Molded roof flashing system

Abstract

A flashing strip for placement at an intersection between a wall and an adjacent roof against which a plurality of shingles are to be laid, the flashing strip comprising an elongated back panel from which a plurality of flashing tabs extend outward. The flashing tabs are disposed at an angle to the axis and in substantially parallel planes to one another. During use, the elongated back panel is disposed against and coupled to the wall at the intersection, and shingles are then placed along the flashing tabs during the roofing process. The flashing strip may also include a ledge and/or a decorative molding above the flashing tabs. The flashing strips may be placed end to end to form a continuous flashing strip that may be installed before the placement of siding or the like on the wall. The siding may be installed by positioning the siding against the ledge before or after placement of the singles.

Description

FIELD OF THE INVENTION

[0001] The present invention relates generally to roof flashing used in the installation and overlapping of roof shingles, and more particularly to a roof flashing system that includes molded lengths of roof flashing that are conveniently installed prior to the application of exterior wall coverings, yet permit installation of the shingles after the application of the wall covering.

BACKGROUND OF THE INVENTION

[0002] Leaks and damage resulting from water from rain or snow seeping into the cracks and crevices of a shingled roof have plagued many an unfortunate home or office dweller. The intersections of inclined roof slopes and upright walls or chimney structures are particularly problematic in that water tends to seep down along the upright wall or chimney stricture, bypassing the roof, and finding its way along the rafters and interior ceilings. The damage resulting from such seepage may be severe, and often results in rotted wood or damaged plaster or plasterboard. Repair costs of these elements of a structure are generally high.

[0003] Aluminum sheet metal flashing, or flashing cards having an “L-shaped” cross-section are typically installed at the intersections of the vertical and angled surfaces at the time the shingles are installed in an effort to minimize such seepage. The flashing is designed to manipulate the flow of water in a certain direction on the roof and to protect sections of a building where the shingles abut a wall or an edge. The horizontal (or angled) part of a flashing card rests on the surface of a roof along the joint between the roof and wall before the shingle is applied. The vertical portion of the flashing card may be nailed or attached via a tar-based adhesive to the upright surface against which it abuts.

[0004] Customarily, flashing is attached to the house one piece, or card, at a time as the roofer alternates between securing a flashing card to the roof and laying a shingle over the horizontal portion of the flashing card, a process which is very labor intensive. Further, due to the cumbersome nature of the handling of the flashing cards and the shingles, it is generally difficult to achieve the desired security for the positioning of these elements in order to obtain the best seal possible. Despite a roofer's great effort to provide an effective seal, water may still tend to seep in-between the flashing cards themselves and in-between the flashing cards and the shingles.

[0005] Wall treatment is typically applied to the vertical wall portion following installation of the shingles and flashing cards. Lap siding, for example, may be installed on exterior walls of a building. Primed lap siding, however, is relatively expensive, and rotting may result in the lower boards when placed directly against the shingles and flashing cards in the conventional manner. As a result, some siding manufactures now require that a given space be maintained between the bottom of the siding boards and the surface of the roof shingle in order to maintain the siding warranties. In installing such siding, carpenters often estimate the clearance, or use a board as a spacer, methods which result in inconsistent results, at best.

[0006] While various methods have been proposed to simplify installation and enhance the sealing characteristics of the flashing cards and shingles, as well as siding, such attempts have been largely unsuccessful. It has generally been considered is difficult to simplify the attachment of flashing material during a roofing project due to the variety of the thickness of shingles and the variety of types of materials used for shingles.

[0007] In U.S. Pat. No. 5,946,862, Hoffman proposed the use of a plurality of individual flashing cards that are secured together in an overlapping fashion by stapling or gluing. The strip of coupled flashing cards is then secured to the roof by the roofer before applying the adjacent rows of shingles. Hoffman indicates that the amount by which the cards overlap is dictated by the width of shingles utilized, greater overlap for smaller shingles, and less overlap for larger shingles. Accordingly, the flashing cards must either be coupled together at the jobsite for the desired shingle size, or the roofer must maintain a large inventory of previously coupled cards that overlap by various amounts.

[0008] In U.S. Design Patent Des. 397,810, Basset proposes a continuous elongated L-shaped strip that is installed along the joint. The strip includes a relatively horizontal shoulder between the vertical leg and the horizontal leg of the strip for placement of siding other wall treatment. Shingles are laid along the horizontal leg in an overlapping fashion. The strip, however, does not account for specific placement of the individual shingles.

[0009] In U.S. Pat. No. 5,894,697, Hunter similarly provides a number of embodiments of a generally L-shaped flashing strip with a horizontal shoulder for placement of siding or the like. As with Basset, however, the horizontal leg of Hunter is flat and continuous, and does not account for specific placement of individual shingles.

[0010] An elongated flashing strip is provided which may be placed at an intersection between a wall and an adjacent roof as a substitute for traditional flashing cards. The flashing strip comprises an elongated back panel from which a plurality of flashing tabs extend outward. The flashing tabs are disposed at an angle to the elongated axis of the back panel, and are disposed in substantially parallel planes to one another. During use, the elongated back panel of one or more strips is positioned against and coupled to the wall at the intersection. The shingles are then placed along the flashing tabs during the roofing process. In this way, the roofer merely positions the shingles and nails them in place, eliminating the use of flashing cards altogether. As a result, the process of shingling a roof is much less time consuming, and more consistent and accurate. Additionally, the use of a unitary elongated flashing strip helps to minimize any potential seepage between flashing cards, shingles, the roof and the wall.

[0011] Preferably, the back panel of the flashing strip extends slightly below the flashing tabs. In this way, when installed at the intersection, the flashing tabs are canted slightly downward in order to direct drainage away from the intersection.

[0012] The flashing strips may be placed end to end to form a continuous flashing strip along a long intersection. Preferably, the leading and trailing edges of the flashing strips are overlapped slightly to provide a seep resistant environment. In this regard, the leading edge may be offset slightly in order to facilitate this overlapping and create a stop to position the strip.

[0013] The flashing strip may also include a ledge and/or a decorative molding above the flashing tabs. The siding may be installed by positioning the siding against the ledge before or after placement of the shingles. Thus, the ledge provides an easy and consistent means for ensuring uniform spacing of the siding from the surface of the roof or shingles. Further, the shingles may be installed after the placement of siding or the like on the wall, providing the builder substantial latitude in the use of subcontractors for the installation of both the roofing and the siding.

[0014] These and other features and advantages of the invention will be more readily apparent upon reading the following description of a preferred exemplified embodiment of the invention and upon reference to the accompanying drawings wherein:

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1a is a schematic fragmentary, perspective view of a molded roof flashing strip according to teachings of the present invention in use with shingles and siding.

[0016] FIG. 1b is a side elevational view of the flashing strip of FIG. 1a.

[0017] FIG. 1c is a top plan view of the flashing strip of FIGS. 1a and 1b taken along line 1c-1c in FIG. 1b.

[0018] FIG. 2a is an enlarged, fragmentary, side elevational view of the flashing strip as illustrated in FIG. 1b.

[0019] FIG. 2b is an end elevational view of the flashing strip illustrated in FIG. 2a.

[0020] FIG. 3 is an enlarged side elevational view of the embodiment illustrated in FIGS. 1a-2b during use.

[0021] FIG. 4a is a fragmentary, side elevational view of a second embodiment of the flashing strip constructed according to teachings of the present invention.

[0022] FIG. 4b is an end elevational view of the flashing strip illustrated in FIG. 4a.

[0023] FIG. 5a is a fragmentary, side elevational view of a third embodiment of the flashing strip constricted according to teachings of the present invention.

[0024] FIG. 5b is an end elevational view of the flashing strip illustrated in FIG. 5a from the leading edge.

[0025] FIG. 5c is an end elevational view of the flashing strip illustrated in FIG. 5a from the trailing edge.

[0026] FIG. 5d is a fragmentary view of the leading and trailing ends of adjacent flashing strips of the embodiment illustrated in FIG. 5a.

[0027] FIG. 6a is a fragmentary, side elevational view of a fourth embodiment of the flashing strip constructed according to teachings of the present invention.

[0028] FIG. 6b is an end elevational view of the flashing strip illustrated in FIG. 6a.

[0029] FIG. 6c is a fragmentary, top plan view of the flashing strip taken along line 6c-6c in FIG. 6a.

[0030] FIG. 7 is a fragmentary, perspective view of the leading and trailing ends of two engaged flashing strips according to the fourth embodiment, as illustrated in FIGS. 6a-c.

[0031] FIG. 8a is a fragmentary, side elevational view of a fifth embodiment of the flashing strip constructed according to teachings of the present invention.

[0032] FIG. 8b is an end elevational view of the flashing strip illustrated in FIG. 8a.

[0033] While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications, and equivalents included within the spirit and scope of the invention as defined by the appended claims.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0034] Turning now to the drawings, there is shown in FIG. 1, a schematic, perspective view of a fragment of a building wall 20 from which a dormer 22 extends. The wall 20 may also include strips of aluminum or wooden lap siding 21, as illustrated, or some other sort of protective or decorative treatment. The dormer 22 includes a roof 24 on which tarpaper 26 and then roofing shingles 28 are laid, and which meets the wall 20 at an intersection 30. A flashing strip 32 is provided along the intersection 30 of the wall and the dormer roof 22.

[0035] In accordance with teachings of the invention, and as shown in more detail in FIGS. 1b, 1c, 2a and 2b the flashing strip 32 is an elongated, molded structure that includes back panel 34 from which a plurality of flashing tabs 36 extend. The flashing tabs 36 are preferably rectangularly shaped and are spaced apart in a parallel, overlapping fashion at an angle to the top and bottom edges 38, 40 of the back panel 34, as may best be seen in FIGS. 1b, 2a and 2b. The flashing tabs 36 are preferably disposed at angle &agr; on the order of 5° from an axis &khgr; along the horizontal elongation of the flashing strip 32, as shown in FIG. 2A. In order to accommodate the shingles, the space between the flashing tabs 36 is uniform, and is equal to at least the thickness of the roofing shingle 28. Accordingly, the flashing tabs provide consistent placement and spacing of the shingles 28, as well as the flashing along a wall 20.

[0036] As may best be seen in FIGS. 1 and 3, in use, the back panel 34 is disposed against, and secured to the wall 20 with the flashing tabs 36 or the bottom edge 40 of the back panel 34 along the roof 24 or tarpaper 26. It will be appreciated that the flat back panel 34 and top edge 38 provide a smooth surface against which caulking my be readily laid, even if the strip 32 is disposed against a relatively uneven surface, such as a brick wall. To facilitate attachment of the back panel 34 to the wall 20, the back panel 34 may include preformed openings 42 through which a nail or screw 44 may inserted to couple the flashing strip 32 to the wall. Alternately, the carpenter or roofer may glue, staple, nail, or screw the flashing strip 32 to the wall 20, using the nail or screw 42 to pierce an opening in the back panel 34 if necessary. The roofing shingles 28 are then laid along and between the flashing tabs 36. Those skilled in the art will appreciate that the flashing strip 32 may be easily and quickly placed, and the shingles 28 conveniently positioned to form a substantially seep resistant intersection 30 between two adjacent angled surfaces 20, 24.

[0037] In order to further discourage liquid and other material from penetrating the space between wall 20, the roof 24, and the shingles 28, the bottom edge 40 of the back panel 34 preferably extends below the flashing tabs 36 (see reference 35), as may be most readily seen in FIGS. 2a and 2b. In this way, the flashing tabs 36 are raised slightly above the roofline to encourage drainage away from the intersection 30 and to allow for the placement of tarpaper 26.

[0038] To facilitate placement of the wall treatment such as siding 21, and to ensure that the siding 21 is disposed a consistent distance from the roof 24, the flashing strip 32 is preferably further provided with a continuous projection or ledge 46 which extends from the back panel 34. In this way, the strips of siding 21 may be easily and consistently positioned and secured to the wall 20 before or after installation of the roofing shingles 28. It will be appreciated by those of skill in the art that the ledge 46 is particularly useful when the ends of the strips of siding 21 are cut at an angle, as shown in FIG. 1a.

[0039] It will further be appreciated that the ledge may take an alternate form as shown, for example, in the embodiments illustrated in FIGS. 4a and b, and FIGS. 5a, b, c and d. For ease of explanation, the same numbers followed by lettered suffixes will designate similar elements of the alternate embodiments (e.g., the ledge in FIGS. 4a and b is identified as 46a, and in FIGS. 5a and b as 46b). In the embodiment shown in FIGS. 4a and b, the back panel 34a juts outward to form the ledge 46a, the back panel 34a extending below (35a) the flashing tabs 36a in a substantially parallel plane and extending back to the wall surface.

[0040] The back panel 34b of the embodiment in FIGS. 5a through 5d similarly juts outward to form the ledge 46b. This embodiment, however, provides a decorative molding or fascia 48 directly below the ledge 46b. The decorative molding 48 may be textured or colored to compliment the appearance of the exterior siding if so desired or to include other architectural features or colors. As may be most easily seen in FIG. 5b, the back panel 34b extends back inwardly 49 below the decorative molding 48, and then continues in substantially the same plane as the upper portion of the back panel 34b.

[0041] In other words, the back panel may include a number of portions extending in planes at angles to one another. For example, the back panel may include three portions extending in planes at angles to the adjacent plane, or five portions extending in planes at angles to the adjacent plane, as shown in FIGS. 4a-b and 5a-b, respectively.

[0042] In order to further inhibit seepage around the flashing strip and shingles, the flashing strip 32c may be provided with an offset portion 50 along the leading edge 52 of the back panel 34c, as shown in FIGS. 6a, 6b, 6c, and 7. In this way, the offset portion 50 of the leading edge 52 of a first flashing strip 32c may be disposed over the trailing edge 54 of an adjacent flashing strip 32d to form a continuous flashing strip assembly along an intersection between the two surfaces of the wall and the roof. Thus, the offset portion 50 must be offset at least enough to accommodate the thickness of the trailing edge 54.

[0043] It will be appreciated that the offset may be in the form of the back panel 34c angling outward from the major plane of the back panel 34c, as shown ill FIGS. 6a-7, or the offset portion may be in the form of a reduced thickness portion of the back panel 34c, so long as the offset is sufficient to accommodate the trailing edge, which may likewise be of a reduced thickness. Alternately, depending upon the geometry, the trailing edge 54 may include an inwardly offset portion. The embodiment illustrated in FIGS. 5a-5d includes both an outwardly offset 50b leading edge 52b, and an inwardly offset section 51b at the trailing edge 54b. As may be best seen in FIG. 5d, the ledge 46b, molded facia 48, and inwardly extending portion 49 are offset inwardly at 51b approximately the thickness of the strip 32b in these areas.

[0044] It has been determined that a leading edge on the order of one and one-half inches is sufficient to provide engagement and adequate sealing between two adjacent strips. According to an important aspect of this embodiment, the leading edge 52, 52b, 52c of the flashing strip 32b, 32c or 32e is disposed downhill along a ramped surface of a roof to inhibit water from seeping around the strip 32b, 32c or 32e.

[0045] To permit the leading edge 52, 52b, 52e and trailing edge 54, 54b of adjacent flashing strips 32b, 32c, 32d to accommodate one another, the offset portion 50, 50b, 50e of the first flashing strip 32b, 32c, 32d is notched out below the leading flashing tab 36e, as shown in FIG. 6a. Further, the ledge 46d at the trailing edge 54 of the second flashing strip 32d is notched out, as shown in FIG. 7 or the protruding facia 48 reduced in size as shown in FIGS. 5c-5d. In this way, the leading 52 and trailing edges 54 may be engaged to provide a continuous ledge or facia and series of flashing tabs as shown in FIGS. 5d and 7. It will be appreciated, however, that the trailing edge 54 need not be so notched if the flashing strip 32e is not provided with a ledge, as illustrated in FIGS. 8a and b.

[0046] According to another important aspect of the invention a flashing strip constructed according to teachings of the invention is preferably molded of a flexible material, such as an elastomeric or a thermoplastic material, preferably a polypropylene copolymer, such as is used in outdoor lighting fixtures. If surfaces of the flashing strip are exposed to the elements, the material should be resistant to degradation due to weather and sunlight. As a result, the individual strips are relatively low in weight, economical to manufacture, and yet have excellent resistance to the elements. The strip may also be molded in different colors, particularly if it is visible when installed.

[0047] In summary, the invention provides a plastic molded, continuous roof flashing system which eliminates the need for the placement of individual flashing cards during the roofing process. The back panel of a strip having a plurality of flashing tabs may be quickly and accurately placed against a wall at its intersection with a roof. The back panel may be secured to the wall by any appropriate mechanism, such as glue, nails, or otherwise, and caulked or otherwise sealed as necessary. The flashing strip may further include a ledge against which a wall treatment, such as siding, may be easily and accurately placed.

Claims

1. A flashing strip for placement at an intersection between a wall and an adjacent roof against which a plurality of shingles are to be laid, the flashing strip comprising:

an elongated back panel having an axis of elongation, an outside surface, and an inside surface,

a plurality of flashing tabs extending outward from the outside surface of said back panel, the flashing tabs being disposed at an angle to the axis and in substantially parallel planes to one another,

such that the inside surface of the elongated back panel may be disposed against the wall and the plurality of shingles disposed along the plurality of flashing tabs.

2. The flashing strip of claim 1 wherein the back panel is disposed in a single plane.

3. The flashing strip of claim 1 for use with siding strips, the flashing strip further comprising an elongated ledge for placement of siding strips.

4. The flashing strip of claim 3 wherein the elongated ledge extends outward from the outside surface of the elongated back panel.

5. The flashing strip of claim 3 wherein the elongated back panel includes a first portion disposed in a first plane, and a second portion disposed in a second plane at an angle to the first plane to form the elongated ledge.

6. The flashing strip of claim 5 wherein the elongated back panel further includes a third portion disposed in a third plane at an angle to said second plane.

7. The flashing strip of claim 6 wherein the flashing tabs extend outward from said third portion of the elongated back panel.

8. The flashing strip of claim 6 wherein the third portion has a width and forms a decorative molding.

9. The flashing strip of claim 6 further comprising a fourth portion disposed in a fourth plane at an angle to said third plane, and a fifth portion disposed in a fifth plane at an angle to said fourth plane, said flashing tabs extending outward from said fifth portion.

10. The flashing strip of claim 6 wherein said fifth and first planes are disposed in substantially the same plane.

11. The flashing strip of claim 1 wherein the inside surface of the back panel is disposed in a first plane, and a flashing tab is disposed in a second plane, said first and second planes being disposed at an angle of less than 90° to one another.

12. The flashing strip of claim 1 wherein the back panel includes an upper edge and a lower edge, an entirety of the flashing tabs extending from the back panel between the upper and lower edges such that placement of the lower edge against the roof spaces at least a portion of said flashing tabs away from the roof.

13. The flashing strip of claim 1 wherein a portion of the back surface is disposed in a major plane, said back panel further comprising a leading edge and a trailing edge having a thickness, said back surface at said leading edge comprising an offset portion offset from the major plane in an amount at least equal to the thickness of the trailing edge.

14. The flashing strip of claim 13 further comprising a leading flashing tab disposed toward the leading edge, and wherein the offset portion does not extend below at least part of the leading flashing tab.

15. The flashing strip of claim 14 further comprising an elongated ledge, said elongated ledge not extending along at least part of the trailing edge.

16. The flashing strip of claim 13 wherein the trailing edge comprises a front surface and said leading edge has a thickness, the front surface at said trailing edge comprising an offset portion offset from a major plane in an amount at least equal to the thickness at the leading edge.