Corner flashing system

Abstract

A corner flashing system is provided for sealing the corners of recessed window frames against moisture penetration. In a preferred embodiment, the system comprises first and second double-flap members, a half-cube member, and caulking. The first and second double-flap members, and the half-cube member are preferably made of asphalt or petroleum based material. In another preferred embodiment, the system comprises one double-flap member, a modified half-cube member, and caulking. In another preferred embodiment, the system comprises a single member that combines a double-flap member and a half-cube member, and caulking. In another preferred embodiment, the system comprises a combination member, a double-flap member, and caulking.

Claims

1. A method of flashing a recessed framed wall of a structure, the framed wall including an inner frame, with an exposed front surface, and an outer frame, the method comprising: providing a monolithic flexible flashing member having a substantially, rectangular flat shape; forming at least two orthogonal creases in the flashing member; forming at least three orthogonal sections of a half cube: a horizontal section, a back vertical section, and a side vertical section, by overlapping a first portion of the flashing member with a second portion of the flashing member; and securing the flashing member in a corner of the outer frame of the structure, the securing step comprising: contacting a vertical surface of the outer frame with the vertical side section of the flashing member; contacting a horizontal surface of the outer frame with the horizontal section of the flashing member; and contacting the exposed front surface of the inner frame with the back vertical section of the flashing member, the back vertical section and the side vertical section extending away from each other along one of the creases.

2. The method of claim 1, comprising making a straight cut in the flashing member to separate the first portion from the second portion.

3. The method of claim 1, wherein overlapping the first and second portions of the flashing member forms the back vertical section.

4. The method of claim 1, wherein the first and second portions are overlapped such that a point of intersection of the three orthogonal sections coincides with an intersection between the at least two creases.

5. The method of claim 1, wherein the back vertical section and the side vertical section have the same vertical height.

6. The method of claim 1, comprising applying a bead of caulk to a seam between the vertical surface and horizontal surface of the outer frame.

7. The method of claim 1 additionally comprising bending the side vertical section to form a first vertical flap, and securing the first vertical flap to a front surface of the outer frame.

8. The method of claim 7 additionally comprising bending the horizontal section to form a second vertical flap, and securing the second vertical flap to a front surface of the outer frame.

9. The method of claim 8 additionally comprising overlapping a web with one or both of the first vertical flap and the second vertical flap of the flashing member.

10. The method of claim 9, comprising contacting the web to the front surface of the outer frame.

11. A method of flashing a recessed framed wall condition in a structure wall, the framed wall condition including an inner frame and an outer frame, the method comprising the steps of: securing a flexible flashing member generally in a corner of the outer frame of the structure wall such that a vertical flange of the flashing member contacts a generally vertical surface of the outer frame, a horizontal flange of the flashing member contacts a generally horizontal surface of the outer frame, a front flange of the flashing member contacts an outer front surface of the outer frame, and a rear flange of the flashing member contacts a front surface of the inner frame of the structure wall; wherein at least a portion of the rear flange has a height as measured from the horizontal surface of the outer frame to a top edge of the rear flange that is less than or equal to a height of the vertical flange as measured from the horizontal surface of the outer frame to a top edge of the vertical flange.

12. The method of claim 11, wherein the flashing member is folded before being secured to the outer frame such that the front flange extends from at least one of the vertical flange and the horizontal flange at approximately 90 degrees.

13. The method of claim 11, further comprising the step of securing another flashing member generally in a corner of the inner frame of the structure wall, such that a vertical flange of the another member contacts a generally vertical surface of the inner frame, a horizontal flange of the another member contacts a generally horizontal surface of the inner frame, and a front flange of the another member overlaps the rear flange of the flashing member.

14. The method of claim 11, wherein securing the flashing member generally in a corner of the outer frame of the structure wall comprises adhering at least one of the flanges to the outer frame.

15. The method of claim 14, wherein the front flange of the flashing member is adhered to an outer front surface of the outer frame.

16. The method of claim 11, wherein securing the flashing member to the structure wall comprises securing to the outer front surface of the outer frame at least a portion of the front flange that is on a side of the generally vertical surface of the outer frame that is opposite the horizontal flange.

17. The method of claim 11, wherein securing the flashing member generally in the corner of the outer frame comprises piercing the flashing member with at least one staple.

18. The method of claim 17, wherein the flashing member substantially seals itself around the at least one staple when the at least one staple pierces the flashing member.

19. The method of claim 11, wherein the horizontal flange of the flashing member has a horizontal length L, and wherein the horizontal length L corresponds to a depth of the recessed framed wall condition.

20. A method of flashing a recessed framed wall condition in a structure wall, the framed wall condition including an inner frame and an outer frame, the method comprising the steps of: providing a flexible flashing member having a first flange, a second flange, a third flange, and a fourth flange; attaching the first flange to a generally vertical surface of the outer frame; attaching the second flange to a generally horizontal surface of the outer frame; attaching the third flange to an outer front surface of the outer frame; and attaching the fourth flange to a front surface of the inner frame, wherein a height of a first top edge of the fourth flange as measured from the generally horizontal surface of the outer frame is a maximum height at a first portion of the fourth flange and a second top edge of the fourth flange as measured from the generally horizontal surface of the outer frame is a minimum height at a second portion of the fourth flange, the second portion of the fourth flange being farther from the first flange than the first portion of the fourth flange.

21. The method of claim 20, wherein the first flange is connected to the second flange, and wherein the first flange is substantially perpendicular to the second flange when the first and second flanges are attached to the outer frame.

22. The method of claim 21, wherein the second flange is connected to the third flange.

23. The method of claim 22, wherein the second flange is connected to the fourth flange.

24. The method of claim 20, wherein a portion of the third flange of the flashing member comprises a web.

25. The method of claim 24, wherein a shape of the web is rectangular.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIGS. 1A-1B are perspective views of a preferred embodiment of the double-flap member, from the front and back, respectively;

(2) FIG. 1C is a rear perspective view of another preferred embodiment of the double-flap member, illustrating the pre-applied rope caulking;

(3) FIG. 1D is a perspective view of a corner of a recessed window frame having a deep recess, illustrating a double-flap member that is adapted to fit such a deep recess;

(4) FIGS. 2A-2C are perspective views of a preferred embodiment of the double-flap member, illustrating the manner in which this member is cut and formed;

(5) FIGS. 3A-3B are perspective views of a preferred embodiment of the half-cube member, from the front and back, respectively;

(6) FIGS. 4A-4D are perspective views of a preferred embodiment of the half-cube member, illustrating the manner in which this member is cut and formed;

(7) FIGS. 5A-5D are perspective views of a preferred embodiment of the combination member, illustrating the manner in which this member is cut and formed;

(8) FIG. 6 is a perspective view of a corner of a recessed window frame, illustrating the step of applying caulk to the corner;

(9) FIG. 7 is a perspective view of a corner of a recessed window frame, illustrating the step of installing a first double-flap member in the corner;

(10) FIG. 8 is a perspective view of a corner of a recessed window frame, illustrating the step of securing the first double-flap member in the corner using a hammer stapler;

(11) FIG. 9 is a perspective view of a corner of a recessed window frame, illustrating the step of installing a half-cube member in the corner;

(12) FIG. 10 is a perspective view of a corner of a recessed window frame, illustrating the step of installing a second double-flap member in the corner

(13) FIG. 11 is a perspective view of a corner of a recessed window frame, illustrating the step of installing a double-flap member in the corner;

(14) FIG. 12 is a perspective view of a corner of a recessed window frame, illustrating the step of installing a half-cube member in the corner;

(15) FIG. 13 is a perspective view of a corner of a recessed window frame, illustrating the step of cutting and folding a portion of the half-cube member; and

(16) FIG. 14 is a perspective view of a corner of a recessed window frame that has been flashed according to a preferred embodiment of the present flashing system, using one double-flap member and one half-cube member.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(17) FIGS. 1A-1B illustrate one preferred embodiment of a double-flap member 20. This member 20 is preferably constructed of an asphalt or petroleum based flashing material, although it will be understood by one skilled in the art that a variety of other materials having water-resistant properties may also be used. This member 20 comprises a vertical seating flange 22 and a horizontal seating flange 24, which are joined at a 90 angle. The vertical flange 22 preferably has substantially the same dimensions as the horizontal flange 24. The length L of the flanges, defined as the direction parallel to both planes defined by the flanges, is appropriate for the dimensions of the structure in which the flanges are installed. Preferred lengths are 1, 3, 12, 18, 24 and 30. FIG. 1D illustrates a double-flap member 20 having a long dimension L.

(18) Extending at a 90 angle from one edge of the vertical flange 22 is a substantially rectangular first flap 26. Extending at a 90 angle from one edge of the horizontal flange 24, is a substantially rectangular second flap 28. The two flaps 26, 28 extend from the same side of the flanges 22, 24, so that both flaps 26, 28 lie in the same plane.

(19) Joining the first flap 26 to the second flap 28 is a web 30. A preferred shape for the web 30 is rectangular, although it will be appreciated by one of skill in the art that other shapes, such as triangular, may be equally useful. The web 30 is preferably constructed from two substantially identical pieces of a flashing material that has an adhesive backing. Preferably, the web 30 is made of a material having an asphalt or petroleum base. The two pieces making up the web 30 face one another on their adhesive sides. The web 30 is secured to and partially overlaps the adjacent edges of the flaps 26, 28, such that two edges of the web 30 are parallel to the adjacent edges of the flaps 26, 28.

(20) As illustrated in FIG. 1C, one alternative embodiment of the double-flap member 20 includes a pre-installed length of rope caulking 32 having a protective backing. Pre-installation of this caulking 32 eliminates one step in the process of installing the flashing system, as explained in detail below.

(21) The double-flap member 20 is preferably formed as illustrated in FIGS. 2A-2C. The manufacturer begins with a substantially rectangular flat sheet 40 of flashing material, preferably one having an asphalt or petroleum base. The dimensions of the sheet 40 are appropriate for the size of the window frame that is to be sealed. In one preferred embodiment, the sheet 40 is approximately 89. Other preferred dimensions include 69, 169, 229, 289 and 349.

(22) With the flat sheet 40 oriented such that one 9 edge defines the bottom edge 42 of the sheet 40, the manufacturer makes a straight cut across the sheet, starting from the center of its bottom edge 42, to a terminus 44 that is preferably approximately 4 up from the bottom 42. Shorter or longer cuts are also acceptable, but a sufficient length of material is preferably left uncut to form the flanges 22, 24. The sheet 40 is then creased as shown in FIG. 2A. A horizontal crease 46 intersects the terminus 44 of the cut and runs in a direction perpendicular to the cut. A vertical crease 48 also intersects the terminus 44, but extends upward in the same direction as the cut. When the sheet 40 is folded along these two creases 46, 48, so that each crease 46, 48 defines the vertex of a ninety-degree angle, the formerly flat sheet 40 defines a first flap 26 and a second flap 28 that each lie in the plane of the flat sheet 40 and do not overlap one another. The first and second flaps 26, 28 are joined at the terminus 44 of the cut.

(23) Projecting into the plane of the former flat sheet 40 from one edge of each flap 26, 28 are two seating flanges, one horizontal 24 and one vertical 22. The vertical 22 and horizontal 24 seating flanges are attached to one another along an edge that extends perpendicularly into the plane of the flat sheet and terminates at one end in the terminus 44 of the cut where the first flap 26 and second flap 28 meet.

(24) To secure the double-flap member 20 permanently in this shape, a substantially rectangular piece of flashing material, a web 30, having an adhesive backing is secured along the adjacent edges of the flaps 26, 28, which were joined prior to being cut. Preferably, the adhesive surface of the web 30 is covered so as to prevent the double-flap member 20 from sticking to neighboring pieces, as in a bulk package of double-flap members 20. Preferably, this covering comprises a second piece of adhesive backed flashing material (not shown), substantially the same shape as the web 30, and secured to the adhesive side of the web 30 such that the adhesive surfaces of each piece face one another.

(25) FIGS. 3A and 3B illustrate a preferred embodiment of a half-cube member 50. This member 50 is preferably constructed of an asphalt or petroleum based flashing material, although it will be understood by one skilled in the art that a variety of other materials having water-resistant properties may also be used. This member 50 comprises a first face 52, a second face 54 and a third face 56, with all three faces 52, 54, 56 lying at right angles to one another. All three faces 52, 54, 56 share three common edges 58, 60, 62, such that the second face 54 and third face 56 share edge 58, second face 54 and first face 52 share edge 62, and third face 56 and first face 52 share edge 60. The half-cube member 50 retains its shape through the addition of a strip of adhesive backed flashing material 64 along the outside of edge 60, or along the inside of edge 62, or along both edges 60, 62.

(26) Although the illustrated embodiment of the half-cube member 50 includes substantially rectangular faces, one of skill in the art will appreciate that the faces may be any of a variety of different shapes without departing from the spirit of the invention. For example, by cutting diagonally across one or more of the faces 52, 54, 56, the half-cube member will comprise three substantially triangular faces.

(27) FIGS. 4A-4D illustrate a preferred method of constructing the half-cube member 50. The manufacturer begins with a substantially rectangular flat sheet 70 of flashing material. Preferably, the material is identical or substantially identical to the material used to construct the double-flap member 20. The sheet 70 is of appropriate dimension for the window frame that is to be flashed. Preferred dimensions are 89.

(28) With the sheet 70 oriented such that one 9 edge defines a bottom edge 72, the manufacturer makes a straight cut across the sheet starting from the center of the bottom edge 72 and ending at a terminus 74 that is approximately one-half of the way up from the bottom 72. The cut thus forms two flaps 76, 78. The manufacturer then forms a horizontal crease 80 and a vertical crease 82, each intersecting the terminus 74 of the cut. The horizontal crease 80 runs perpendicularly to the cut, while the vertical crease 82 runs in the same direction as the cut.

(29) The manufacturer then folds the creases for the half-cube member 50 in the opposite direction as for the double-flap member 20 so that the two flaps 76, 78 substantially overlap one another and the member 50 resembles a half-cube with three faces 52, 54, 56 sharing three common edges 58, 60, 62. To secure this member 50 permanently in the shape of a half-cube, a strip of adhesive backed flashing material 64 is applied along the inside of edge 60 of the half-cube member 50, where the cut edge of flap 78 meets face 54, as illustrated in FIG. 4D.

(30) If desired, both the double flap member 20 and the half-cube member 50 may be constructed from a single sheet of flashing material. A complete combination member 102 is illustrated in FIG. 5D. A preferred method of forming the combination member 102 is illustrated in FIGS. 5A-5D. The manufacturer begins with a single sheet of flashing material 110. Preferably, the sheet is rectangular, having a bottom edge 112 and a top edge 114 that are each approximately 9 in length, and side edges of length 9+L. L preferably corresponds to the depth of the window to be flashed, as explained below.

(31) The manufacturer makes two straight cuts across the sheet, the first cut 116 begins at the center of the bottom edge 114 and continues vertically for approximately 4. The second cut 118 begins at the center of the top edge 112 and continues vertically for approximately 4. The first cut 116 thus forms a first flap 120 and a second flap 122, and the second cut forms a third flap 124 and a fourth flap 126. The manufacturer also forms three creases in the sheet. The first two creases 128, 130 extend horizontally across the sheet, each intersecting the terminus of one of the cuts 116, 118. The third crease 132 extends vertically across the sheet between the two termini of the cuts 116, 118.

(32) To form the double flap component of the combination member 102, the first flap 120 and second flap 122 are separated while the first horizontal crease 130 is folded to a 90 angle and the vertical crease 132 is similarly folded to a 90 angle, as illustrated in FIG. 5B. To form the half-cube component of the combination member 102, the third flap 124 and fourth flap 126 are brought together while the second horizontal crease 128 is folded to a 90 angle, as illustrated in FIG. 5C. To secure the combination member 102 in this configuration, a web 134 is added to the double flap component in the same manner as above, and a strip of adhesive-backed flashing material 136 is added to one edge of the half-cube component in the same manner as above.

(33) FIGS. 6-10 illustrate one preferred method of combining and installing the members 20, 50 in a recessed window frame 82. The recessed window frame 82 has an outer frame 84 and an inner frame 86. The outer frame 84 has a vertical support 88, a horizontal sill 90, and a front surface 92. The inner frame 86 has a front surface 94, a vertical support 98 and a horizontal sill 100.

(34) As illustrated in FIG. 6, first an L-shaped bead of caulk 80 is applied along a seam between the horizontal sill 90 and the vertical support 88, and along a seam between the horizontal sill 90 and the front surface 94. An identical bead 81 is applied above the first bead 80 at the height of the upper sill 100. Second, a first double-flap member 20 is placed in the corner of the outer frame 84 such that the horizontal 24 and vertical 22 seating flanges contact the horizontal sill 90 and vertical support 88, respectively, of the corner of the outer frame 84. The first double-flap member 20 is placed such that the first flap 26, second flap 28 and web 30 are flush with the front surface 92 of the outer frame 84.

(35) The double-flap member 20 is secured in place, preferably with a hammer stapler 96, as illustrated in FIG. 8. Because the flashing material is preferably of an asphalt or petroleum base, it is self-sealing. Thus, the staples do not compromise the water sealing capability of the flashing material.

(36) In the third step, illustrated in FIG. 9, a half-cube member 50 is placed in the corner of the outer frame 84. The corner of the half-cube 50, where all three edges intersect, sits in the corner of the outer frame 84 so that one face of the half-cube is flush with the front surface 94 of the inner frame 86, one face is flush with the vertical support 88 of the outer frame 84, and one face is flush with the horizontal sill 90 of the outer frame 84. In this orientation, the faces of the cube that are flush with the horizontal sill 90 and vertical support 88 of the outer frame 84, partially overlap the horizontal 24 and vertical 22 seating flanges, respectively, of the double-flap member 20. The half-cube member 50 is secured in place in the same manner as the first double-flap member 20, preferably with a hammer stapler 96.

(37) In the fourth and final step, a second double-flap member 20 is placed in the corner of the inner frame 86, in the same manner and orientation as the first double-flap member 20 was placed in the corner of the outer frame 84. The first flap 26, second flap 28, and web 30 of the second double-flap member 20 partially overlap one face of the half-cube member 50.

(38) To complete the flashing of the recessed window, the remaining corners are finished in the same manner just described, and flashing material is applied to the remaining surfaces of the frame in a manner well known within the art.

(39) Another preferred method of installing the flashing system includes an alternate embodiment of the first and second double-flap members 20. This embodiment, illustrated in FIG. 1C, is substantially identical to the double-flap members 20 already described. This embodiment, however, includes a bead of caulk 32 that is pre-applied to the back of the member 20 along the edge that forms the border between the two seating flanges 22, 24, as shown in FIG. 1C. The pre-applied bead of caulk 32 preferably includes a protective backing to prevent the bead from collecting debris prior to installation.

(40) Because the double-flap members 20 already have a bead of caulk 32 applied to the region that mates with the corners of the window frames 84, 86, there is no need to apply a bead of caulk to the portions of the frames where the pre-applied bead sits. The first step in the installation process, then, is to remove the protective backing from the bead of caulk 32 on the first double-flap member 20 and place the first double flap member 20 into position as described above. The rest of the process proceeds as described above.

(41) In another preferred method of installation, shown in FIGS. 11-14, only one double flap member 20 is installed. The double flap member 20 may or may not include a pre-applied bead of caulk 32. Thus, in the first installation step, caulk is applied to the frame as needed in the locations described above, and if a pre-applied bead of caulk is used, the protective backing is removed. The double flap member 20 is seated in the corner of the outer frame 84 in the same manner as above, and as illustrated in FIG. 11. The half-cube member 50 is also seated in the corner of the outer frame 84 in the same manner as above. In this method, however, the first face 52, which comprises the two flaps 76, 78, is preferably flush with the front surface 94 of the inner frame 86. Rather than placing a second double-flap member 20 in the corner of the inner frame 86, the corner of the half-cube member 50 is cut and folded over the inner frame as illustrated in FIGS. 13 and 14. Because the first face 52 comprises two flaps 76, 78, one flap is cut and folded across the vertical support 98 of the inner frame, and the other flap is cut and folded across the horizontal sill 100 of the inner frame. Which flap is folded across which face makes no difference. To complete the installation, the folded portions of the flaps are preferably secured to the inner frame 86 with staples.

(42) In another preferred method (not shown) of installing the flashing system, one combination member 102 is installed in a recessed window frame. To begin, caulk is added to the window frame as needed in the same manner as in the previous methods. The combination member 102 is then seated in the corner of the frame such that the flaps 120, 122 are flush with a front surface of the outer frame, and one face 124 of the half-cube component is flush with the front surface of the inner frame. The combination member 102 is preferably secured in place with staples. To complete the installation, either the half-cube component is cut and folded over the inner frame, as described above, or a double flap member is installed in the corner of the inner frame, also as described above.

SCOPE OF THE INVENTION

(43) The above presents a description of the best mode contemplated for the present corner flashing system, and of the manner and process of making and using it, in such full, clear, concise, and exact terms as to enable any person skilled in the art to which it pertains to make and use this corner flashing system. This corner flashing system is, however, susceptible to modifications and alternate constructions from that discussed above which are fully equivalent. Consequently, it is not the intention to limit this corner flashing system to the particular embodiments disclosed. On the contrary, the intention is to cover all modifications and alternate constructions coming within the spirit and scope of the corner flashing system as generally expressed by the following claims, which particularly point out and distinctly claim the subject matter of the corner flashing system.