromium up to 0.2% copper
up to 0.2% iron up to 0.2% lead up to 0.2% magnesium up to 0.2%
nickel up to 0.2% tin up to 0.2% titanium up to 0.08% Impurities
<0.05%
EXAMPLE E
TABLE-US-00005 [0057] Component Weight Percent zinc 94-99.9%
aluminum up to 0.1% cadmium up to 0.2% chromium up to 0.1% copper
up to 0.2% iron up to 0.1% lead up to 0.2% magnesium up to 0.1%
nickel up to 0.1% tin up to 0.1% titanium up to 0.05% Impurities
<0.01%
[0058] The zinc or zinc alloy materials can be formed into the zinc
flashing in a variety of ways. For example, the zinc flashing can
be at least partially stamped or cut (e.g., mechanical cutting,
water cutting, laser cutting, etc.) from a sheet or strip of zinc,
cast from molten zinc, etc. One or more portions of the zinc
flashing can be connected together by use of a solder (lead/tin
mix, lead free, etc.), weld bead, adhesive (e.g., urethane, epoxy,
methacrylate, meth methacrylate, isocyanate, cyanoacylate, etc.),
and/or by forming a mechanical seam. When one or more portions of
the zinc flashing are coated, the coating can be applied by any
number of techniques (e.g., dip coating, brush coating, spray
coating, electroplating, air knife coating, etc.). The coating,
when used on the zinc flashing, is used to protect the zinc
material from corroding and/or to inhibit or prevent the zinc
materials from directly contacting another material, which contact
could result in accelerated corrosion of the zinc material and/or
material in direct contact with the zinc material. When one or more
portions of the zinc flashing including the use of a barrier layer
(e.g., rubber sleeve, etc.), the barrier layer can be connected to
one or more portions of the zinc flashing by use of an adhesive
(e.g., urethane, epoxy, methacrylate, meth methacrylate,
isocyanate, cyanoacylate, etc.), and/or by a mechanical connection
arrangement (e.g., clamp, friction fit, rivet, tape, etc.).
[0059] The zinc flashing of the present invention can have many
shapes. Several of these shapes are described in more detail below
(e.g., base plate plus vertical tube, base plate plus fluted base
portion plus vertical tube, base plate plus vertical tube plus cap,
split base plate plus split vertical tube, base plate plus vertical
tube plus flexible sleeve, etc.). Several of these shapes are
described in more detail below.
[0060] Referring again to FIGS. 1-19, several non-limiting
embodiments of zinc flashing in accordance with the present
invention are illustrated. In general, the zinc flashing
illustrated in FIGS. 1-19, that are suitable for use with
penetrations in a roofing system. In each of the illustrated
embodiments, the zinc flashing 100 includes a base plate 110 that
includes an opening or aperture 120. The base plate is illustrated
as having a planar shape; however, this is not required. FIGS. 1-17
illustrate a vertical tube 130 that extends upwardly from the top
surface 112 from the base plate and which encircles opening 120 in
the base plate. The vertical tube is generally formed of the same
material as the base plate, but this is not required. The vertical
tube is generally a separate component from the base plate that is
connected to the base plate; however, it can be appreciated that
the base plate and vertical tube can be a one piece unit that is
formed from the same piece of material.
[0061] The cross-sectional size and shape of opening 120 is
selected to enable a roof penetration to pass through the opening
when the zinc flashing is secured to a roofing system. The
longitudinal length of the vertical tube can be the same or greater
length as the longitudinal length of the roof penetration; however,
this is not required. As illustrated in FIG. 1, vertical tube 130
has a generally circular cross-sectional shape; however, this is
not required. FIG. 1 also illustrates that the vertical tube has a
generally constant cross-sectional shape and size along the
longitudinal length of the vertical tube; however, this is not
required. FIG. 1 also illustrates that the vertical tube is
generally perpendicular from the top surface of the base plate;
however, this is not required.
[0062] Referring to FIGS. 4-6, the zinc flashing can include a
protective barrier to inhibit or prevent direct contact between the
zinc or zinc alloy of the zinc flashing with the roofing system
and/or roof penetration; however, this is not required. Referring
now to FIG. 4, there is illustrated a coating 140 that is
positioned on the inside surface 132 of the vertical tube and a
coating 150 that is positioned on the bottom surface 114 of the
base plate. Coatings 140, 150 can be formed of the same or
different material and have the same or different thickness.
Coatings 140, 150 can be applied to the zinc flashing in a variety
of ways (e.g., spray coating, dip coating, brush coating, etc.).
The method of coating for coatings 140, 150 can be the same or
different. Non-limiting examples of compositions of coatings 140,
150 include plastisol, PVC, vinyl, etc. As mentioned above,
coatings 140, 150 provide a physical barrier between the zinc or
zinc alloy of the zinc flashing and the roofing system and roof
penetration. Coating 140, 150 is generally used to inhibit or
prevent corrosion from being initiated by or accelerated by the
contact of the zinc or zinc alloy with the roofing system and/or
the roof penetration. Coating 150 can also be used to improve
adhesion of the base plate 110 with the surface of the roof system;
however, this is not required. Coatings 140, 150 can also or
alternatively be used to inhibit or prevent the zinc or zinc alloy
from oxidizing in the environment; however, this is not
required.
[0063] Referring now to FIG. 5, there is illustrated a coating 140
that is positioned on the inside surface 132 of the vertical tube,
a coating 160 positioned on the outside surface 134 of the vertical
tube, a coating 150 that is positioned on the bottom surface 114 of
the base plate, and a coating 170 that is positioned on the top
surface 112 of the base plate. Coatings 140, 150, 160, 170 can have
the same or different formulation and/or have the same or different
thickness. The method of applying these coatings to the zinc
flashing can be the same or different. The function of coatings
140, 150, 160, 170 can be the same or different from coatings 140,
150 as described in FIG. 4.
[0064] Referring now to FIG. 6, there is illustrated a sleeve 180
that is positioned on the inside surface 132 of the vertical tube
and a portion on the outside surface 134 of the vertical tube. As
can be appreciated, sleeve 180 does not need to extend to the
outside surface 134 of the vertical tube. The sleeve can be
connected to the vertical tube in a variety of ways (e.g.,
adhesive, melt connection, mechanical connection, etc.). As can be
appreciated, a sleeve can also or alternatively be positioned on
the complete outside surface 134 of the vertical tube, positioned
on the bottom surface 114 of the base plate, and/or positioned on
the top surface 112 of the base plate. Sleeve 180 is generally used
to inhibit or prevent corrosion from being initiated by or
accelerated by the contact of the zinc or zinc alloy with the
roofing system and/or the roof penetration. As can be appreciated,
the zinc flashing can include both a coating and a sleeve; however,
this is not required.
[0065] The coatings and/or sleeve as described above in FIGS. 4-6
can be used on any of the zinc flashing arrangements illustrated in
FIGS. 1-3 and 7-19; however, this is not required.
[0066] Referring now to FIG. 2, there is illustrated a zinc
flashing similar to the zinc flashing of FIG. 1 that includes a
split 200 in the base plate and a split 210 in the vertical tube.
The split in the base plate and the vertical tube enables the zinc
flashing to be fitted about a roof penetration. As illustrated by
the arrows, the zinc flashing can be opened along the side of the
zinc flashing so that the zinc flashing can be fitted about a roof
penetration. Once the zinc flashing is fitted about a roof
penetration, the split is closed by moving the zinc flashing in a
direction that is opposite of the arrow. The split can then be
closed in a variety of ways (e.g., adhesive, weld, solder, rivet,
etc.).
[0067] Referring now to FIG. 3, there is illustrated a roofing
system 300 that includes a roof penetration 400 that extends
through the surface of the roofing system and a zinc flashing 100
that is positioned on the roofing system and about the roof
penetration. The roofing system illustrated in FIG. 3 is a built-up
roofing system; however, it will be appreciated that the zinc
flashing can be used on other types of roofing systems. As
illustrated in FIG. 3, the base plate 110 is positioned between two
layers 310, 320 of roofing system 300. FIG. 3 also illustrates a
vent cover 500 that is positioned on the top of the roof
penetration. The use of a vent is not required. The vent can be
made of the same or different materials than the zinc flashing. The
vent can include a coating or sleeve as described above with regard
to FIGS. 4-6. The vent can be connected to the roof penetration
and/or vertical tube of the zinc flashing is a variety of ways. As
can be appreciated, vent cover 500 can be eliminated. As also can
be appreciated, the top edge of vertical tube can be bent into the
roof penetration; however, this is not required.
[0068] Referring now to FIG. 7, there is illustrated another
modified version of the zinc flashing. The zinc flashing is similar
to the zinc flashing of FIG. 1 except that the base portion 136 of
the vertical tube includes a fluted or corrugated portion 600. The
fluted portion enables the longitudinal length of the vertical tube
to be adjusted to accommodate various longitudinal lengths of roof
penetrations. The fluted portion can also or alternatively enable
the angle of the vertical tube that extends from the base plate 110
to be adjusted to accommodate various orientations of the roof
penetration extending from the surface of a roofing system.
Generally the fluted portion 600 forms less than 60% of the
longitudinal length of the vertical tube, and typically less than
50% of the longitudinal length of the vertical tube, and more
typically less than 40% of the longitudinal length of the vertical
tube, and more typically less than 30% of the longitudinal length
of the vertical tube, and more typically less than 25% of the
longitudinal length of the vertical tube.
[0069] Referring now to FIG. 8, there is illustrated the zinc
flashing of FIG. 7 that is connected to a roofing system 300 in a
manner similar to the connection of the zinc flashing illustrated
in FIG. 3. The roofing system 300 includes a roof penetration 400
that extends through the surface of the roofing system and a zinc
flashing 100 that is positioned on the roofing system and about the
roof penetration. The roofing system is a built-up roofing system;
however, it will be appreciated that the zinc flashing can be used
on other types of roofing systems. As illustrated in FIG. 8, the
base plate 110 is positioned between two layers 310, 320 of roofing
system 300. FIG. 8 also illustrates a vent cover 500 that is
positioned on the top of the roof penetration. The use of a vent is
not required. The vent can be made of the same or different
materials than the zinc flashing. The vent includes a coating or
sleeve as described above with regard to FIGS. 4-6. The vent can be
connected to the roof penetration and/or vertical tube of the zinc
flashing in a variety of ways. As can be appreciated, vent cover
500 can be eliminated. As also can be appreciated, the top edge of
vertical tube can be bent into the roof penetration; however, this
is not required. The fluted potion 600 on the vertical tube enables
the longitudinal length of the vertical tube and the angle of the
vertical tube that is extending from the base plate to be adjusted
for a particular roof penetration while the zinc flashing is being
installed on the roofing system.
[0070] Referring now to FIG. 9, there is illustrated a modification
of the zinc flashing illustrated in FIG. 1 wherein the vertical
tube 130 is connected to the base plate at a non-perpendicular
angle. Such zinc flashing can be used on sloped roofing
systems.
[0071] Referring now to FIG. 10, there is illustrated the zinc
flashing of FIG. 9 that is connected to a roofing system 300 in a
manner similar to the connection of the zinc flashing illustrated
in FIGS. 3 and 8. The roofing system 300 includes a roof
penetration 400 that extends through the surface of the roofing
system and a zinc flashing 100 that is positioned on the roofing
system and about the roof penetration. The roofing system is a
built-up roofing system; however, it will be appreciated that the
zinc flashing can be used on other types of roofing systems. As
illustrated in FIG. 10, the base plate 110 is positioned between
two layers 310, 320 of roofing system 300. FIG. 10 also illustrates
a vent cover 500 that is positioned on the top of the roof
penetration. The use of a vent is not required. The vent can be
made of the same or different materials than the zinc flashing. The
vent can include a coating or sleeve as described above with regard
to FIGS. 4-6. The vent can be connected to the roof penetration
and/or vertical tube of the zinc flashing in a variety of ways. As
can be appreciated, vent cover 500 can be eliminated. As also can
be appreciated, the top edge of the vertical tube can be bent into
the roof penetration; however, this is not required. The angled
relationship of the base plate to the vertical tube enables the
vertical tube to accommodate roof penetrations extending upwardly
from sloped roofing systems while the zinc flashing is being
installed on the sloped roofing system.
[0072] Referring now to FIG. 11, there is illustrated a
modification of the zinc flashing illustrated in FIG. 1 wherein the
vertical tube 130 has a cone shape. The cone-shaped vertical tube
is also illustrated as being connected to the base plate at a
non-perpendicular angle; however, this is not required. Such zinc
flashing, similar to the zinc flashing illustrated in FIG. 9, can
be used on sloped roofing systems. Although the vertical tube is
illustrated as being cone-shaped, it will be appreciated that the
vertical tube can have other shapes. The cross-sectional area of
the cone-shaped vertical tube is illustrated as being greater at
the base of the vertical tube where the vertical tube begins to
extend upwardly from the base plate; however, this is not
required.
[0073] Referring now to FIG. 12, there is illustrated the zinc
flashing of FIG. 11 that is connected to a roofing system 300 in a
manner similar to the connection of the zinc flashing illustrated
in FIGS. 3, 8 and 10. The roofing system 300 includes a roof
penetration 400 that extends through the surface of the roofing
system and a zinc flashing 100 that is positioned on the roofing
system and about the roof penetration. The roofing system is a
built-up roofing system; however, it will be appreciated that the
zinc flashing can be used on other types of roofing systems. As
illustrated in FIG. 12, the base plate 110 is positioned between
two layers 310, 320 of roofing system 300. A vent cover, not shown,
can be positioned on the top of the roof penetration; however, this
is not required. The top edge of the vertical tube is illustrated
as only partially extending up the side of the roof penetration;
however, it can be appreciated that the top edge of the vertical
tube can extend to the top edge or beyond the top edge of the roof
penetration. A sealant, not shown, can be positioned about the top
edge of the vertical tube to form a water tight seal between the
top edge of the vertical tube and the roof penetration; however,
this is not required. As also can be appreciated, the top edge of
vertical tube can be bent into the roof penetration; however, this
is not required. The angled relationship of the base plate to the
vertical tube enables the vertical tube to accommodate roof
penetrations extending upwardly from sloped roofing systems while
the zinc flashing is being installed on the sloped roofing
system.
[0074] Referring now to FIG. 13, there is illustrated a
modification of the zinc flashing illustrated in FIG. 1 wherein the
vertical tube 130 has a cone shape. Connected to the top edge of
the vertical tube is a sealing gasket 600 that can be made of a
variety of materials (e.g., plastic, rubber, EPDM, silicone, etc.).
The gasket can be formed of a rigid or flexible material.
Generally, the gasket is formed of a flexible material. The
cone-shaped vertical tube is illustrated as being connected to the
base plate at a non-perpendicular angle; however, this is not
required. Such zinc flashing, similar to the zinc flashing
illustrated in FIGS. 9 and 11, can be used on sloped roofing
systems. Although the vertical tube is illustrated as being
cone-shaped, it will be appreciated that the vertical tube can have
other shapes. The cross-sectional area of the cone-shaped vertical
tube is illustrated as being greater at the base of the vertical
tube where the vertical tube begins to extend upwardly from the
base plate; however, this is not required. The gasket 700 includes
a slot 710 that is designed to receive the top edge of the vertical
tube; however, this is not required. The slot 710 is used to
facilitate in securing the gasket to the vertical tube. As can be
appreciated, other or additional arrangements can be used to secure
the gasket to the vertical tube (e.g., adhesive, melted connection,
friction fit, etc.). The top 720 of the gasket 700 generally
includes a cross-sectional shape and size that is the same or
similar to the cross-sectional shape of the roof penetration so
that a seal can be formed between top 720 and the outer surface of
the roof penetration; however, this is not required.
[0075] Referring now to FIG. 14, there is illustrated the zinc
flashing of FIG. 13 that is connected to a roofing system 300 in a
manner similar to the connection of the zinc flashing illustrated
in FIGS. 3, 8, 10 and 12. The roofing system 300 includes a roof
penetration 400 that extends through the surface of the roofing
system and a zinc flashing 100 that is positioned on the roofing
system and about the roof penetration. The roofing system is a
built-up roofing system; however, it will be appreciated that the
zinc flashing can be used on other types of roofing systems. As
illustrated in FIG. 14, the base plate 110 is positioned between
two layers 310, 320 of roofing system 300. A vent cover, not shown,
can be positioned on the top of the roof penetration; however, this
is not required. The top edge of the vertical tube 130 and the top
720 of the gasket 700 is illustrated as only partially extending up
the side of the roof penetration; however, it can be appreciated
that the top 720 can extend to the top edge or beyond the top edge
of the roof penetration. A sealant, not shown, can be positioned
about the top 720 of the gasket to form a water tight seal between
the top of the gasket and the roof penetration; however, this is
not required. The angled relationship of the base plate to the
vertical tube enables the vertical tube to accommodate roof
penetrations extending upwardly from sloped roofing systems while
the zinc flashing is being installed on the sloped roofing
system.
[0076] Referring now to FIG. 15, there is illustrated a
modification of the zinc flashing illustrated in FIG. 1 wherein the
vertical tube 130 has a polygonal cross-sectional shape (e.g.,
square-shaped, rectangular-shaped, etc.). The vertical tube is
illustrated as being connected to the base plate at a perpendicular
angle; however, this is not required. The cross-sectional area of
the polygonal-shaped vertical tube is generally greater than the
cross-sectional area of the roof penetration; however, this is not
required.
[0077] Referring now to FIG. 16, there is illustrated a zinc
flashing similar to the zinc flashing of FIG. 15 that includes a
split 200 in the base plate and a split 210 in the vertical tube.
The split in the base plate and the vertical tube enables the zinc
flashing to be fitted about a roof penetration. As illustrated by
the arrows, the zinc flashing can be opened along the side of the
zinc flashing so that the zinc flashing can be fitted about a roof
penetration. Once the zinc flashing is fitted about a roof
penetration, the split is closed by moving the zinc flashing in a
direction that is opposite of the arrow. The split can then be
closed in a variety of ways (e.g., adhesive, weld, solder, rivet,
etc.).
[0078] Referring now to FIG. 17, there is illustrated the zinc
flashing of FIG. 15 or 16 that is connected to a roofing system 300
in a manner similar to the connection of the zinc flashing
illustrated in FIGS. 3, 8, 10, 12 and 14. The roofing system 300
includes a roof penetration 400 that extends through the surface of
the roofing system and a zinc flashing 100 that is positioned on
the roofing system and about the roof penetration. The roofing
system is a built-up roofing system; however, it will be
appreciated that the zinc flashing can be used on other types of
roofing systems. As illustrated in FIG. 17, the base plate 110 is
positioned between two layers 310, 320 of roofing system 300. A
vent cover, not shown, can be positioned on the top of the roof
penetration; however, this is not required. The top edge of the
vertical tube 130 is illustrated as only partially extending up the
side of the roof penetration; however, it can be appreciated that
the top edge can extend to or beyond the top of the roof
penetration. As illustrated in FIG. 17, the cross-sectional area of
the vertical tube is greater that the cross-sectional area of the
roof penetration. Positioned between the inside surface 132 of the
vertical tube and the outer surface of the roof penetration is a
sealing arrangement 800. The sealing arrangement 800 is formed of
two layers, a bottom layer that is formed of a non-shrinkable grout
810 and a top sealant layer 820 (e.g., asphalt, polymer, pitch,
etc.). As can be appreciated, may other or additional sealant
arrangement can be used.
[0079] Referring now to FIG. 18, there is illustrated zinc flashing
100 that is used to form a seal about a drain in a roofing system.
The zinc flashing includes a base plate 900 and a downwardly
extending tube 950 that is connected to the bottom surface 910 of
the base plate. The base plate is illustrated as having a planar
shape; however, this is not required. The downwardly extending tube
950 extends downwardly from the bottom surface 910 from the base
plate and which encircles opening 920 in the base plate. The
downwardly extending tube is generally formed of the same material
as the base plate, but this is not required. The downwardly
extending tube is generally a separate component from the base
plate that is connected to the base plate; however, it can be
appreciated that the base plate and downwardly extending tube can
be a one piece unit that is formed from the same piece of
material.
[0080] The cross-sectional size and shape of opening 920 is
selected to enable the downwardly extending tube to extend into a
roof drain when the zinc flashing is secured to a roofing system.
As illustrated in FIG. 18, downwardly extending tube 950 has a
generally circular cross-sectional shape; however, this is not
required. FIG. 18 also illustrates that the downwardly extending
tube has a generally constant cross-sectional shape and size along
the longitudinal length of the downwardly extending tube; however,
this is not required. FIG. 18 also illustrates the downwardly
extending tube generally perpendicularly from the bottom surface
920 of the base plate; however, this is not required. The base
plate and/or downwardly extending tube can include a coating or
sleeve as described above with regard to FIGS. 4-6; however, this
is not required.
[0081] Referring now to FIG. 19, there is illustrated a roofing
system 300 that includes a roof drain 1000. The roofing system is a
built-up roofing system; however, it will be appreciated that the
zinc flashing can be used on other types of roofing systems. As
illustrated in FIG. 19, the baseplate 110 is positioned between two
layers 310, 320 of roofing system 300. A drain cover 1100 is
positioned over drain 1000. The drain cover 1100 is not required.
The top edge of the downwardly extending tube extends only
partially into drain 1000. As illustrated in FIG. 19, the
cross-sectional area of the downwardly extending tube is less than
the cross-sectional area of the interior of drain 1000. A sealing
arrangement, not shown, can be used to form a seal between the
roofing system and the zinc flashing; however, this is not
required. Clamping rings, bolts, etc. can also be used to secure
the zinc flashing in position relative to the drain; however, this
is not required.
[0082] It will thus be seen that the objects set forth above, among
those made apparent from the preceding description, are efficiently
attained, and since certain changes may be made in the
constructions set forth without departing from the spirit and scope
of the invention, it is intended that all matter contained in the
above description and shown in the accompanying drawings shall be
interpreted as illustrative and not in a limiting sense. The
invention has been described with reference to preferred and
alternate embodiments. Modifications and alterations will become
apparent to those skilled in the art upon reading and understanding
the detailed discussion of the invention provided herein. This
invention is intended to include all such modifications and
alterations insofar as they come within the scope of the present
invention. It is also to be understood that the following claims
are intended to cover all of the generic and specific features of
the invention herein described and all statements of the scope of
the invention, which, as a matter of language, might be said to
fall therebetween.
* * * * *