Abstract:
A structure and method for making a structure for use in building construction is provided. The structure is defined by a body having a top surface, a bottom surface, and side surfaces. A flashing liner is integrally formed with the body, and the flashing liner is defined at one or more of the side surfaces of the body. The body is capable of being attached to a building structure, and the flashing liner provides a weather interface with the building structure.

Description:
This Patent Application claims priority from U.S. Provisional Patent Application No. 60/523,377, filed on Nov. 18, 2003, and entitled “Building Protection Structures and Methods for Making and Using the Protection Structures.” The contents of this provisional application are hereby incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates generally to form molded structures, and more particularly, to the manufacturer, installation and use of molded building component structures. 
     2. Description of the Related Art 
     In current construction practice, there are two known and common methods of building outdoor decks and balconies, to be used as part of building structure. The first is the classic redwood deck, which allows rain water to leak down between gaps in the planks. The second is the moisture resistant tile or liquid plastic coating deck. 
     Most people are familiar with redwood decks. Floor joists are attached to the house either cantilevered from the second floor, or built on beams and posts for a larger deck. The 2×6 (inch) dimensional redwood boards are nailed down flat perpendicular to the joists with a ¼ inch gap between the planks. This has been a very popular and attractive decking system. 
     One downside to this system is that redwood cracks and ages, and redwood is becoming more scarce and expensive. Recently, firms like Trex™ have addressed these problems by extruding synthetic decking planks, that are similar in shape and size to the redwood 2×6 planks. They can be sawed and drilled almost as easily as wood. By mixing plastic and sawdust these products are longer lasting than redwood, wear and look better than redwood over the years and claim to be termite and mold resistant. 
     The problem that both redwood and synthetic wood decks have is that they are not rain-proof. When it rains, the water drops down between the gaps of the boards, hitting the ground below and wetting the joists and beams. Over time this rots the structural wood, eventually requiring rebuilding of the deck, or worse, complete structural collapse, killing in many cases those on the deck at the time. 
     The other drawback is that no habitable space can be built below. A watertight decking system is required for this application. There has been a long history of watertight decks and balconies built over the years. The most common way is to build a slightly sloping hot mopped deck using modified bitumen and galvanized metal flashings, much the same way a flat roof is done by roofing contractors. The difference is that a walking deck must be built much stronger than a roof, and must have a hard, slip resistant surface over the asphalt coating. Typically this is done like a tile shower pan. Over the hot mop, ¾′ of grout is placed, properly sloped for drainage, then tile or stone or pavers are set, then grouted, and finally weather sealed. Finally flashing must be installed and checked to avoid leaks into the house during rain storms. 
     The hot mopped and tiled exterior rain resistant deck is a very expensive and complex endeavor, involving 4 or 5 building trades, spending weeks on each deck. And worse, the deck is the most vulnerable part of the house to the freeze thaw cycle, the expansion and contraction between hot and cold weather. During hot weather the deck may expand cracking the asphalt coating underneath which may have become brittle over time. In the cold weather the tiles may pull away from the house, allowing water infiltration. Then when it rains, water may seep below the tile and migrate to some other location where the asphalt is cracked, causing leaks down into the sheet rock ceiling below. 
     When the homeowner calls out the contractor it generally happens that the real point of leakage is hidden from view from the deck above. Many times the only fix is to tear up the expensive tile and hot mop and do it all again. 
     In part to address this problem of the invisible leak, as well as the high cost of the installation of rain-proof decks, many liquid epoxy and plastic walkable coatings have been developed over the past 20 years. Firms like Dex-O-Tex sell liquid coatings installed by factory-approved installers, in several coats and with special flashings and fiberglass reinforcing. A sand finish is tossed onto the final coat for skid resistance, and different colors are offered. Durability depends on the sloping and structural strength of the exterior grade plywood on which the liquid coats are spread. A 5-coat job may take a week to complete and is still a relatively expensive and risky endeavor. These have also been leaks and liability problems in housing projects. The deck must be inspected regularly and repaired promptly to protect the habitable areas below. 
     Therefore, what is need is a durable and reliable structure that can be used as a deck or building component, without introducing the aforementioned problems. 
     SUMMARY OF THE INVENTION 
     Broadly speaking, the present invention fills these needs by providing a structure that is form-molded, in one piece. The form-molded structure can take on any number of forms, as will be described below. One particular form is the form of a deck of a building. The resulting deck is defined from plastic, and when formed, defines a plastic deck shell with integral flashing. The deck shell can be installed over or up against structural framing of a building to provide moisture protection and enable human traffic, if the form is a deck. It should be appreciated that the present invention can be implemented in numerous ways, including as a method, a structure, a system, or an article of manufacturer. Several inventive embodiments of the present invention are described below. 
     In accordance with a first aspect of the present invention, a structure for use in building construction is provided. The structure is defined by a body having a top surface, a bottom surface, and side surfaces. A flashing liner is integrally formed with the body, and the flashing liner is defined at one or more of the side surfaces of the body. The body is capable of being attached to a building structure, and the flashing liner provides a weather interface with the building structure. 
     In accordance with a second aspect of the present invention, a deck structure to be attached to a building is provided. The deck structure has a grooved top surface, a bottom surface, and side surfaces, and the deck structure is defined from a plastic mold. A flashing liner is integrally formed from the plastic mold along with the deck structure, and the flashing liner and the deck structure define a unitary structure without connecting seams. The flashing liner is defined at one or more of the side surfaces of the deck structure. The body is capable of being attached to the building, and the flashing liner provides a weather interface with the building and the top surface providing a supporting interface for human support and traverse when the deck structure is attached to the building. 
     In accordance with a third aspect of the present invention, a deck structure to be attached to a building is provided. The deck structure has a rough top surface, a bottom surface, and side surfaces, and the deck structure is defined from a plastic mold. A flashing liner is integrally formed from the plastic mold along with the deck structure, and the flashing liner and the deck structure define a unitary structure without connecting seams. The flashing liner is defined at one or more of the side surfaces of the deck structure, and the flashing liner is configured as an interface with the building at one of a wall or a door way of the building. The flashing liner establishing a weather tight interface between the wall or the door way of the building, and the rough top surface having grooves defined by the plastic mold. The grooves extend substantially perpendicularly away from the building, such that the grooves drive water away from the building. 
     In accordance with a fourth aspect of the present invention, a method for making building structure is provided. The method includes defining a mold. The mold having surfaces for defining a body with a top surface, a bottom, and side surfaces, and the mold further including surfaces for defining flashing liners to be coupled to at least one of the side surfaces of the body. The method then includes filling the mold with a plastic to define a deck structure with integral flashing. The deck structure defined for supporting a human when the deck structure is attached to a building. 
     In one embodiment, the deck is formed in the factory to the size and shape desired by the customer, and includes integral flashing, water run-off channels and a non-skid walking surface. The deck of the present invention provides a cost effective, easy and fail-safe method of installing moisture resistant decking surfaces in residential or commercial construction projects. In one embodiment, the process of making the one piece deck utilizes vacuum-formed technology, which allows the deck to be made as a seamless unitary and integral structure. The integral structure, in the decking application, will include integral flashing. The deck therefore installs easily and quickly to provide rain tight protection to structural wood and habitable space below and around the deck. 
     By using tough and flexible polyethylene plastic, ribbed for strength and surfaced for a skid resistance, a strong and nearly indestructible walking surface is provided. By including integral flashing down over the sides of the deck and up under the building paper and stucco, leaks are eliminated. By design, potential weak spots are strengthened, and expansion and/or contraction is anticipated and allowed. The deck surface can move back and forth through temperature and humidity swings, or earthquakes. 
     As a benefit, due to the single piece design, installation can be done in as little as one half hour per deck. This is compared to over a week for all other rain proof systems. In some markets, total material and labor cost can be as low as 10% of what is currently paid for prior art, less desirable techniques. Further, once a carpenter builds the structural deck and covers the joists with plywood, he can immediately cover the deck with a white neoprene foam, staple building paper to the lower walls, nail on the 1×2 cleats and then screw on the Deck with stainless steel screws and washers, and then tap in the plastic screw cover plugs. Compare to hot mop decks, after the carpenter frames the deck, the following sub-contractors are required: a. roofing/hot mop sub; b. sheet metal flashing sub; c. tile setter; d. sealer/painter; and e. more flashing. Liquid plastic decking subs handle most flashing themselves but the sheet metal sub usually is involved. By design, stops and guides allow the carpenter to install the deck in only one way—the right way. Should the carpenter forget a piece of building paper, he can unscrew a section until he can slip the paper in, then re-screw. 
     Other aspects and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, and like reference numerals designate like structural elements. 
         FIG. 1  is a perspective view of a cantilever deck, in accordance with one embodiment of the present invention. 
         FIG. 2  is an exploded view of the deck to be attached to a building, in accordance with one embodiment of the present invention. 
         FIGS. 3A-3I  show the deck attached to a building and integral flashing installed up against the building and detailed magnifications, in accordance with one embodiment of the present invention. 
         FIG. 4  illustrates a recessed deck, in accordance with one embodiment of the present invention. 
         FIG. 5  illustrates a recessed deck attached to a building, in accordance with one embodiment of the present invention. 
         FIGS. 6 and 7  illustrate a multi-panel deck, in accordance with one embodiment of the present invention. 
         FIGS. 8 and 9  illustrate an awning with integral flashing, in accordance with one embodiment of the present invention. 
         FIG. 10  illustrates a fireplace roof and integral flashing, in accordance with one embodiment of the present invention. 
         FIG. 11  illustrates a bay window roof with integral flashing, in accordance with one embodiment of the present invention. 
         FIG. 12  illustrates a bow window roof with integral flashing, in accordance with one embodiment of the present invention. 
         FIGS. 13-19  illustrate additional applications of a plastic molded structure for use in building construction, in accordance with one embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     An invention is described for plastic form molded structures, which can be used in the construction of buildings. The structures can take on any number of forms, and examples of such forms are provided below. Of particular interest, a deck can be defined from a single plastic piece with integral flashing. In one example, the deck is formed in a mold which is filed with liquid plastic, and the liquid plastic is cured or allowed to cool until a hard material results. The plastic can optionally include fibers to introduce strength, and colors can be added to provide different ready to use styles. It will be obvious, however, to one skilled in the art, that the present invention may be practiced without some or all of these specific details. In other instances, well known process operations have not been described in detail in order not to unnecessarily obscure the present invention. 
     A deck system is a one piece molded plastic unit. In one embodiment, the decking surface curves up the wall and becomes flashing. The flashing is thus integral with the deck body. At a sliding door or French doors, the flashings bend down under the door sill, preventing driving rains from soaking the carpet or wood framing. The plastic used is similar to that used in pickup truck bed liners, many of which have suffered 20 years of abuse (like daily loading and unloading of bricks) in the desert sun without cracking or denting. In one specific example, the plastic material will include fibers to introduce additional strength. Examples of the plastics, without limitation, can be selected from the group consisting of one or a combination of (a) polyethylene, (b) olefin (c) olefin fibers (d) polypropylene and polyethylene, (e) polystyrene, (f) poly (vinyl chloride), and (g) polytetrafluoroethylene. 
     In another alternative and optional embodiment, supporting framing may also be embedded in a mold so that the resulting molded plastic can have additional strength. 
     Slotted screw holes and the inherent flexibility of the plastic make it impervious to expansion, contraction and structural movement. Ample flashing wings are designed for horizontal rains. Radiant heat can be resisted by a light gray color of the plastic, the white painted underside and the white neoprene under-layment. Direct sunlight has no deterioration effect, chemicals or animal urine will not damage surface, and moist or salt air will not damage the plastic or the stainless steel screws. In sum, the resulting form molded deck or other structure, is capable of withstanding harsh outdoor weather elements, while maintaining its serviceability to the structure. 
       FIG. 1  is a perspective view of a cantilever deck, in accordance with one embodiment of the present invention. Made from a single piece of plastic, it is heat formed to the shape shown. The heat is used to melt the plastic used to define the deck, and the plastic is applied to a mold. The molding process can include, for example, a vacuum molded process, a form molded process, a pressure form molded process, or an injection molded process. In essence, the molding process can vary, so long as the mold can receive liquefied plastic, allow the plastic to flow into the appropriate shape, and then allow the plastic to cool until reaching a solid state. 
     In the illustrated example, the deck  20  has a slightly sloping flat surface, sloping about 2% from back to front. Of course, the slope is optional depending on the application. The flat areas at the left and right are the guard railing attachment areas. The drainage grooves  24  also slope back to front and also act as structural ribs spaced inches apart, giving the roughen walking surface  26  strength and the ability to span imperfections in the plywood structural wood surface below. The ribs prevent buckling and tie the entire unit together. 
     Sloping up from the back of the walking surface  26  is the back flashing  32  and to the right and left sides are the side flashings  36 . The flashings  32 / 36  facing forward have embedded grooves to define screw guide grooves  28 . The screw guide grooves  28  let the carpenter or installer know where to place the attachment screws  40 , as well as to help the screw tap into the plastic by starting it in the groove without slipping off the plastic. The screw will not be placed too close to the edge where it might break the plastic. The vertical cut guide grooves  30  in the back flashing  32  are placed to assist the installer in making the vertical cuts needed to install the patio doors and fold back that portion of the back flashing  32 . The grooves are placed at the rough opening widths of common patio doors. The grooves aids the use of a utility knife by providing a scored vertical line. The other horizontal grooves are the bending grooves  48  used when that portion of the back flashing  32  is bent back into the patio door opening. Reference should be made to the description of  FIG. 3  for more information. 
     In the front apron  39  and the side aprons  49 , are screw hole recesses  46  which have slotted expansion holes inside. After installing the stainless steel screws  40  and washers provided, screw cap plugs  42  are tapped into the recesses  46 . The caps keep water out and visually hide the screws. Drip ledges  44  are designed to keep rain water away from the structure below. Gutters, stucco or wood trim can be installed by the contractor in the space provided beneath the bottom flashing  38 . 
       FIG. 2  shows the one-piece cantilever deck  20  floating directly above where it will be installed onto a typical wood framed house. We are looking down onto the wood framed second floor of a house under construction from the front right. Directly below the deck is the wood framed cantilever deck. Smaller floor joists  56  cantilever towards us supported by the stud wall  70 ,  68 , below. The first floor studs  70  support the double top plates  68  above. The rim joist  58  of the second floor sits on the plates  68 . Note that the deck plywood  52  is 2′-4′ lower  72  than the second floor main level plywood  50 . 
     Perpendicular to the rim  58  and sitting on the top plates  68  are the large second floor joists  60 . Plywood  62  is nailed down on the joists  60  and the second floor wall is built. The sole plate  64  and the studs  66  are shown, as well as the opening  50  for the patio door. A cantilever deck is framed by extending the deck joists  56  out past the wall below and finished of with the deck rim joist  54 . These joists  56  slope down about 2% away from the wall. Plywood  52  is nailed to the top of the joists  56  and the rim  54 . Plywood sheathing and building paper will be placed on the studs later. 
       FIG. 3  shows the deck  20  installed on the wood framing. Building paper installed under the plastic deck is not shown for clarity. The front apron  39  and side aprons  49  are screwed using screw hole recesses  46  to the deck rim joist  54  and the deck joists  56 . The back flashing  32  and side flashings  36  are screwed to second floor studs  66 , sole plate  64  and rim joist  58 . In the patio door opening  50 , vertical cuts  76  are made in the back flashing  32  and the flashing is bent back  90  degrees along one of the bending grooves  48  and screwed down to the plywood  62 . 
     The deck is ready for more building paper, the patio door, lathe and plaster and stucco. After the stucco is painted a guard rail can be installed directly to the top of the plastic deck, or to the deck wood framing below. Nothing else needs to be done to the plastic deck—no paint, no sealer, no surfacing. The decking can take on any number of colors, and the colors are added to the plastic as an additive, to produce the desired color shading. 
     In the case where the rain proof deck is recessed back into the second floor, the recessed deck  78  takes the form shown. Looking at the deck from the front right, we see the drainage grooves  24 , which are also strengthening ribs, and the roughened walking surface  26 . Along the front apron  39  are the screw hole recesses  46  where the screws  40  and screw plugs  42  are installed. The back flashing  32  and side flashings  36  bend up from the walking surface. The entire deck is formed from one sheet of plastic, so it installs as one unit, and thus prevents leaks (as there are not seams). No hot mop or asphalt felt is required below the deck since it itself is rain tight. On the vertical flashings are bending grooves  48 , screw guide grooves  28  and vertical cut grooves  30 . This design allows doors to be installed anywhere on the left, right or back of the deck. Bottom flashing and drip  38  allows for a gutter or wood trim to be installed. 
     Looking at the recessed deck  78  again from the front right, we see it installed in typical wood framing. Note that the level of the deck drops 2′-4′ from the main second floor level  72 . This helps keep blowing rain out of the house. Like we saw in  FIG. 3 , the first floor studs  70  support top plates  68  which support rim joist  58  and floor joists  60 , which are taller than the deck joists (not shown). Plywood  62  covers the second floor and is under the deck. Sole plate  64 , studs  66  and the patio door opening  50  are shown. The back flashing  32  is cut  76  at each side of the patio door opening  50  and bent back  74  along the bending grooves  48 , and it is screwed  40  down to the plywood  62 . The flashing are screwed to studs  66 , plates  64  and rims  58 . The front apron  39  is screwed  40  to the rim  58 , finished with tapped in screw plug covers. 
       FIGS. 1 through 5  illustrated the deck in its one piece configuration. Some deck projects are so large that they cannot be produced in one piece due to the size of available sheet plastic, the size of delivery trucks or the ability of the crew to efficiently and safely handle the material. 
       FIG. 6  shows a three piece deck system that when assembled and snapped together creates the watertight deck shown in  FIG. 7 . In  FIG. 6  we see the roughened walking surface  26 , the structural rib drainage grooves  24 , and the side  36  and back flashing  32 .  FIG. 6  shows the three different pieces of the system: the left deck section  80 , center deck section  82  and right deck section  84 . Bottom flashing  38 , drip  44  and screw hole recess  46  are shown. Special overlap snap grooves  86  are shown facing the center section  82  on the left  80  and right section  84 . 
       FIG. 7  shows the three pieces assembled. The patio door opening  50  is shown with the cut section of the back flashing bent back  74  along a bending groove  48  and screwed  40  down Screws  40  are placed in the guide grooves  28  in the side  36  and back flashing  32 . Together, the three pieces can create a large deck that is completely water tight and three times bigger that the one piece deck. Of course, the size will depend on the application and the number of decks that are combined to form a large deck. In some commercial applications, the number of joined decks can be many, while in smaller residential projects a single deck will be sufficient. 
     The one piece awning is very similar to the one piece deck. The main surface slopes steeper like a roof, it has ribs  88  for strength and drainage grooves  24 , but it needs no wood structural support under it. It gains its strength from the triangular shape, the ribs and the screws  40  holding the side  36  and back flashings  32  to the structural wall. The flashing has structural ribs  88  which transfers loads to the screws  40 . It is intended to be installed over doors or windows for sun or rain protection. Since the flashings go under the stucco or siding, it is intended for new construction. But, it can also be used in remodels if appropriate adjustments are made. 
       FIG. 9  shows the optional built-in gutter  92 , which includes a hole to which a down spout can be attached.  FIG. 10  provides the detailed illustration of a direct vent gas fireplace roof. The use of a direct vent fireplace is becoming more popular as municipalities are required to reduce pollution, and thus restrict the use of traditional wood burning fireplaces. Direct vent gas-only fireplaces are increasing sold with the gas vent going sideways straight out the back of the firebox. The traditional boxes are projecting into the side setbacks, but the chimneys are eliminated. As something has to cover the 2′×5′ projection so architects have been specifying matching composition or tile roof, or galvanized metal flashing.  FIG. 10  shows the DV Fireplace Roof  100  installed over the box  96  with the side vent  98 . The back and side flashing  32   36  are attached with screws  40  though the screw grooves  28 . The top of the roof has structural ribs  88  and a drip  44  around the front and side aprons. 
     There are many smaller projections in residential construction like bay and bow windows that can use rain proof preformed roof and flashing systems. Installing the plastic molded bay and bow window roofs save a lot of time and money. No rafters or plywood are needed, and the structural ribs  88  keep the roof  104  from sagging. Screw  40  the flashing  32   36  and apron on, then snap the strip screw cover  106  into the screw channel  34 , and you are done. 
       FIG. 13  shows a parapet or free-standing stucco wall  102 . Too often no cap at all is placed on a stucco wall, only to discover years later that water has leaked down the wall through small crack in the stucco on the top of the wall. A metal cap is a better solution, but is not attractive if in a visible location such as a 36′ high stucco wall around a deck.  FIG. 13  shows one piece plastic decorative caps that interlock with adjacent caps, maintaining the water seal even at the joints  86 . Four caps are offered: the end cap  110 , straight run  112 , 90 degree corner  114 , and end cap terminating into a wall  116  integral with top  32  and side flashing  36 . In this embodiment, all pieces have drips  44 . 
       FIG. 14  is a one piece cap  118  for pilasters  102  such as pilasters that support entry gates. Screws  40  are installed into screw recesses  46  and covered with screw caps. Drip  44  accepts trim or stucco.  FIG. 15  shows a railing cap  120  designed to work with the recessed deck of  FIGS. 4 and 5 . 
       FIG. 16  shows a patio cover. Similar to the 3 piece deck, the 3 piece Patio Cover spans the full length from wall to beam without any rafters or plywood, just with the strength of the ribs. 
       FIGS. 17 ,  18  and  19  illustrate a retro-deck. The retro-deck is designed to go over any size or shape existing redwood deck. Although not 100% watertight, retro-deck is a big improvement in keeping rain out from under the deck, it prevents further rotting of the joists and looks new and clean. All sections  122  are the same and they snap together at the long edges  124 . The top edges at the house side of the deck are finished with head stop  130 , and the front edge is contained by base stop  132  which has an integral drip. Stops are screwed down  40  to the existing decking  126  and joists  127 . 
     Although the foregoing invention has been described in some detail for purposes of clarity of understanding, it will be apparent that certain changes and modifications may be practiced within the scope of the appended claims. Accordingly, the present embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalents of the appended claims. In the claims, elements and/or steps do not imply any particular order of operation, unless explicitly stated in the claims.