Self flashing assembly

Abstract

A window or door assembly includes a frame for a window or door. Preinstalled flashing is coupled along the frame and includes overlapping portions substantially adjacent to at least one intersection of the flashing so the flashing is continuous around at least a portion of the frame. In one option, the preinstalled flashing is pliable and foldable against the frame in a storage position. In another option, at least one bracket is coupled to the frame and bendable against the frame and retained thereto in a storage position. In still another option, the preinstalled flashing is coupled to the frame along at least an upper frame member and side frame members. Optionally, the overlapping portions are substantially adjacent to the at least two corners defined by the upper frame member and side frame members.

Description

TECHNICAL FIELD

The present invention relates generally to weatherproofing of windows and doors, and in particular to a self flashing assembly that aids in reducing moisture and air flow around a window or door.

BACKGROUND

Many of the current weatherizing installations for doors and windows provide inadequate protection from air and moisture. In some instances, contractors do not weatherize windows and doors to cut costs and labor. Where flashing is not installed with a door or window, or there is poor installation, air and moisture are able to pass around the window or door. Moisture can collect in the walls and cause a host of problems. Moisture deposits in a wall soak insulation material and greatly decrease the insulative effectiveness thereby requiring additional heating or cooling. Further, collected moisture due to poor flashing installation causes mold growth within walls. Mold can be a health concern for building occupants. Further still, the moisture allowed to collect within a wall does serious damage to the structure of a building, in some cases rotting out floors and/or walls around windows or doors.

In an attempt to weatherize doors and windows for stucco homes, building paper is applied to the wall surfaces. The building paper is disposed around window and door openings. The opening is lined with caulking and the window (or door) placed within the opening. Tape is subsequently applied around the window or door and extends to the building paper. Stucco or siding is then erected over the tar paper and taping. One disadvantage of this weatherizing installation is the need for multiple installation steps that increase labor costs. Additionally, if the caulking or tape is poorly applied breaches are present or develop over time. Such breaches allow moisture collection within the wall. To cut costs, in some instances contractors forego taping and simply erect stucco or siding around the window or door without otherwise weatherizing.

Another method for weatherizing doors and windows includes wrapping a protective barrier material around a building and trimming the material around openings in walls for doors and windows. Caulking is applied around the openings and the windows and/or door are placed in the opening. The windows or doors are then nailed into the wall surface through nailing fins extending from the windows or doors. The area around the windows and doors is then taped in a similar manner as described above. As above, with the installation for a stucco surface, increased labor is a disadvantage of this method. Further, if the tape, caulking, or elastomeric material are improperly applied gaps form that allow air passage and undesirable moisture collection within the wall.

What is needed is a flashing system that overcomes the shortcomings of previous weatherizing methods. What is further needed is a flashing system that decreases labor costs, installation time, and overcomes the problems associated with moisture collection.

SUMMARY

A weatherproofing flashing assembly, for example a self flashing assembly, includes a frame for a window or door. Preinstalled flashing is coupled along the frame and includes overlapping portions substantially adjacent to at least one intersection of the flashing (e.g. the intersection of two ends of the flashing) so the flashing is continuous around at least a portion of the frame. In another option, preinstalled flashing includes flashing coupled to the frame prior to installation of the frame, for example, during manufacture of a window or door assembly.

Several options for the flashing assembly follow. In one option the flashing assembly includes brackets coupled to the frame. The brackets extend from the frame substantially parallel to a plane defined by the frame. In another option, at least a portion of the preinstalled flashing is adhered to frame. In yet another option, the preinstalled flashing includes at least one boss dimensioned and configured to engage with at least one groove on the frame to couple the preinstalled flashing to the frame. In still another option, at least one clamping member is coupled to the frame. The clamping member, in one example, secures the preinstalled flashing to the frame. The preinstalled flashing is self sealing, in another option. Optionally, the preinstalled flashing includes an adhesive disposed along at least a portion of one side of the preinstalled flashing. In another option, the preinstalled flashing is pliable, foldable and bendable.

In yet another option, the preinstalled flashing is coupled to the frame along at least an upper frame member and side frame members. The preinstalled flashing includes, in one option, overlapping portions substantially adjacent to at least two corners defined by the upper frame member and side frame members. The preinstalled flashing is coupled to the frame along a lower frame member, in another option, and the preinstalled flashing includes overlapping portions substantially adjacent to the side frame members and the lower frame member.

In another embodiment, a method for installing a weatherproofing flashing assembly includes providing a window frame. Flashing is coupled along the frame to form a window or door assembly prior to installation of the window or door assembly. Portions of the flashing are overlapped substantially adjacent to at least one intersection of the flashing. In one option, the flashing is continuous around at least a portion of the frame.

Several options for the method follow. In one option, securing the frame within the opening includes coupling at least one bracket extending from the frame to a surface such as a wall. In another option, a portion of at least one bracket is bent from a storage position. In the storage position, the bracket is adjacent to the frame. In yet another option, the frame is secured within a wall opening by coupling the flashing to the surface. In one example, the frame is secured by piercing the flashing and the surface with pins (for example nails, screws, staples or the like). In another option, the flashing self seals around the pins. In yet another option, engaging one side of the flashing to the surface includes adhering the flashing to the surface. In still another option, backing paper adhered to the flashing is removed therefrom. Removing the backing paper exposes the adhesive used to adhere the flashing to the surface, in one example. The flashing is unfolded from a storage position where the flashing is folded against the frame, in one option. In another option, engaging one side of the flashing to the surface includes overlapping a first flashing segment coupled to an upper frame member over a second flashing segment coupled to one side frame member and a third flashing segment coupled to another side frame member. In still another option, supplemental flashing is lapped over the first flashing segment, second flashing segment and third flashing segment substantially adjacent to the upper frame member and side frame members. Optionally, engaging one side of the flashing to the surface further includes overlapping the second and third flashing segments over a fourth flashing segment coupled to a lower frame member. Supplemental flashing is lapped over the second, third and fourth flashing segments substantially adjacent to the side frame members and lower frame member, in another option. In another option, the flashing is trimmed to fit within confined spaces, for example between closely spaced windows.

The weatherproofing flashing assembly for a window or door assembly allows for quick effective flashing installation. Error prone and labor intensive caulking and taping procedures are unnecessary with flashing coupled to the frame. Flashing and the door or window assembly are provided as a single unit. In one option, the flashing is preinstalled with the door or window assembly. The flashing and brackets for securing the frame within an opening are folded against the frame in a compact storage position. Installing the flashing involves unfolding it from the frame, engaging it to a wall surface and overlapping portions of the flashing segments with one another. If desired supplemental flashing is provided substantially adjacent to the upper member and side members, and side members and lower member. In another option, the flashing is rigid, or a combination of rigid and pliable portions, and engaged to the wall surface with nails or the like. A gasket is provided, if desired, substantially adjacent to the upper member and side members, and side members and lower member to further seal the flashing against moisture and air flow. Moreover, the overlapping nature of the flashing segments ensures a continuous substantially weatherproof barrier is disposed around at least the upper member and side members of the frame. Further, the pliable flashing allows for installation on nonstandard surfaces, for instance, between windows if the flashing is trimmed.

These and other embodiments, aspects, advantages, and features of the present invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art by reference to the following description of the invention and referenced drawings or by practice of the invention. The aspects, advantages, and features of the invention are realized and attained by means of the instrumentalities, procedures, and combinations particularly pointed out in the appended claims and their equivalents.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view illustrating a window assembly with self flashing constructed in accordance with one embodiment.

FIG. 2 is a perspective view illustrating a window assembly with self flashing constructed in accordance with another embodiment.

FIG. 3 is a sectional view illustrating a window assembly with self flashing constructed in accordance with an embodiment.

FIG. 4 is a sectional view illustrating a window assembly with self flashing constructed in accordance with yet another embodiment.

FIG. 5A is a perspective rear view illustrating a window assembly with self flashing constructed in accordance with an embodiment where the window assembly is in transition between a storage position and installation position.

FIG. 5B is a perspective rear view illustrating a window assembly with self flashing constructed in accordance with an embodiment where the window assembly is in an installation position.

FIG. 5C is an exploded view illustrating a window assembly with self flashing constructed in accordance with an embodiment.

FIG. 6 is a perspective rear view illustrating a window assembly with self flashing constructed in accordance with another embodiment.

FIG. 7 is a front view illustrating a door assembly with self flashing constructed in accordance with one embodiment.

FIG. 8 is a perspective view illustrating a window assembly kit in accordance with one embodiment.

FIG. 9 is a block diagram illustrating a method for constructing and installing a window assembly with self flashing in accordance with one embodiment.

DESCRIPTION OF THE EMBODIMENTS

In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the present invention. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.

FIG. 1 illustrates a window assembly 100 that includes a frame 102 that retains upper and lower sashes 104. In one option, the frame 102 includes wood. In another option, the frame 102 includes but is not limited to aluminum, steel and/or plastic. The sashes 104 include glass panes 106, and are dimensioned and configured to move within the frame 102. In one option, the sashes 104 are double hung, and translate vertically within the plane defined by the frame 102. In another option, a single sash 104 is singly hung within the frame 102 and able to translate within the frame, while the remaining sash 104 is fixed. Channels and rails are provided along the inner surfaces of the frame 102 to retain the sashes 104 and allow slidable movement of the sashes with respect to the frames 102. In yet another option, the window assembly 100 is an awning window or hopper window and includes a sash having overlapping glass planes that are rotated (for example by a cranking mechanism). In still another option, the window assembly 100 is a casement window, and the sashes rotate around a vertical side of the frame 102. The window assembly, in a further option, is a horizontally sliding window with two or more sashes, each moveable within the frame or stationary. Optionally, the window assembly is a direct glaze window including a glass pane coupled to the frame 102.

In the embodiment shown in FIG. 1, flashing 108 is coupled to the window assembly 100 and extends around the frame 102 to define a unitary assembly for installation. In one option, the flashing 108 is installed during manufacture of the window assembly 100 or prior to installation of the window assembly. The flashing 108 includes segments, in another option, that extend continuously around at least a portion of the frame 102 perimeter. The flashing 108, in yet another option, defines a continuous preinstalled barrier against air and moisture passage around at least two portions of the frame. The continuous construction of the flashing 108 around the frame 102 provides a substantially weatherproof barrier. For example, the flashing 108 extends continuously around the side members 112 (side jambs), the upper member 110 (head jamb), and the lower member 113 (sill). In another example, the flashing 108 extends continuously around the side members 112 and upper member 110, and the lower member 113 includes a nailing fin.

As shown in FIG. 1, the flashing 108 includes in one option a first flashing segment 114, second flashing segment 116, third flashing segment 118 and fourth flashing segment 120. The first segment 114 is coupled to the upper member 110, the second segments 116, 118 are coupled to the side members 112, and the fourth segment is coupled to the lower member 113. In this example, the flashing segments 114, 116, 118, 120 extend beyond the respective frame portions 110, 112, 113 and overlap at intersections of the flashing 108 to define a continuous and substantially weatherproof barrier. The first flashing segment 114 and second and third flashing segments 116, 118 overlap substantially adjacent to the upper member 110 and side members 112 at 115, in one option (see the area defined with phantom lines). In another option, the flashing segments 114, 116, 118 overlap adjacent to the corners of the frame 102 defined by the upper member 110 and side members 112. In a similar manner, flashing segments 116, 118 overlap flashing segment 120 substantially adjacent to the side members 112 and lower member 113 at 1 5.

FIG. 2 illustrates a window assembly 200, similar to window assembly 100, that includes a frame 102 and flashing 108. In one option, the window assembly 200 shown in FIG. 2 has flashing 108 that forms a continuous membrane that extends around the frame 102. The flashing 108 includes two ends 202 that overlap substantially adjacent to the lower member 113. In another option, the segments of flashing 108 overlap substantially adjacent to the intersection of the two ends 202. Optionally, the two overlapping ends 202 are joined together, for example by heat welding, chemical welding, adhesives, mechanical fastening or the like. Joining the ends 202 forms a continuous gasket of flashing 108 around the frame 102.

In another option, the flashing 108 is coupled to a window assembly having a triangular, semicircular geometry, or the like. The flashing 108 includes segments coupled to the frame that overlap substantially adjacent to corners of the frame. In another option, the segments of flashing 108 overlap substantially adjacent to the intersections of the segments. Where the window assembly frame has a circular or ovular geometry the flashing 108 includes segments coupled to the frame that overlap, in yet another option, at least once at a location around the frame.

Referring again to FIG. 1, in another option, supplemental flashing 121 is disposed substantially adjacent to the upper member 110 and side members 112 as well as the side members and lower member 113 to enhance the barrier provided by the flashing 108 around the window assembly 100. Optionally, the supplemental flashing 121 is disposed upon, between and/or over the overlapped portions of the flashing segments 114, 116, 118, 120. Supplemental flashing 121 and the window assembly 100 having flashing 108 are optionally included with each other as a kit. In one option, the flashing 108 is constructed from a rubberized pliable material operable for folding and bending of the flashing. The supplemental flashing 121 is folded and/or bent around the frame 102, as shown in FIG. 1, in another option. The supplement flashing 121, in yet another option, is disposed along the flashing 108, for example, flashing segments 114, 116, 118, 120 to form a secondary barrier around the frame 102.

One suitable flashing 108 material includes a polyethylene base, for example, Tyvek® StraightFlash™, manufactured by DuPont of Wilmington, Del. or Grace Ice & Water Shield®, manufactured by Grace Construction Products of Cambridge, Mass. Other suitable flashing 108 materials include, but are not limited to, polyvinyl chloride, rubber or the like. The pliable flashing 108 is self sealing around nails, screws, and staples that may pierce the flashing during installation and application of exterior finishing systems (e.g. siding or the like). In other words, when pierced, the pliable flashing 108 seals around the nail, or the like. In another option, the flashing 108 is constructed from a more rigid material, for example, aluminum or zinc coated steel. The flashing 108, in yet another option, includes at least one rigid portion and a pliable portion. In one example, pliable supplemental flashing 121 is disposed along the rigid flashing 108, as described above, to provide a self sealing secondary barrier around the frame 102. In one option, the flashing 108 extends from the frame. The flashing 108 extends from the frame 102, optionally, at least 4 inches. The flashing 108 is coupled to the frame 102 during manufacture of the window assembly 100, in another option. In yet another option, the flashing 108 is preinstalled before installation of the window assembly 100 within an opening.

FIG. 3 is a sectional view of one example of the window assembly 100 described above including flashing 108. The flashing 108 is coupled to the frame 102. In one option, the flashing 108 is coupled to at least one boss 300 and the boss is dimensioned and configured to engage the frame 102. In an option, the flashing 108 is coupled to the boss 300 with an adhesive. In another option, the flashing 108 is coextruded with the boss 300. As shown in FIG. 3, the frame 102 includes at least one groove 304 that receives the boss 300 and thus retains the flashing 108 around the frame. The boss 300 is interference fit within three grooves 304, in one option. In another option, the boss 300 is adhered to the frame 102. Moreover, in yet another option, the flashing 108 is coupled to the frame 102 without a boss. One such example is shown in the sectional view of window assembly 100 in FIG. 4. In the example, a portion 400 of the flashing 108 is adhered to the frame 102. The flashing 108 is bent in an “L” shape and an adhesive is disposed between the portion 400 and the frame 102. Referring again to the window assembly 200 of FIG. 2, the flashing 108 is bent in an “L” shape and optionally retained with at least one clamping member 204. The clamping member 204 is coupled to the frame 102, in one option, with fasteners 206 (e.g. nails, screws or the like) driven through the clamping member 204. The fasteners 206 couple the clamping member 204 to the frame 102 and also engage the clamping member 206 against the flashing 108. The clamping member 204 presses against the flashing 108 and secures the flashing 108 to the frame 102. In another option, the fasteners 206 are driven through the clamping member 204 and the flashing 108 to further secure the flashing 108 to the frame 102. In yet another option, the clamping member 204 is deformed and bent, for instance by crimping, to secure the flashing 108 to the frame 102. The clamping member 204 is useable with other window and door assemblies, for instance, window assembly 100, door assembly 700 and kit 800, described above and below. Optionally, the flashing 108 is coupled to the frame 102 during manufacture of the window assembly 200. The flashing 108, in another option, is preinstalled before installation of the window assembly 200 within an opening.

In one option, the window assembly 100 is secured to a surface with brackets 500, as shown in the perspective rear view of FIGS. 5A, 5B. The brackets 500 are coupled to the frame 102 and are bendable, in another option. As shown with the arrows 501 in FIG. 5A, the brackets are bent from a storage position, where the brackets lay over the frame 102, to an installation position for securing the frame 102 within a wall opening (FIG. 5B). In a similar manner to the brackets 500, the pliable flashing 108 is unfolded from a storage position (as indicated by the arrows 501 in FIG. 5A), where the flashing lays over the frame 102, to an installation position for coupling the flashing 108 to a wall surface, in another option. The brackets 500 optionally include aluminum or other metals operable for bending by hand away from the storage position against the frame 102.

To secure the frame 102 to a wall in an option, nails are driven through the brackets 500. In the example shown in FIGS. 5A, 5B, the brackets 500 include orifices 502 dimensioned and configured to receive nails, screws, or other fastening means that are driven into a wall. In another option, brackets 500 are disposed around the frame 102 along upper member 110, side members 112, lower member 113 or any combination thereof. Optionally, where the frame has a triangular, semicircular, or other geometry, brackets 500 are disposed around the frame in a similar manner, as described above. In yet another option, where the flashing 108 is constructed with more rigid materials (described above) the window assembly 100 is installed without brackets and the fastening means are driven through the flashing 108 into a wall.

As shown in FIGS. 5A, 5B, 5C flashing 108 includes backing paper 504 adhered to at least one side of each flashing segment 114, 116, 118, 120, in one option. As shown in FIG. 5C, the flashing segments 114, 116, 118, 120 include an adhesive 506 applied along each side that is engaged to a wall in another option. The adhesive 506 is optionally applied along portions of each side engaged to a wall or along one or more of the flashing segments 114, 116, 118, 120. The backing paper 504 covers the adhesive 506 and is removed during installation weatherproofing of the window assembly 100 to expose the adhesive for coupling the flashing 108 to a wall system (described below). In another option, the adhesive is applied to the flashing 108 just prior to installation. In one option, adhesive 506 and fastening means such as nails, screws or the like are used together to couple the flashing 108 to a wall system. In another option, tape, for example double sided tape, is applied along the flashing segments 114, 116, 118, 120 prior to installation. The flashing segments 114, 116, 118, 120 are optionally coupled to the wall system with tape applied along the edges of the flashing substantially adjacent the wall system.

FIG. 6 illustrates another embodiment of the window assembly 100. In this example, the flashing segments 114, 116, 118, 120 are constructed with materials more rigid (described above) than the pliable flashing. Supplemental flashing such as a pliable gasket 600 is coupled to one or more of the flashing segments 114, 116, 118, 120 and in an option, to a wall system. In one option, the gasket 600 is lapped over the flashing segments 114, 116, 118 substantially adjacent to the intersections of the flashing segments 114, 116, 118. The gasket 600 extends along the flashing segments 114, 116, 118, 120, in another option, and extends at least part way around the window assembly 100. The gasket 600, in yet another option, is lapped over the flashing segments 114, 116, 118 substantially adjacent to the upper member 110 and side members 112. In still another option, the gasket 600 is lapped over the flashing segments 116, 118, 120 substantially adjacent to the side members 112 and lower member 113. The gasket 600 is optionally coupled to a wall system and the flashing segments 114, 116, 118, 120 are disposed over the gasket. In another option, the gasket 600 is interposed between the flashing segments 114, 116, 118, 120. The gasket 600 is constructed with similar materials to pliable flashing 108, in an option.

Optionally, the gasket 600 is coupled to the flashing segments 114, 116, 118, 120 and/or wall system with an adhesive, nails, or the like, as described above with regard to the flashing 108. The gasket 600 is self-sealing and seals around nails or the like driven through the gasket 600 and flashing segments 114, 116, 118, 120 to seal punctures in the flashing segments. The gasket 600 further seals the window assembly 100 and provides enhanced weatherproofing. The gasket 600 augments the barrier against moisture and airflow provided by the flashing segments 114, 116, 118, 120. At least one gasket 600 and the window assembly 100 are optionally included with each other as a kit.

FIG. 7 illustrates another example of flashing 108, here as part of a door assembly 700. The door assembly 700 includes a frame 702 that includes, for example, wood, aluminum, steel and/or plastic. The door assembly 700 includes, but is not limited to, in-swinging, out-swinging, or horizontally sliding configurations. In one option, the door assembly includes multiple panels within one frame. In another option, the panels are moveable relative to the frame. In yet another option, the panels are stationary. In the example shown in FIG. 7, flashing 108 is coupled to the door assembly 700 and extends around the frame 702. In an option, flashing 108 is coupled to the door assembly 700 during manufacture of the door assembly or prior to installation of the door assembly. The flashing 108 includes segments that extend continuously around at least two portions of the frame 702. In one option, the flashing 108 extends continuously around the side members 706 (side jambs) and the upper member 704 (head jamb). The flashing 108, in another option, defines a continuous barrier against air and moisture passage around at least two portions of the frame 702.

The flashing 108 includes a first flashing segment 114, second flashing segment 116 and third flashing segment 118. In a similar manner to the flashing 108 of window assembly 100, the flashing segments 114, 116, 118 overlap to define a continuous and substantially weatherproof barrier. The first flashing segment 114 and second and third flashing segments 116, 118 overlap substantially adjacent to the upper member 704 and side members 706, in one option. In another option, the flashing segments 114, 116, 118 overlap adjacent to the corners of the frame 702 defined by the upper member 704 and side members 706. The flashing segments 114, 116, 118 overlap at the intersections of the flashing segments 114, 116, 118, in yet another option. In this example, for a door assembly 700, the flashing 108 is constructed with similar materials described above for the window assembly 100. Optionally, flashing segments 114, 116, 118 are coupled to a wall with adhesive, tape, nails, screws, staples or the like. In one option, the door assembly 700 includes brackets to secure the frame 702 within a wall opening. In another option, where the flashing 108 is constructed with more rigid materials (described above) the door assembly 700 is installed without brackets and the fastening means (for example, nails, screws or staples) are driven through the flashing 108 into a wall. In still another option, where the flashing 108 includes more rigid materials, a pliable gasket or supplemental flashing is coupled to the flashing segments 114, 116, 118, as described above with regard to the window assembly 100. When the flashing segments 114, 116, 118 are coupled to a wall face, in one option, the gasket correspondingly engages the flashing segments and wall face to further seal the door assembly 700 and provide enhanced weatherproofing. An adhesive and/or fastening means (for example nails) are used to engage the gasket to the wall face, in another option.

FIG. 8 illustrates a kit embodiment for a window assembly, of the kind described above. The kit 800 includes a window assembly with flashing 108 coupled thereto. In one option, the flashing 108 includes flashing segments 114, 116, 118, 120 coupled to the frame 102. In another option, the flashing segments 114, 116, 118, 120 are pliable and are folded into storage positions substantially adjacent to the frame 102. In an example, the flashing segments 114, 116, 118, 120 are folded against the frame 102. Optionally, the flashing segments 114, 116, 118, 120 are retained in the storage positions with removable tape sections coupled between the segments 114, 116, 118, 120 and frame 102. In another option, the window assembly 100 includes at least one bracket 500 coupled to the frame 102. Optionally, the bracket 500 is folded into a storage position substantially adjacent to the frame 102. In yet another option, the flashing segments 114, 116, 118, 120 are folded over the folded brackets 500. The kit 800 includes supplemental flashing 121, in one option. In another option, where the flashing 108 is constructed with more rigid materials, at least one gasket 600 (See FIG. 6) is included in the kit 800. Fastening means 802, to couple the flashing 108 and/or frame 102 to a wall system, are included in the kit 800, in an option. In one option, the fastening means include adhesive, tape, nails, screws or the like. In an example where adhesive is applied along at least a portion of a flashing segment 114, 116, 118, 120, backing paper 504 is removably coupled to the adhesive.

FIG. 9 describes a method of construction and installation 900 for a window or door assembly, such as window assembly 100, described above. The method 900 described herein is applicable for comparable assemblies, including but not limited to a door assembly. A frame, such as a window frame is provided, as shown in block 902. As shown in block 904, flashing is coupled along the frame to form a window or door assembly prior to installation of the window or door assembly. In an option, the flashing is preinstalled, for example, during manufacture of the window or door assembly such that the installer does not need to attach the flashing at the job site or prior to installation. In one example, the flashing is coupled along the frame during manufacture of the window or door assembly and prior to installation of the assembly. Block 906 generally shows portions of the flashing are overlapped substantially adjacent to at least two corners of the frame. In one option, portions of the flashing are overlapped substantially adjacent to where the flashing segments intersect. In another option, the flashing is continuous around at least a portion of the frame.

In one option, the frame is secured within the opening with brackets bent from a storage position adjacent the outer perimeter of the frame into an orientation substantially parallel with a plane defined by the upper member and side members. The brackets are bent into this orientation before seating of the window assembly within a wall opening. In an option, the brackets extend from the frame to the face of a wall. In another option, the brackets include orifices. The orifices are dimensioned and configured to receive nails, staples, screws or the like to secure the frame within the opening.

In another option, before seating the window assembly, the flashing, including flashing segments are unfolded from a storage position where the flashing is folded adjacent the outer perimeter of the frame. In the option including brackets, the flashing segments are unfolded from the storage position before the brackets are bent into the orientation for securing the frame. In an example, the flashing segments lay over the brackets at least in the storage position. In another option, securing the frame within the opening includes coupling the flashing to the wall by piercing the flashing and wall with pins (including but not limited to nails, screws, staples or the like). In the option where the flashing is a pliable material, the flashing self-seals around the pins.

In yet another option, the flashing includes an adhesive that is covered with a backing paper. The backing paper is removed prior to engaging the flashing to the wall system surrounding the opening. The flashing is then adhered to the face of the wall system. In one option, the flashing is sufficiently pliable so it may be folded back away from the wall before adhering to allow for securing of the frame with the brackets (described above).

In still another option, the first flashing segment coupled to an upper frame member is overlapped over a second flashing segment and third flashing segment coupled to side frame members. In this option, disposing the first flashing segment over the second and third flashing segments allows accumulated moisture to run over the first segment and not otherwise leach behind the second and third flashing segments where it might otherwise seep to the inner side of the wall system. The overlap of the first segment over the second and third segments substantially prevents moisture from undesirably moving behind the flashing. In yet another option, the second flashing segment and third flashing segment are lapped over a fourth flashing segment coupled to a lower frame member (described above). FIG. 5C illustrates the relative orientations of the flashing segments with respect to each other. In this example, the overlapping of the second and third segments prevents moisture from running behind the fourth segment and accumulating therein and seeping to the inner side of the wall system. In a further option, additional flashing (for example supplemental flashing or a gasket) is lapped over the first flashing segment, second flashing segment, and third flashing segment substantially adjacent to the upper frame member and side frame members. Optionally, the supplemental flashing or gasket is disposed over the second flashing segment, third flashing segment and fourth flashing segment substantially adjacent to the side frame members and lower frame member. In another option, the flashing is trimmed to suit the requirements of the surface the flashing is engaged against (for example, the window assembly is substantially adjacent to another window assembly requiring trimming of the flashing to fit).

The flashing assembly described herein allows for quick effective flashing installation. Error prone and labor intensive caulking and taping procedures are unnecessary with flashing coupled to the frame. Preferably, the flashing and the door or window assembly are provided as a single unit from the manufacturer. In an example, the flashing comes preinstalled with the door or window assembly. The flashing and brackets, for securing the frame within an opening, are folded against the frame in a compact storage position. Installing the flashing involves unfolding it from the frame, engaging it to a wall system and overlapping portions of the flashing segments with one another. If desired supplemental flashing is provided substantially adjacent to the upper member and side members, and side members and lower member. In another option, the flashing is rigid, or a combination of rigid and pliable portions, and engaged to the wall system with nails or the like. A gasket is provided, if desired, along the flashing to further seal the flashing against moisture and air flow. Moreover, the overlapping nature of the flashing segments ensures a continuous substantially weatherproof barrier is disposed around at least the upper member and side members of the frame. Further, the pliable flashing allows for installation on nonstandard surfaces, for example between windows if the flashing is trimmed.

It is to be understood that the above description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. It should be noted that embodiments discussed in different portions of the description or referred to in different drawings can be combined to form additional embodiments of the present application. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Claims

1. A window or door assembly comprising:

a frame for a window or door; and

preinstalled flashing coupled along the frame, wherein the preinstalled flashing includes overlapping portions substantially adjacent to at least one intersection of the flashing so the preinstalled flashing is continuous around at least a portion of the frame.

2. The window or door assembly of claim 1 further including, brackets coupled to the frame, wherein the brackets extend from the frame substantially parallel to a plane defined by the frame.

3. The window or door assembly of claim 1, wherein at least a portion of the preinstalled flashing is adhered to the frame.

4. The window or door assembly of claim 1, wherein the preinstalled flashing includes at least one boss dimensioned and configured to engage with at least one groove on the frame to couple the preinstalled flashing to the frame.

5. The window or door assembly of claim 1, further comprising at least one clamping member coupled to the frame, wherein the clamping member is dimensioned and configured to secure the preinstalled flashing to the frame.

6. The window or door assembly of claim 1, wherein the overlapping portions are joined at the at least one intersection of the flashing.

7. The window or door assembly of claim 1, wherein the preinstalled flashing is self sealing.

8. The window or door assembly of claim 1, wherein the preinstalled flashing includes an adhesive disposed along at least a portion of one side of the preinstalled flashing.

9. The window or door assembly of claim 1, wherein the preinstalled flashing is pliable, foldable and bendable.

10. The window or door assembly of claim 1, wherein the frame includes at least two corners, and the overlapping portions are substantially adjacent to the at least two corners.

11. The window or door assembly of claim 10, wherein additional flashing is disposed over the preinstalled flashing substantially adjacent to the at least two corners.

12. The window or door assembly of claim 1, wherein additional flashing is disposed over the preinstalled flashing, and the additional flashing is self sealing.

13. A window assembly comprising:

a window frame including an upper member, side members, and a lower member;

at least two brackets coupled to at least one of the upper member, side members or lower member of the frame, wherein the at least two brackets extend from the frame substantially parallel to a plane defined by the frame; and

preinstalled flashing disposed along at least the upper member and side members, wherein the preinstalled flashing is foldable and bendable to overlap the preinstalled flashing substantially adjacent to at least the upper member and side members.

14. The window assembly of claim 13, wherein the preinstalled flashing is disposed along the lower member, and the preinstalled flashing includes overlapping portions substantially adjacent to the side members and the lower member.

15. The window assembly of claim 13, wherein the preinstalled flashing includes an adhesive disposed along at least a portion of one side of the preinstalled flashing, and the adhesive is operable to substantially seal the preinstalled flashing against the face of a wall.

16. The window assembly of claim 13, wherein the preinstalled flashing is foldable against the frame and retained thereto in a storage position.

17. The window assembly of claim 13, wherein the at least two brackets are bendable against the frame and retained thereto in a storage position.

18. The window assembly of claim 13, wherein additional flashing is disposed over the preinstalled flashing.

19. The window assembly of claim 18, wherein the additional flashing is self sealing.

20. A kit for a window or door assembly comprising:

a frame assembly including a frame and flashing coupled along the frame, wherein the preinstalled flashing includes overlapping portions substantially adjacent to at least one intersection of the flashing so the preinstalled flashing is continuous around at least a portion of the frame; and

additional flashing dimensioned and configured to be disposed over the overlapping portions.

21. The kit for a window or door assembly of claim 20, wherein the preinstalled flashing includes an adhesive disposed along at least one side of the preinstalled flashing.

22. The kit for a window or door assembly of claim 21, wherein the frame assembly further includes backing paper disposed over the adhesive and removably coupled thereto.

23. The kit for a window or door assembly of claim 20, further comprising pins for fastening the frame assembly to a wall surface.

24. The kit for a window or door assembly of claim 23, wherein the frame assembly further includes at least one bracket coupled thereto, and the pins extend through the brackets to fasten the frame assembly to the wall surface.

25. A method comprising:

providing a frame;

coupling flashing along the frame to form a window or door assembly prior to installation;

overlapping portions of the flashing substantially adjacent to at least one intersection of the flashing so the flashing is continuous around at least a portion of the frame.

26. The method of claim 25, further comprising securing the frame within an opening including coupling at least one bracket extending from the frame to a surface surrounding the opening.

27. The method of claim 25, further comprising securing the frame within an opening including coupling the flashing to a surface surrounding the opening.

28. The method of claim 27, wherein securing the frame further includes piercing the flashing and surface with pins, and sealing the flashing around the pins.

29. The method of claim 25, further comprising bending a portion of at least one bracket from a storage position, where in the storage position the at least one bracket is adjacent to the frame.

30. The method of claim 25, further comprising unfolding the flashing from a storage position wherein the flashing is folded against the frame.

31. The method of claim 25, further comprising engaging one side of the flashing to a surface.

32. The method of claim 31, wherein engaging one side of the flashing includes adhering the flashing to the surface.

33. The method of claim 31, wherein engaging one side of the flashing includes removing backing paper adhered to the flashing prior to engaging one side of the flashing to the surface.

34. The method of claim 25, wherein overlapping portions of the flashing includes overlapping a first flashing segment coupled to an upper frame member over a second flashing segment coupled to one side frame member and a third flashing segment coupled to another side frame member.

35. The method of claim 34, further including overlapping additional flashing over the first flashing segment, second flashing segment and third flashing segment substantially adjacent to the upper frame member and side frame members.

36. The method of claim 34, further including overlapping the second flashing segment and third flashing segment over a fourth flashing segment coupled to a lower frame member.

37. The method of claim 25, further comprising trimming the flashing.