DETAILED DESCRIPTION

[0048] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications of the inventive features illustrated herein, and any additional applications of the principles of the invention as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.

[0049] With reference to FIG. 1 of the drawing figures, which are given by way of example, and not by way of limitation, a flashing system 10 in one embodiment comprises metal or plastic flashing pieces 12, 13, 14, 15 which cooperate to form a water-tight seal around a window 16 in a wall structure 18. Taking as an example the case of a stucco exterior treatment, though the invention will be applicable to other exterior treatments, such as stone, siding, brick, etc., frame members 19, 21, cooperate with exterior sheathing 20, such as exterior grade medium density fiberboard, plyboard or the like to form a wall which, receives the window 16, either before, or after, an exterior waterproofing layer 22 (vapor barrier) is applied to the sheathing, as shown in FIG. 3. The waterproof layer can be, for example, tar paper, TYVEK or a suitable substitute, and is applied to the sheathing. Therefore a nailing flange 24 of the window can be inside or outside the paper 22. In either case, the system in the illustrated embodiment is installed by first installing a bottom piece 12 underneath the bottom of the window. As well be appreciated with respect to FIGS. 2 and 3, this is to provide a seal below the window. This is by virtue of a seal between the bottom piece 12 and the window and the downwardly extending flashing portion 26, and also to direct water coming off the bottom of the window, for example from weep holes 28, and otherwise off the window, downwardly and outwardly by virtue of a drip flange 30 which extends downwardly for some length, usually between an ⅛″ and 1″, for example about ½″, and outwardly at an oblique deflection angle of about 30 degrees. This inclined portion extends for about ½″ to ¾″. This insures that water 32 drips down and away from the front face of the exterior treatment 34 (in this case stucco) and does not immediately contact it. Although the water may drip down free of the wall, or may be blown back into the wall by wind lower down in its fall, at least it is not a concentrated stream of water running off the window as would otherwise be the case. The drip flange acts to protect the stucco beneath the window 16 from deterioration due to excessive water exposure. As is well known, stucco is not entirely water-tight, and water can seep back underneath the window were it not for the bottom piece 12 thus configured. As can be seen, the “wing” portions 35 of bottom piece extend outwardly beyond the sides of the window for some distance 36, commensurate with the depth of the flashing portion 26. Typically, this distance will be between 4″ and 8″, for example about 6″. This outwardly extending wing portion 35 is present on both sides of the bottom piece 12 below the window.

[0050] A bead of sealant (not shown) can be applied to the top of the bottom piece 12 or the bottom of the window before installing the bottom piece. This can be flattened and provide a continuous seal by pushing up the flashing piece against the bottom of the window. In another embodiment, a form strip can be provided along a top portion 37 of the flashing piece, this provides a seal by virtue of a restoring force of the foam causing it to fill the space when the bottom piece 12 is pushed up against the window. An adhesive foam can be used to stick to both the flashing and the window. For example, an adhesive foam tape strip can be applied to the top of the flashing, leaving a peel-back paper backing over the side of the tape that will stick to the bottom of the window until just before installation.

[0051] Furthermore, when the bottom piece 12, is cut, tabs 38 of varying length remain. Tabs 38 can be folded up around the bottom outer portion of the window 16. While these tabs are optional there is little incremental cost to providing them as the metal would otherwise need to be removed in any event. In one embodiment a seal, such as the adhesive foam strip described above, can be provided on these tabs also. Tabs 38 provide additional water resistance around the corner regions formed by flashing pieces 12, 13, 14 and 15.

[0052] In one embodiment, the flashing piece 12 is attached by staples or other fasteners directly through the flashing piece. In another embodiment, a laminate sealing product, sometimes referred to as Vitchathyne, which is a laminate 40 of a polymeric sheet and bituminous sealant, is applied over the flashing and then staples or other fasteners are driven through the vitchathyne and the laminate and the paper 22, into the sheathing 20. This way, the sealant of the laminate is drawn in to seal the staple holes made in the flashing piece 12.

[0053] Next, two side flashing pieces, 13, 14 are set up against the sides of the window 16. These pieces, as can more clearly be seen with reference to FIGS. 4 and 5, cooperate with the window 16 to provide a water-tight seal around the window. A sealing flange 42, extends outward and then at a right angle across the front of the window from the flashing portion 26, and doubles back on itself behind to provide a smooth edge 44 and increased strength. In one embodiment a foam seal strip 46 can be provided. The foam seal can be for example, a foam tape with adhesive on both sides which adheres to a turned back portion 48 of the sealing flange, and also to a front portion 50 of the window 16.

[0054] These side pieces also have portions of the outwardly extending flange 26 which extend above and below the window, which for convenient reference will also be called wing portions 35. These overlap the similar wing portions 35 of the bottom sealing flange member 12, which has previously been attached. They also extend above the window 16 a distance 52 commensurate with the width of a top flashing piece, 15 to be discussed. As will be appreciated, that dimension, 52, can be the same, greater, or lesser, than the width 36 of the side pieces 13 and 14. Also, the width 52 can be the same as, or different than, the distance 36 of the side members 13 or 14, and can be the same lesser or greater than a thickness 52 of the bottom member 12. As will be appreciated, in the illustrated embodiment all these dimensions are the same and the pieces overlap by the same amount.

[0055] As discussed before in connection with the bottom piece 12, the sealing flanges can have folding tab portions 38, which fold under and over the outwardly extending portion of the window 16 and cooperate with the other flashing members to provide a water-tight seal. As will be appreciated, the bottom tab portions 38 on the side flashing pieces 13 and 14 will fold under the window and also behind the drip flange 30, up against a bottom inner portion (54 in FIG. 3) of the bottom flashing member 12.

[0056] As discussed before the flashing pieces are attached by staples, or other fasteners. Vitchathyne laminate sealing strips 56 can also be used in one embodiment, as described above.

[0057] Completing the system, the top flashing piece 15 is fit over the top of the window 16, and wing portions 35 of this top piece overlap the upwardly extending wing portions of the side pieces 13 and 14. The sealing flange 42 of the top piece extends down over the outwardly extending portion of the window, and contacts the front face 50 thereof in a sealing engagement, as before described with reference to the side pieces. The top piece can be further appreciated with reference to FIG. 6, where different, alternate, embodiments are shown in outline form. In one embodiment the sealing flange 42 is trimmed back at an angle 58 which can be for example 45 degrees. Likewise, the tab portion 38, which folds down, (if provided) can be cut back by an angle 60 from the front, to hide the front edge under stucco (not shown) to be applied. For example, this angle 60 can be between 5 and 15 degrees in the illustrated embodiment. In another embodiment the tab 38 can be brought downward commensurate with a front portion of the sealing flange 42 and then cut back at another angle 62, for example 45 degrees. In another embodiment the top can be dressed by cutting back the tab at an angle 64 from a top front corner 66. For example, that angle can be 45 degrees. As with the side pieces, the sealing flange can be provided with a further seal 46 which can again be a double-adhesive form tape strip. Such tape strips are widely commercially available.

[0058] A further laminate strip sealing 68 can be applied over the flashing piece 15 to seal any holes made by staples 70 or other fasteners driven through the flashing, as described above.

[0059] Furthermore, as mentioned the flashing can be made of metal or plastic. As will be appreciated, in this and all the embodiments described herein, the metal can be aluminium, tin, sheet metals of other alloys, and the plastic can be a polymeric resin such as PVC, and other substances which are suitable in terms of long term stability, resistance to UV breakdown, etc. Composites of polymeric resins and fiberous materials, metal and plastic laminated materials, and other suitable materials which can be used for flashings and can be configured as shown herein are contemplated for use in embodiments disclosed herein.

[0060] With reference now to FIGS. 7, 8 and 9, in another embodiment the invention can be implemented by incorporating salient features directly in the window 72. For example, this can be done by molding the features in a window frame formed of a polymeric resin. The sealing flashing described above can be provided by extending a nailing flange outward to form a sealing flange 74 around the outer periphery of the window. For example, this flange could extend at least 6″ rather than the 1″ or 2″ nailing flange commonly provided. Again, the reason for extending this flange is to prevent water leaking back into the structure from the joint between the stucco and the window 72 at a forwardly extending portion 76 which comes outward through the exterior treatment. Again, for sake of convenience, we will discuss this embodiment in connection with a stucco exterior treatment, but as will be appreciated, the same is applicable to other exterior treatments such as the brick and siding mentioned. A bottom drip flange 78, again extending downwardly some distance from an ⅛″ to a ½″ to as much as ¾″, for example, and then outward at an oblique deflection angle 80 of between about 15 and 45 degrees (and in the illustrated example about 30 degrees) is provided. This drip flange portion can be molded integrally, or can be afterwards attached by heat welding, solvent welding, ultrasonic welding, or otherwise as is known in the art to join pieces of polymeric resin.

[0061] With reference particularly to the embodiment shown in FIGS. 8 and 9, in one embodiment the drip flange 78 can extend downwardly from an outward face 82 of the window, and in another embodiment it can be set back to depend downwardly from a bottom portion 84 of the frontwardly projecting portion 76 of the window 72. As will be appreciated, which of the embodiments that of FIG. 8 or FIG. 9, is provided, depends on many factors, such as the exterior treatment to be used, the distance which the forwardly extending portion 76 extends outward from the sealing flange portion 74. In another example, the embodiment illustrated in FIG. 8 could be used with a stucco pop-out, whereas that of FIG. 9 could be used without a stucco pop out.

[0062] With reference to FIG. 10, in another embodiment the water management system comprises a unitary flashing piece 90, which can be formed of polymeric resin, for example by a molding process. In this embodiment, the flashing piece is sized to fit over a window 92 previously attached to a wall 94. The unitary piece is substantially the same as the four-piece system, but is made specifically with the same dimensions as the window 92 to cooperate therewith to provide the same advantages for that window specifically. A sealing strip 96, for example the adhesive foam tape described above, is attached to the inner surface 98 of the unitary flashing element 90, to provide the configuration described above in connection with the four-piece unit. In one embodiment, a bead of sealant (not shown) is applied between the bottom of the window 92 and the bottom 100 of the opening in the unitary flashing piece. In another embodiment a foam strip (without adhesive on one side) can be used. The unitary flashing piece of the water management system in this embodiment can be attached by fasteners, such as staples, as described above, and also in another embodiment a sealant strip can be used to seal the holes through a flashing portion 102, as described above.

[0063] In this embodiment also, a lower drip flange 104 is provided, substantially as described above. In the polymeric resin embodiment, the drip flange can be molded unitary with the rest of the unit, or can be added by heat welding, solvent welding, ultrasonic welding, etc.

[0064] In another embodiment, the unitary flashing unit 106 illustrated in FIG. 11 is formed of a metal material. In the illustrated embodiment, the unit is formed by cutting out the center, and folding the bottom drip flange 108 and a top window enclosing flange 110 from the unitary sheet. Side portions 112, 114 are formed of separate fold and metal pieces, which are pushed through the opening from behind, and welded, brazed, or are otherwise sealingly attached to the rest of the unitary sheet 106 at least along an attachment flange 116 provided on each metal piece. A portion 118 of the upper window and casing portion 110 is folded around behind the two side extension pieces 116 provided 112, 114, and is folded back on itself to interlock. This configuration provides a dressed appearance, similar to that which is provided by the embodiment using four-pieces described above, when completed. As with an added embodiment, in this one also a sealant can be used between the piece 106, and the window 92 such as the adhesive foam tape described above, for example.

[0065] With reference now to FIGS. 12 and 13, in the case where the exterior treatment comprises stone work 119 a flashing 120 can be configured to direct moisture outward and over the stone work, by means of a drip flange 122 similar to that described above. Water 124 is directed outward to fall away from the face of the stone work. In one embodiment a portion 126 which extends from the (covered) face of the sheathing 20 outward over the top of the stone work is inclined at a slight angle 128 to lessen the tendency for water to pool there. Stucco 130 another exterior treatment may be applied over the flashing 120 but other exterior treatments could also be used, for example siding, on a brick, board and batten, etc.

[0066] With reference now to FIGS. 14 and 15, in another embodiment a flashing strip 132 can be configured to fit over top a brick exterior treatment 134 at an upper edge, again, to deflect water 136 outward and away from the brick work. This embodiment, the drip flange 138 can further comprise a downwardly extending flange portion 140 which provides greater depth of the drip flange downward from the top of the brick work 134. As will be appreciated, this feature can be deleted in another embodiment. A portion 142 of the flashing adjacent a top of the brick work can be inclined at a first smaller angle 143, while a second portion 144 is disposed at a second, steeper angle 145. Again these features are provided to discourage water ponding within an exterior treatment, such as stucco 146, siding, etc.; but, rather runs off.

[0067] Moreover, with both the embodiments illustrated in FIGS. 12 through 15, if a brick work, for example of a different type, size, etc. is used above the flashing, the sloping portions (126 in FIG. 12, 142 and 144 in FIG. 14) support a back edge (not shown) of a brick, and the widening gap, as it extends outward, will be filled with mortar, and is usually provided with weep holes. In any case, it has been found that the sloping confirmation helps the bottom portion of a brick exterior treatment dry more quickly, as the water moves outwardly and downwardly along the inclined portion of the flashing 120, 132.

[0068] With reference now to FIG. 16 in another embodiment, similar to that discussed above and illustrated in FIGS. 14 and 15, a flashing strip 150 is configured to fit over an inclined portion 152 of an upper portion of a brick work exterior treatment 154. A drip flange 156 and downwardly depending portion 158 below that, are made wide enough to cover the stepping set backs of the bricks of the exterior treatment 154, and can be, for example, 3″ or more in total depth 160 from a sloping portion 162 which extends outward and downward from the sheathing 20 of the structure. This flashing 150 can be configured to form a set back area, and be exposed between the top of the brick 154 and the eaves 164, in which case flashing will be exposed, or to provide a transition to stucco 166 extending between the brick work and structure above, such as the eaves 164. In the former case, the flashing is tucked behind a structure, such as additional flashing 168 covering a roof overhang. Such additional structure may be attached to the flashing 150 and the sheathing 20 in an overlapping portion 170, for example by staples, screws, nails, or other fasteners.

[0069] Like the embodiments illustrated in FIGS. 12 through 15, the configuration shown in FIG. 16 assures that water will be deflected outward and over, and away from the brick exterior treatment 154. It may be used to obtain architectural effects, for example it may fill an aesthetic function, as well as a practical one of keeping water out of a top portion of a wall of a structure. With reference now to FIGS. 17 and 18, another problematic area, as mentioned, is the interface between a foundation 172, and an exterior treatment, for example brick work 174. The flashing 176 attached to the sheathing 20 the structure extends underneath the brick work, and over top the foundation, to extend down the front of the foundation some distance 178, for example between ½ and ½″. A drip flange 180 which can be folded back, as described above, is provided to direct water 182 out and over the remainder the outside of the foundation 172 which can be covered by a finished coat 184 for example.

[0070] The flashing can be provided with a sloping portion 186 extending between the sheathing and outside front corner 188 of the foundation. If a brick exterior treatment is to be supported, a grout 190 is laid down on top of the foundation before the flashing is applied, to provide support for the weight of the exterior brick work when set up. When the brick work 174 is placed on top of the flashing 176, mortar 192 fills the outward widening space between a back bottom corner 194 of the bottom course of bricks, and the front of the exterior. Again, this provides a sloping surface to direct water outward and away from the bottom of the brick exterior treatment. As will be appreciated, weep holes are periodically provided in the bottom of brick work, and this sloping surface will provide a sloping weep hole as well.

[0071] With reference now to FIGS. 19 and 20, another embodiment, a flashing can be configured to perform a similar function at an interface between a foundation 196 and a stucco exterior treatment 198 at the bottom portion of an exterior wall 200. In this case, a flashing 202 extends over the lower portion of the exterior sheathing 20, and then deflects backwards and under the exterior sheathing to contact the foundation wall, extends downward for some portion 204 between ½″ and 1½″, for example, and then comprises a drip flange 206, to direct water 208 outwardly and over an exterior finish coat 210 applied to the foundation 196. The drip flange can be doubled back to form a second slanting portion 212 as described above. The Flashing in one embodiment is configured to extend down about 3 inches from the top of the foundation wall. This distance can be made shorter, or longer, depending on the particular application and any aesthetic or functional architectural considerations dictating a different distance.

[0072] A vapor barrier 213 applied to the sheathing is made to overlap the flashing 202 so that water is prevented from running down the wall behind the flashing. As with all the embodiments, the exterior finish below the drip flange can be pushed up under it, to prevent water getting between the drip flange and the exterior finish coat below it. For example, if the foundation is plastered, then the plaster is applied under a bottom drip flange 206 to seal the opening to prevent water climbing up behind the flashing by capillary action.

[0073] A “J” strip 214 is attached to the flashing 202 in the illustrated embodiment. The J strip is provided with weep holes 216 to accommodate moisture 218 escaping from the bottom of the stucco exterior treatment 198. The J channel, is conventional, and known in the art.

[0074] With both the embodiments illustrated in FIGS. 17 and 18, as well as that of 19 and 20, the height of the flashing, or how far it goes up the exterior wall sheathing 20 of the structure depends on conditions in a particular application. For example, it can extend up a first height 220 in either case, for example about 6″, or 8″, or so, or, if snow is expected to lay against the structure, or if frequent floods are expected, a taller flange, extending up to a second height 222, for example 18″, can be provided to keep moisture from entering the structure at the interface between the foundation (172 in FIG. 17, 196 in FIG. 19), and the structure.

[0075] Turning now to FIGS. 21 and 22, at an upper portion of an exterior treatment, such as stucco 224 where it approaches the eaves 226 of the structure 228, is particularly important to keep water from entering the structure, to get behind the exterior treatment. This goal is complicated by the fact that venting, to provide for air flow 230 through vents 232, and into the roof of the structure 228 for cooling purposes (as is known, vents are provided near the top of the roof for this air to escape through) once it has absorbed heat from the roof 234. As will be appreciated, this helps the roofing materials used to last longer.

[0076] A top protective flashing piece 236 which accommodates air flow, is provided in this embodiment to extend from the exterior sheathing 20 down outward and over an exterior treatment, such as the stucco 224 and down the face thereof for some distance. This distance can be relatively short e.g. first length down to a bottom edge 238 or a longer downward distance to a bottom edge 240 and in either case, a drip flange 242 can be provided as described above. As will be appreciated, it is more important the farther down the flange bottom 240 is, exposing it to wind driven water for example. A curving portion 244 extending upward and outward from the exterior sheathing 20 of the structure, and attaching to bottom of the roof trusses 246 provides protection for the top of the exterior treatment from any moisture which may be driven through the vents 232 in the eaves 226. This can happen, for example, when strong winds drive rain or snow against the side of the structure 228 and at the same time creating a negative pressure at the roof top vents (not shown) which tends to draw the air through the vents 232. Any such moisture, in this embodiment is prevented from entering the structure itself, by the curving portion 244, and is directed back downward and outward and over the exterior treatment 224 as in the embodiments described above. As can be appreciated, this provides an extra measure of security that moisture will not enter the structure at the top of the exterior treatment, at the interface between the roof 234 and walls of the structure. An outward edge 248 can be turned back in one embodiment to provide increased stiffness of the outer edge of the flashing piece 236.

[0077] As will be appreciated, the flashing system described herein provides improved water tightness of structures, and particularly prevents water ingress at critical points, such as joints and interfaces between two differing exterior treatments, at the roof line, and at the foundation, structure wall interface. Moreover, the system in accordance with the invention can be implemented with minimal additional cost, and the benefit of lower maintenance cost over the life of the structure, and the prevention of water damage which could otherwise occur providing substantial cost savings overall. Further, the system as illustrated herein mitigates the formation of mold, mildew, mold and mildew, and the like, which can be harmful to the health of the occupants of the structure.

[0078] While several embodiments of the invention have been illustrated and described, it will be appreciated that various modifications can be made, without departing from the spirit and scope of the invention.