Flashing attachment apparatus

A flashing attachment apparatus and method includes an angle plate with a horizontal leg and a vertical leg wherein the horizontal leg includes a top and a back and wherein the vertical leg includes a front and a back. A bent plate is connected with the back of the vertical leg and a self adhering membrane is connected between the bent plate and the vertical leg to the back of the vertical leg wherein the self adhering membrane includes a removable cover shielding adhesive on the self adhering membrane.

FIELD OF THE INVENTION

This invention relates to a flashing attachment apparatus and method. In particular, in accordance with one embodiment, the invention relates, to a flashing attachment apparatus including an angle plate with a horizontal leg and a vertical leg wherein the horizontal leg includes a top and a back and wherein the vertical leg includes a front and a back. A bent plate is connected with the back of the vertical leg and a self adhering membrane is connected between the bent plate and the vertical leg to the back of the vertical leg wherein the self adhering membrane includes a removable cover shielding adhesive on the self adhering membrane.

BACKGROUND OF THE INVENTION

A serious problem exists in attempts to prevent water penetration into structures. In fact, as long as there have been structures, there has been a search for water prevention devices of all types. By way of example only and not by limitation, thru-wall flashings are used in buildings to prevent water penetrating through the interior wall of a cavity wall system. In concrete masonry unit (CMU) construction these flashings are installed at door heads, window heads and sills, and at the base of cavity walls. Flashing is also installed at floor lines in multi-story buildings and in curtain wall and storefront glazing systems.

For many years flashing materials were made from semi-rigid metal sheets, such as copper, galvanized steel, and aluminum. The metal flashings were installed in the CMU joints as coursing reached the point where they had to be installed to assure proper anchorage. The distance varies, but is usually sixteen inches above a finished floor line and eight inches above a door or window head. This approach left the exposed metal flashing material hanging down the face of the CMU and subject to physical damage and weather for long periods of time. Also, the vertical or lapped joints between sections of flashing had to be soldered or joined in some permanent, waterproof method, typically by a metal worker. While this system helped solve the problem of holding the flashing in place, this system added significant cost because it involved expensive materials that could be damaged easily, were difficult to replace properly, and required two different laborers to complete the work.

As a variety of plastics and rubber-based materials became available for flashings they were quickly substituted for the metal flashings to reduce costs. But the installation sequence remained unchanged so the materials were still hanging down the face of the wall subjecting the membrane to weather and physical damage and resulting in the flashing falling away from or totally off the structure until the veneer was applied.

Recently a system of self-adhering membranes and metal termination bars has become a popular flashing system. The self-adhering membrane is the primary flashing material and has one surface consisting of an adhesive that is temporarily protected by a paper coating. The coating is removed to expose the adhesive when installation begins. This material is commonly referred to as a “peel and stick” membrane. The membrane thickness varies but is generally in the forty mil range. The membrane is usually manufactured in rolls so that specific widths can be cut from the roll as wall height and cavity width conditions require.

With the self-adhering membrane, the flashing can be installed just before the outer veneer is to be applied which eliminates weather damage and significantly reduces physical damage prevalent in prior art systems. At the time of installation, a portion of the paper coating is removed and the top edge of the membrane is secured to the CMU wall by pressing the adhesive surface against the CMU. This membrane is fully adhered to the face of the wall starting, typically, a minimum of sixteen inches above the floor line (eight inches at a window or door head) and extending downward at least eight inches (one block). The remaining membrane section is loosely hung and curved away from the inner wall where it is terminated on top of the outer veneer at the outside edge.

The membrane adhesive alone, however, is not considered an adequate or long-term solution for holding the membrane to the wall. The membrane is subject to peeling back from the top and falling away from the CMU. Thus, installation of a termination bar at the top edge of the membrane is still required to provide long-term attachment. The termination bar is commonly fabricated in eight to ten foot long pieces of stainless steel or aluminum of varying thicknesses. Screws, made of similar materials, are installed in predrilled holes spaced anywhere from two to twelve inches on center along the centerline of the termination bar. To secure the bar it is necessary to either drill holes into the CMU using the pre-drilled holes in the bar as a guide, or use a power actuated fastener shot into the CMU through the holes. Once the bar is installed, a continuous bead of sealant is often applied along the top edge and at the drilled holes. This is done to prevent water that may penetrate the wall cavity from collecting on top of the bar and at the holes and eventually working through the mortar joint to the interior.

While the current membrane and termination bar system reduces potential damage to the flashing and does an adequate job of holding the flashing in place, it does not significantly reduce the cost of labor. And there is no certainty that the screws or other fasteners, and the sealant have been properly or completely installed. Once the veneer is applied and the wall cavity is enclosed it is impossible to detect and repair the source of the leak or reattach the membrane without removing the veneer.

What is required is a flashing attachment apparatus and method that is inexpensive, easy to use and that creates no new entries for water while ensuring that the flashing is held in place. It, therefore, is an object of this invention to provide a flashing attachment apparatus and method that requires no drilling, that once installed is held in place without screws or additional securing devices, that creates a stable termination bar that provides an overlapping attachment with flashing, and that is inexpensive to manufacture and easy to install.

SUMMARY OF THE INVENTION

Accordingly, the flashing attachment apparatus of the present invention, according to one embodiment includes an angle plate with a horizontal leg and a vertical leg wherein the horizontal leg includes a top and a back and wherein the vertical leg includes a front and a back. A bent plate is connected with the back of the vertical leg and a self adhering membrane is connected between the bent plate and the vertical leg to the back of the vertical leg wherein the self adhering membrane includes a removable cover shielding adhesive on the self adhering membrane.

As used herein, terms are given their common meaning as known in the art. Thus, “angle plate” describes a device, preferably made of metal but which may be made of any suitable material such as plastic or any other material now known or hereafter developed. The “angle plate” as is described more fully herein, is formed, typically, from a single, flat piece of material that is bent between the edges along its length to form, typically, an “L” shaped device in which both legs are of about the same approximate width. When the length of the angle plate is held horizontally, the two legs form a horizontal leg and a vertical leg.

Further, as used herein, the term “membrane” includes material that is more flexible than the angle plate, for example, although the membrane may be composed of the same material but thinner in dimension. Preferably, the membrane is a flexible material such as a flexible plastic or rubber of some suitable and useful type.

Further, the term “self-adhering” is used commonly to describe a material that preferably includes adhesive on at least some part of the material and may be connected by the adhesive to another surface without need of adding adhesive material. The term also includes material that becomes self adhering due to the use of heat or chemicals, for example only and not by limitation.

In another aspect of the invention, the angle plate includes at least one slot completely through the horizontal leg from the top to the back of the horizontal leg. In one aspect, the bent plate is connected directly to the back of the vertical leg along a first portion of the bent plate and wherein along a second portion of the bent plate the bent plate is spaced apart from the back of the vertical leg. In a further aspect, the second portion creates a mortar space above the second portion, underneath the back of the horizontal leg and adjacent the back of the vertical leg, and a membrane space between the second portion and the back of the vertical leg.

In one aspect, the first portion includes a number of connection welds connecting the first portion to the vertical leg. In another aspect, the membrane is connected to the second portion by at least one serrated hole punched through the second portion and into the membrane. In a further aspect, the second portion includes a lower edge and the vertical leg includes a lower edge and the lower edges are approximately parallel to each other. In another aspect, the membrane extends below the lower edges. In yet another aspect, the membrane is a flexible, peel and stick membrane and includes a perforation in the removable cover such that the removable cover is detachable from the flexible membrane along the perforation and below the lower edges.

According to another embodiment of the invention, a flashing attachment apparatus includes an angle plate with a horizontal leg and a vertical leg wherein the horizontal leg includes a top and a back and wherein the vertical leg includes a front and a back and wherein the angle plate includes at least one slot completely through the horizontal leg from the top to the back of the horizontal leg. A bent plate is connected with the back of the vertical leg wherein the bent plate is connected directly to the back of the vertical leg along a first portion of the bent plate and wherein along a second portion of the bent plate the bent plate is spaced apart from the back of the vertical leg and wherein the second portion creates a mortar space above the second portion, underneath the back of the horizontal leg and adjacent the back of the vertical leg, and a membrane space between the second portion and the back of the vertical leg. A flexible, peel and stick membrane is connected between the bent plate and the vertical leg to the back of the vertical leg wherein the flexible, peel and stick membrane includes a removable cover shielding adhesive on the flexible, peel and stick membrane and wherein the membrane includes a perforation in the removable cover such that the removable cover is detachable from the flexible, peel and stick membrane along the perforation.

In another aspect of this invention, the first portion includes a number of connection welds connecting the first portion to the vertical leg. In one aspect, the membrane is connected to the second portion by at least one serrated hole punched through the second portion and into the membrane. In a further aspect, the second portion includes a lower edge and the vertical leg includes a lower edge and the lower edges are approximately parallel to each other. In one aspect, the flexible, peel and stick membrane extends below the lower edges.

According to another embodiment of the invention, a method for attaching flashing includes the steps of:

a. providing an angle plate with a horizontal leg and a vertical leg wherein the horizontal leg includes a top and a back and wherein the vertical leg includes a front and a back; a bent plate connected with the back of the vertical leg; and a self adhering membrane connected between the bent plate and the vertical leg to the back of the vertical leg wherein the self adhering membrane includes a removable cover shielding adhesive on the self adhering membrane; and

b. placing the horizontal leg on top of a structure with a top and an outer face wherein the outer face is covered with a flashing such that the self adhering membrane overlaps the flashing; and

c. connecting the self adhering membrane with the flashing.

In another aspect of this invention, the angle plate includes at least one slot completely through the horizontal leg from the top to the back of the horizontal leg such that mortar on the top of the structure passes through the at least one slot. In one aspect, the bent plate is connected directly to the back of the vertical leg along a first portion of the bent plate and wherein along a second portion of the bent plate the bent plate is spaced apart from the back of the vertical leg such that the second portion creates a mortar space above the second portion, underneath the back of the horizontal leg and adjacent the back of the vertical leg, and a membrane space between the second portion and the back of the vertical leg.

In a further aspect, the second portion includes a lower edge and the vertical leg includes a lower edge and the lower edges are approximately parallel to each other and the self adhering membrane extends below the lower edges.

In another aspect, the membrane is a flexible, peel and stick membrane and includes a perforation in the removable cover such that the removable cover is detachable from the flexible membrane along the perforation and below the lower edges and further includes the steps of:

a. removing the removable cover along the perforation; and

b. connecting the adhesive on the flexible membrane with the flashing.

In another aspect, the method further includes the steps of

a. providing a number of angle plates; and

b. overlapping the angle plates such that the entire top of a structure is covered by angle plates in overlapping relation.

DETAILED DESCRIPTION OF THE INVENTION

The preferred embodiment of the present invention is illustrated by way of example inFIGS. 1-6. With specific reference toFIGS. 1 and 2, flashing attachment apparatus10, according to a preferred embodiment, includes an angle plate12. Angle plate12includes a horizontal leg14and a vertical leg16. Horizontal leg14includes an outer surface or top18and vertical leg16includes an outer surface or front20. Both horizontal leg16and vertical leg18include an inner surface or back22.

Again, angle plate12is preferably formed from a single piece of material, preferably metal such as for example only stainless steel or aluminum, bent along its length to form two parts, horizontal leg14and vertical leg16. Obviously, the angle plate12may be formed by welding or connecting by some other suitable means two separate legs. As illustrated, horizontal leg14is connected with vertical leg16nearly perpendicularly. Certainly, the angle of connection may be more than or less than ninety degrees according to the needs of a particular situation. Likewise, angle plate12may be reversed such that vertical leg16faces up from horizontal leg14and not down as illustrated. Further, angle plate12may be positioned vertically on a structure, such as lengthwise on a corner of a structure, and not horizontally, such that the legs extend to either side of the corner, for example only and not by way of limitation.

A bent plate24is connected to the back22of vertical leg16as illustrated. Preferably, bent plate24includes a first portion26and a second portion28. Preferably, first portion26is connected to the back22of vertical leg16by spot welds30or any other connection device now known or hereafter developed.

Second portion28of bent plate24is bent such that it is spaced apart from the back22of vertical leg16. This feature of the present invention is important in that it accomplishes several required elements of the invention. First, it creates a membrane space32into which membrane34is inserted and retained, as will be described more fully hereafter. Secondly, it creates a mortar space36above the second portion28. That is, mortar space36is created underneath the back22of horizontal leg14and adjacent the back22of the vertical leg16as illustrated. Mortar space36creates a space for mortar38to collect when flashing attachment apparatus10is installed as will be more fully described hereafter. Applicant has determined, however, that this mortar space36significantly and unexpectedly increases the strength of the connection of the flashing attachment apparatus10with a structure40, again as will be more fully described hereafter.

Additionally, preferably, angle plate12includes a slot15that passes completely through the top18to the back22of horizontal leg14. The provision of slot15allows mortar38to pass through the slot15and greatly enhances the ability of mortar to hold angle plate12in place as will be more fully described hereafter.

Membrane34is preferably a self-adhesive material as discussed above. Preferably, membrane34is a “peel and stick” membrane with an adhesive42on at least one side. Preferably, adhesive42is temporarily protected by a removable cover44. In a preferred embodiment removable cover44includes a knife cut or perforation46at a desired location to assist in the detachment of removable cover44from some or all of membrane34when desired.

According to a preferred embodiment, membrane34is held in place in membrane space32by connection with second portion28. Applicant has found that a suitable connection is obtained by punching a hole48through second portion28into membrane34after membrane34is located in membrane space32. The punched hole48creates splayed or serrated edges49that expand to grip membrane34securely in place without fear membrane34will drop out of membrane space32in use. Certainly, any other suitable device for connecting membrane34in membrane space32, such as glue or epoxy, for example only and not by way of limitation, that may be suitable for the purposes of the invention is included.

In a preferred embodiment, after connection of the first portion26to the back22of vertical leg16, the lower edge50of second portion28generally aligns with and is approximately parallel to the lower edge52of vertical leg16as illustrated. Preferably, membrane34extends some distance below the lower edges50and52such that a long section of overlapping membrane34below the lower edges50and52is provided.

Still referring toFIGS. 1 and 2, the installation of flashing attachment10is illustrated in a typical situation where the horizontal leg14of angle plate12is placed on the top54of a particular part of structure40. Top54includes a mortar joint56and mortar38. As illustrated, applicant's flashing attachment apparatus10is positioned such that horizontal leg14is completely covered by mortar38. This ensures that flashing attachment is securely connected with structure40without the need to drill holes, as in the prior art. Further, applicant has determined that the provision of through slot15enables mortar38to create a solid link from the top14to the back22of horizontal leg14to the structure40which has been found to greatly increase the stability of the connection, all again without need to drill or add screws.

Once horizontal leg14is in place, the membrane34is conformed to overlap the underlying flashing58on the outside60of flashing58. This creates a covering, overlap and effectively prevents the passage of moisture passed membrane34. Thereafter, removable cover44is removed from membrane34which exposes adhesive42. Preferably, perforation46provides an easy to use, predetermined place for removal such that the portion of the membrane34below the lower edge52of vertical leg16has exposed adhesive42. Certainly, removable cover44may be removed before horizontal leg14is placed in position as described above.

Once horizontal leg14is in proper position and the removable cover44is removed, final installation of the flashing attachment apparatus requires the connection of the adhesive42and thus membrane34with the flashing58. Connection simply requires pressing membrane34against flashing58so as to seal the two membranes together.

Referring now toFIG. 3, it is shown that a preferred embodiment of flashing attachment10includes connecting sections of angle plate12by creating an overlap62. The overlap62may be as much or as little as required by the particular situation and provides the advantage of enabling complete coverage of the top54of a structure40without need to cut or re-cut angle plates12. Once in position, flashing attachment apparatus10is held in position as described above by mortar38and by connection of membrane34to flashing58. Further membranes34include the same overlap62and in the overlap62one of the membranes34is adhered to the other membrane34which is in contact with flashing58. Adhesive42ensures that no moisture will penetrate the vertical seam created by the overlap62.

Referring now toFIGS. 4 and 5, it is illustrated how applicant's flashing attachment apparatus10is used to cover corners. As illustrated, in this instance, one angle plate12overlaps another angle plate12as described with reference toFIG. 3but in this instance the angle plates12are overlapped at an angle to each other. As illustrated, the two angle plates are overlapped at approximately ninety-degrees to each other. Obviously, any angle is easily accommodated by the invention. It should be understood that the flashing58covers the corner and membranes34create a vertical line64at the corner where the two angle plates overlap. Because membranes34are sealed by adhesive42to flashing58and because flashing58covers the corner underneath vertical line64a complete moisture barrier is created.FIG. 5shows a top view of a corner connection as just described. Certainly, it should be understood that membrane34may be conformed to extend beyond the end66of angle plate12so as to provide some membrane34to cover vertical line64if desired.

Referring now toFIG. 6it is illustrated how flashing attachment apparatus10may be easily modified to create an end dam68. The user uses metal shears to cut a portion of horizontal leg14away from vertical leg16. The cut portion is then moved to create the end dam68. The movement is a simple bending movement and requires no special tools to accomplish. Importantly, no damage is done to the other elements of the invention, the vertical leg16, bent plate24and/or membrane34. Thus, applicant has found that in situ modification of flashing attachment apparatus10is simple and easy to accomplish, requires no special tools and greatly increases the overall capabilities of the invention.

By way of further explanation, the thru-wall flashing58, a peel and stick membrane typically, that is adhered directly to the wall surface and is the primary waterproofing component for the structure40. Applicant's flashing attachment apparatus and method10, among other things, replaces the termination bar component currently used in wall flashing systems. Applicant's invention provides the security required at the top of the thru-wall flashing58and additional protection from water penetration because there is no continuous joint at the top of the flashing58as there is with the termination bar system. Because the invention is set flush against the wall at the mortar joint56and the edge is a smooth, curved transition, no water will be able to accumulate and penetrate the structure40. The vertical joints64at the overlaps62and in the internal corners do not need to be sealed with such precision because the small amount of water that may enter the joints will be below a mortar joint56and thus protected by underlying flashing58.

The applicant's flashing attachment apparatus and method10is usable with any of the flexible, self-adhering membranes presently manufactured and eliminates the screw-applied termination bar and sealant as required currently. The flashing attachment apparatus and method10consists of three major components: an angle plate12, a self-adhering flexible membrane34with a removable paper backing or cover44, and a bent plate24.

Angle Plate12Description: The angle plate12is preferably a one and one-half inch by one and one-half inch twenty-gauge galvanized steel metal angle that is eight feet long (stainless steel may be substituted) with slots30in one face, horizontal leg14. The angle plate12is oriented with the slotted face horizontal and set into a standard mortar joint56as described above. The top surface of the horizontal leg14is pierced with slots15that, according to a preferred embodiment, are one-quarter inch wide by one and one-quarter inch long spaced at two inches on center. A one-eighth inch radius may be applied at the corners depending upon the manufacturing tool used to make the slots15. The edge of the first slot15is preferably located one inch from the end66. The slots15allow for the angle plate14to be securely embedded in the mortar joint56as described above. (SeeFIGS. 1 and 2)

Membrane34Description: The flexible membrane34is a self-adhering material commonly referred to as a “peel and stick” membrane typically used for flashing. The membrane34is preferably eight feet long, to match the length of the angle plate12, and is referred to as a “peel and stick” membrane typically used for flashing. The eight foot long membrane34is sandwiched between the angle plate12and the bent plate24and preferably extends a minimum of two inches below the lower edges50and52of the angle plate12. A knife cut or perforation46, preferably along the lower edges50and52of the bent plate12, is provided in one embodiment in the paper backing, removable cover44, only so that the paper can be removed easily at a later time. All of the protective paper coating that is provided by the membrane manufacturer remains in place.

The top one-half inch of the membrane34is secured, in a preferred embodiment, to the lower section of the bent plate24by conical, serrated, holes48punched at two inches on center with the first punch one-half inch from the end66of the angle plate12. The cone and serrations, edges49, of holes48prevent the membrane34from sliding off of or becoming detached from the bent plate24. Again preferably, the membrane34is extended from the bottom, lower edge52of the vertical leg16of the angle plate12by a minimum of two inches to allow sufficient surface area to secure the membrane34to the final section of thru-wall flashing58. (SeeFIGS. 1,2,4and6)

Bent Plate24Description: The bent plate24preferably is a one and one-eighth inch by twenty gauge plate, also eight feet long, made of the same material as the angle plate12, bent slightly along the center axis to the thickness of the membrane material34. (SeeFIGS. 1,2,4and6) The bent plate24with the membrane24attached is then secured to the back side22of the vertical leg16of the angle plate12with spot welds30starting at one-half inch from the end66and spaced at two inches on center from that point. The bottom edge, lower edge50of the bent plate24is preferably located flush with the bottom edge, lower edge52, of the vertical leg16of the angle plate12. The second portion28of bent plate24thus creates a mortar space36of approximately one-quarter of an inch between the top of the bent plate24and the underside, back22, of the horizontal leg14of the angle plate12as described above. The mortar space36allows for excess mortar38in the mortar joint56to accumulate behind the angle plate12greatly increasing the stability of the flashing attachment apparatus10. (SeeFIGS. 1 and 2)

In use, again, the flashing attachment apparatus10is laid by the mason at the outside face of the CMU in the normal block mortar joint, then pushed against the outside face60of the masonry structure40, for example only, and left exposed until the veneer is installed. At that time, membrane34is lifted up and the upper edge of the final thru-wall flashing58material (a compatible “peel and stick” membrane) is stripped of its protective paper backing and adhered to the masonry wall if not already attached, as is current practice. The exposed two inches of the paper backing, the removable cover44, of the membrane34is then removed and the adhesive face is pushed flush against the outside face of the final thru-wall flashing membrane58continuously along the wall. The resulting horizontal joint65(seeFIGS. 13, and4) in the two membranes overlaps in the direction of potential water flows so no additional sealant or soldering or other attachment is required at the horizontal joint. (SeeFIGS. 1,2, and3)

Further, the horizontal joints65that occur along the wall are overlapped by a minimum of three-quarters of an inch with the individual exposed membranes,34and58, adhered to each other. Any water that might migrate horizontally through the open end of the overlapping devices to the end of the one that is on the bottom will be minor. The protective paper can remain in place until the final thru-wall flashing58is installed. The overlapping section of membrane34can be adhered to the adjacent device at that time.

Forming External Corners: External and internal corners of any angle can be formed from the basic flashing attachment apparatus10. The horizontal legs14of two devices are simply overlapped at the corner. The horizontal joint at the top of the external corner devices will be buried in the mortar joint56. The vertical joint64of the external corner devices is at the end of a device similar to a horizontal joint65lap. The final thru-wall flashing58is wrapped slightly around the corner to avoid creating an open vertical joint64. Importantly, the protective paper, removable cover44, on the apparatus must remain in place until the final thru-wall flashing58is installed.

Forming Internal Corners: For an internal corner the ends66of a pair of flashing attachment apparatus10are terminated in the corner. Overlapping is not required. The void between the ends66of the horizontal legs14of both devices will be filled with mortar38. The final thru-wall flashing58is wrapped slightly around the corner to avoid creating an open vertical joint64. Again, for best results, the protective paper, removable cover44, on the apparatus10must remain in place until the final thru-wall flashing58is installed.

Some trim of the top horizontal leg14may be necessary if the angle of the wall is greater than ninety degrees, but typical cavity dimensions should permit the flashing attachment apparatus10to be installed without trimming it. Still further, curved sections may be developed by making a series of straight or vee-shaped cuts in the horizontal leg14at intervals that will allow the bend to develop.

Among many advantages over the prior art, applicant has determined that the only tool required to completely install the flashing attachment apparatus10of the present invention is a standard sheet metal cutter, and all work can be performed by masons as the wall is constructed. The invention, further, may also be used in cavity wall systems where deep concrete beams are used to span openings. Still further, scrap pieces of the device can be salvaged for use in other projects.

As described herein, it should be understood that angle plate12and bent plate24could be constructed from a single piece of material. That is, starting with the lower edge52of angle plate12, a single piece of material would extend upward to form the vertical leg16then horizontally to form the horizontal leg14. From there it would fold under itself and run horizontally under horizontal leg14and then extend down to form bent plate24and end at lower edge50. While two separate pieces, angle plate12and bent plate24, may be desired, again, a single piece of material formed to create the required structure, including the membrane space32, would suffice.

The description of the present embodiments of the invention has been presented for purposes of illustration, but is not intended to be exhaustive or to limit the invention to the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. As such, while the present invention has been disclosed in connection with an embodiment thereof, it should be understood that other embodiments may fall within the spirit and scope of the invention as defined by the following claims.