SYSTEMS AND METHODS FOR PIPE BOOTS
20260035927 ยท 2026-02-05
Assignee
Inventors
- Richard Fieldhouse (Gresham, OR, US)
- David Starr (Burton, WA, US)
- Fernando Gamez-Rivas (Cornith, TX, US)
Cpc classification
E04D13/1476
FIXED CONSTRUCTIONS
International classification
Abstract
In some embodiments, a pipe boot flange may include one or more fitting portions. The pipe boot flange may include one diaphragm gate. In some embodiments, a method may include injecting a flow of a resin through a runner and into a diaphragm gate of a mold cavity for a pipe boot flange. The method may include directing the resin through the mold cavity. The method may include forming the pipe boot flange. The method may include removing the formed pipe boot flange from the mold cavity.
Claims
1. A pipe boot flange comprising: one or more fitting portions; and one diaphragm gate.
2. The pipe boot flange of claim 1, wherein the one or more fitting portions comprise a plurality of concentric fitting portions of different circumference, wherein adjacent fitting portions are separated by a boundary.
3. The pipe boot flange of claim 2, wherein each of the boundaries are at a boundary angle of about 90 degrees relative to a vertical axis.
4. The pipe boot flange of claim 1, wherein a wall of each of the one or more fitting portions are each disposed at a wall angle relative to a vertical axis.
5. The pipe boot flange of claim 4, wherein the wall angle is about 1 to 3 degrees relative to the vertical axis.
6. The pipe boot flange of claim 1, wherein the pipe boot flange is formed using an injection molding process.
7. The pipe boot flange of claim 6, wherein the pipe boot flange is made of a thermoplastic elastomer material.
8. The pipe boot flange of claim 6, wherein the pipe boot flange is formed as a unitary molded body without vertical weld lines formed therein.
9. The pipe boot flange of claim 1, wherein each of the one or more fitting portions define a tab having a first portion and a second portion.
10. The pipe boot flange of claim 9, wherein the tab of each of the one or more fitting portions protrudes from a wall of the respective fitting portion such that one of the first portion or the second portion is configured to flex and engage a pipe to form a seal against the pipe when the pipe boot flange is placed over the pipe.
11. The pipe boot flange of claim 1, further comprising an attachment member defining one or more fastener towers.
12. A pipe boot comprising: a flange extending between a first end and a second end, the flange defining a plurality of concentric fitting portions between the first end and the second end, each of the plurality of concentric fitting portions sized for a respective pipe size, the flange having one diaphragm gate connected to a first one of plurality of concentric fitting portions at the first end of the flange.
13. The pipe boot of claim 12, wherein adjacent concentric fitting portions are separated by a boundary that is at a boundary angle of about 90 degrees relative to a vertical axis.
14. The pipe boot of claim 12, wherein a wall of each of the plurality of concentric fitting portions are each disposed at a wall angle relative to a vertical axis.
15. The pipe boot of claim 14, wherein the wall angle is about 1 to 3 degrees relative to the vertical axis.
16. The pipe boot of claim 12, wherein the flange is formed using an injection molding process.
17. The pipe boot of claim 16, wherein the flange is made of a thermoplastic elastomer material.
18. The pipe boot claim 16, wherein the flange is formed as a unitary molded body without vertical weld lines formed therein.
19. The pipe boot of claim 12, wherein each of the plurality of concentric fitting portions define a tab having a first portion and a second portion.
20. The pipe boot of claim 19, wherein the tab of each of the plurality of concentric fitting portions protrudes from a wall of the respective fitting portion such that one of the first portion or the second portion is configured to flex and engage a pipe to form a seal against the pipe when the flange is placed over the pipe.
21. The pipe boot of claim 12, wherein the flange further comprises an attachment member defining one or more fastener towers each sized and configured to receive a fastener.
22. A method comprising: injecting a flow of a resin through a runner and into a diaphragm gate of a mold cavity for a pipe boot flange; directing the resin through the mold cavity; forming the pipe boot flange; and removing the formed pipe boot flange from the mold cavity.
23. The method of claim 22, wherein the resin is uniformly directed through the mold cavity circumferentially, whereby the formed pipe boot flange is formed as a unitary molded body without vertical weld lines formed therein.
24. The method of claim 22, further comprising removing the diaphragm gate from the formed pipe boot flange.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The features and advantages of the present disclosure will be more fully disclosed in, or rendered obvious by, the following detailed descriptions of example embodiments. The detailed descriptions of the example embodiments are to be considered together with the accompanying drawings wherein like numbers refer to like parts and further wherein:
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[0040] While the present disclosure is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. It should be understood, however, that the present disclosure is not intended to be limited to the particular forms disclosed. Rather, the present disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the disclosure as defined by the appended claims.
DETAILED DESCRIPTION
[0041] This description of the exemplary embodiments is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. It should be understood, however, that the present disclosure is not intended to be limited to the particular forms disclosed and that the drawings are not necessarily shown to scale. Rather, the present disclosure covers all modifications, equivalents, and alternatives that fall within the spirit and scope of these exemplary embodiments.
[0042] As used herein, the singular forms a, an, and the include plural references unless the context clearly dictates otherwise. Thus, for example, reference to a component includes aspects having two or more such components, unless the context clearly indicates otherwise. Relative terms such as lower, upper, horizontal, vertical, above, below, up, down, top, and bottom as well as derivatives thereof (e.g., horizontally, downwardly, upwardly, etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description and do not require that the apparatus be constructed or operated in a particular orientation. Terms concerning attachments, coupling and the like, such as connected and interconnected refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. The terms couple, coupled, operatively coupled, operatively connected, and the like should be broadly understood to refer to connecting devices or components together either mechanically, or otherwise, such that the connection allows the pertinent devices or components to operate with each other as intended by virtue of that relationship. As used herein, the term substantially or generally denotes elements having a recited relationship (e.g., parallel, perpendicular, aligned, circular, etc.) within acceptable manufacturing tolerances.
[0043] Ranges can be expressed herein as from about one particular value, and/or to about another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent about, it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.
[0044] The present disclosure pertains to building products manufactured in an injection molding process. More specifically, the present disclosure is related to building products, such as (i) flashing, including ventilation flashings and pipe boot flashings, (ii) boots, including pipe boots, rain boots, and rain collars, and (iii) collars, including repair collars and repair boots.
[0045] Some pipe boots are manufactured using a multi-gate injection molding process.
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[0047] Thus, during manufacturing resin may flow through the injection molding machine through the runner 120 and into the gate 118 where it is dispersed uniformly throughout the flange 112 mold, as will be discussed in more detail below. The flange 112 may be formed in any suitable shape, such as a generally circular shape, a generally square shape, a generally rectangular shape, a generally triangular shape, or other suitable polygonal shape.
[0048] In various embodiments, the pipe boot flange 112 may be manufactured from an automotive grade thermoplastic elastomer material, which may provide a better resistivity against ultraviolet (UV) light and moisture enhancing the quality of the flange 112. In some embodiments, the material may be the AURORA FLEXTM 8068N thermoplastic elastomer (TPE) material from Aurora Plastics, LLC of Streetsboro, Ohio. These TPE materials may have many of the same properties as vulcanized rubber, but can be molded and extruded using thermoplastic process equipment. Thermoplastic processing may provide advantages over vulcanized, thermoset rubbers which are processed using a slower and more costly curing process. These TPE materials can be formulated to desired plasticity, color, UV resistance, durometer requirements, chemical resistance and the need to accommodate certain temperatures. TPE options may be available as low as 10A* and up to 50D durometer hardness.
[0049] After a 6000-hour QUV/Weathering test was performed on the material (ASTM D4329 (Standard Practice for Fluorescent Ultraviolet (UV) Lamp Apparatus Exposure of Plastics) Cycle C (polymer building products)), little to no change in the material color was found, which indicates low damage to the material after exposure to these conditions. For reference, 1000 hours of weathering conditions equals a little over a year, so after 6000 hours it can be concluded that pipe boot 100 made of the material should exhibit little to no damage from 6 to 7 years. It was also determined that the color shift was acceptable for most consumer and industrial market applications with no degradation or surface blooming observed.
[0050] The base 116 may define one or more dimples 121a-g sized and configured to receive a fastener (e.g., nail, screw, bolt, etc.) such that the base 116 can be coupled to the roof 11 or other surface. For example, fasteners may be used to couple the base 116 to a surface by inserting the fasteners through the dimples 121a-g by puncturing the base 116 material at the top end of the dimples 121a-g, inserting the fasteners through the dimples 121a-g, and engaging the coupling surface, such as the roof 11. The base 116 may also define one or more tags 122 which may be used to display information (e.g., product information such as logos, name, dimensions, etc.). In some embodiments, the base 116 may be made of a metal, a metal alloy, a plastic (e.g., polypropylene), or some other suitable material.
[0051] The base 116 may be formed in any suitable shape, such as a generally circular shape, a generally square shape, a generally rectangular shape, a generally triangular shape, or other suitable polygonal shape. In some embodiments, the base 116 is generally the same shape as the flange 112. In other embodiments, the base 116 is a different shape from the flange 112. For example,
[0052] In some embodiments, the flange 112 may be crimped to the base 116 or other suitable surface with a crimping tool. In other embodiments, the flange 112 may be coupled to the base 116 using an overmolding manufacturing process.
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[0054] The fitting portions 132a-d may be formed in any suitable shape, such as a generally circular shape, a generally square shape, a generally rectangular shape, a generally triangular shape, or other suitable polygonal shape. In some embodiments, the fitting portions 132a-d may be different shapes. In some embodiments, the fitting portions 132a-d may be generally the same shape as the overall flange 112. For example, the flange 112 and the fitting portions 132a-d may be a generally circular shape as best seen in
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[0056] In one example, the diaphragm gate 118 may be removed from the first end 123 of the flange 112 and the flange 112 may be placed over a pipe 14 having a first size. If the void 137 is not large enough to fit the pipe 14, a user may then remove one or more of the fitting portions 132a-d by cutting and/or ripping the boundary 135a-c between the fitting portions 132a-d. For example, a user may cut along boundary 135a and remove fitting portion 132a such that the flange 112 can be placed over a pipe 14.
[0057] Each of the fitting portions 132a-d define a tab 139a-d. Each of the tabs 139a-d have a first portion 141a-d and a second portion 144a-d configured to engage the pipe 14 such that the flange 112 is securely fit over the pipe to prevent the flange 112 from moving and also to prevent water, debris, etc. from entering the void 137 and potentially leaking through the roof 11. In some embodiments, the fitting portions 132a-d have a wall angle that may be between about 1 to 3 degrees off the vertical (i.e., the Y-axis illustrated in
[0058] Referring back to
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[0066] The second pipe boot flange 300 may include an attachment member 305 coupled to the second end 126 of the flange 300. The attachment member 305 may define one or more fastener towers 309a-d. The fastener towers 309a-d may be sized and configured to receive a fastener (e.g., screw, nail, clip, bolt, etc.) to couple the flange 300 to a surface, such as the roof 11 illustrated in
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[0068] In some embodiments, the resin may be uniformly directed through the mold cavity 202a-b circumferentially. In some embodiments, the formed pipe boot flange 112, 300 may be formed as a unitary molded body without vertical weld lines 20 formed therein. In some embodiments, the method 400 may include removing the diaphragm gate 118 from the formed pipe boot flange 112, 300.
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[0070] In some embodiments, the method 500 may include securing a base 116 to a roof 11 with one or more fasteners. In some embodiments, the method 500 may include coupling the pipe boot flange 112, 300 to the base 116 with one or more fasteners, a crimping tool, or an overmolding manufacturing process.
[0071] It may be emphasized that the above-described embodiments, particularly any preferred embodiments, are merely possible examples of implementations, set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiments of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure.
[0072] While this specification contains many specifics, these should not be construed as limitations on the scope of any disclosures, but rather as descriptions of features that may be specific to a particular embodiment. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.
[0073] Similarly, while operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments.
[0074] Although the disclosure has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be construed broadly, to include other variants and embodiments of the disclosure, which may be made by those skilled in the art without departing from the scope and range of equivalents of the disclosure.