Abstract:
A device for forming flashing, and a method for forming the same for adaptation to freeze boards. The present invention is a device for forming flashing comprising a plate with at least one groove cut through the plate. The groove in the plate has at least one angle changing the groove from a first direction to a second direction on the plate. The grooves may be organized in V-shape or Z-shape arrangements. Flashing is inserted into the groove, bending the sheet metal to take on the form of a similar shape to the groove. The flashing is then pulled through the device, creating a uniform bend along the length.

Description:
BACKGROUND OF THE INVENTION 
     I. Field of the Invention 
     The present invention relates to flashing. More particularly, the present invention relates to flashing and a method for forming the same. Even more particularly, the present invention relates to a method for forming flashing for adaptation to freeze boards. 
     II. Description of the Prior Art 
     Flashing is a building material that is employed to prevent water seepage into a home or other building. Metallic flashing is sold in rolls or sheets of sheet metal thin enough to allow a builder to cut, form and modify sections of the flashing for different applications. Generally, a builder will take the roll of sheet metal and cut it to a desired length. At that point, the cut length is formed to a required angle by pounding the sheet metal against the corner of a board, or it is manually bent. 
     For example, a builder is generally required to manually bend flashing around each window casing. To accomplish this task, flashing is cut to the desired length, then formed by placing the flashing up against the casing, and hit with a hammer until the flashing takes the form of the casing or board. This process is often slow and labor intensive. Moreover, manually forming an angle, in even moderate lengths of flashing, seldom provides a uniform angle across the entire length. 
     Some companies, acknowledging the fact that forming flashing at a building or remodeling site is very time consuming, pre-form specialized flashing pieces at a factory or shop. Most pre-formed flashing is formed by a method of pressing or stamping. An apparatus and method for pre-forming flashing for roof vent pipes is illustrated by U.S. Pat. No. 3,895,467 (1975, C. Clement). The flashing is formed by pressing a role of sheet metal with a male die against a female die thereby taking on the shape of the dies. Additionally, each die set will make one flashing piece at a time. This device will work well in an assembly line set up, creating numerous pieces by feeding the roll through the set of dies. Unfortunately, stamping out pieces is only economical in a manufacturer setting. The apparatus is too big to move around from site to site the way a builder moves. 
     What is needed is a device that is inexpensive to manufacture, and small enough to be able to be moved from site to site. What is also needed is a device that is compact and that it is easily stored and set up. In addition, the device should be capable of forming angles along an entire roll of flashing, to an entire length of pre-cut flashing or to portions of a roll or cut piece of flashing. What is further needed is a device to form multiple angles in flashing, including a Z-shaped angle. Z-shape angles in flashing are commonly used on the top of window and door casings and comprise a flashing member having two substantially perpendicular angles, with each of the three segments of the flashing having a variable length as appropriate for the task. Additionally, the device should be able to accommodate forming a variety of angles at different lengths and sizes of flashing. 
     SUMMARY OF THE INVENTION 
     It is therefore an object of the present invention to provide an apparatus that is inexpensive to manufacture, and is capable of forming flashing to various angles. It is another object of the present invention to provide an apparatus that is capable forming flashing to various angles, and small enough to be able to be moved from site to site. It is still another object of the present invention to provide a device that is capable of forming flashing to various angles, and compact so that it is easily stored and set up. It is yet another object of the present invention to provide a device that is capable of forming flashing to various angles along an entire length of sheet metal or in small sections of flashing material. It is yet another object of the present invention to provide an apparatus that is capable of forming multiple angles in flashing at different lengths and sizes, including a Z-shaped angle. 
     The present invention achieves these and other objectives by providing a device that is capable of forming flashing to various angles, and is compact and easy to set up. The present invention is a device for forming flashing comprising a plate with at least one groove cut through it. Additionally, the groove in the plate has at least one angle changing the groove from a first direction to a second direction on the plate. (For example, if only one angle was to be used, the groove would be in the form of a V-shape.) The flashing is manually shaped at one end to an angle approximating the angle of the groove in the device and then inserted into the groove. The flashing is then pulled through the device creating a uniform bend along the length flashing passing through the device. 
     In one embodiment of the present invention the device also includes at least one adjustable guide slidably attached to the groove. The guide provides support to the flashing as it passes through the groove. This guide may be combination of a bolt and nut, a shaft with latches to fix it in a given position, a clamp, or any other device known in the art that would provide an adjustable guide for a groove. 
     The device may also include, as shown in one embodiment, a measuring means in-line with the groove. Some examples of a measuring means may include a scale, measuring tape, tick marks (indented or raised), or any other means known in the art for measuring a linear distance along a groove. The measuring device may be integrated into the plate or attached to the plate by some other means. 
     Another embodiment of the present invention includes at least one groove wherein the angle forms a Z-shape. Z-shaped angles in flashing are commonly used by builders. The angle may also be sized to form the flashing to an applied window casing. Additionally, the angle may be sized to form the flashing to an applied door casing. Furthermore, the angle may be sized to substantially fit a three-quarter inch window and freeze board flashing, a one-inch freeze board flashing, or other size freeze board flashing. 
     Another embodiment of the present invention further comprises a means for supporting shaping plate. This is achieved by attaching the shaping plate to rigid structure such as a building&#39;s frame structure. The frame structure gives the device support to prevent movement while pulling the flashing though a groove in the shaping plate. Examples of a means for attaching may include at least one clamp, webbing, string, rope, blocks, adhesive, or any other means for attaching known by one skilled in the art. The device may also include at least one aperture, which preferably would be placed around the perimeter of the shaping plate. The aperture would further expand the means for attaching to include nails, screws, bolts, pegs, anchors, or any other device that could be used to attach a plate to a support structure through an aperture. 
     The device for forming flashing may also include varying thickness in the groove. The groove may vary between approximately ⅛ inch thick to approximately {fraction (1/16)} inch thick. The varying thickness allows the flashing to bend in areas without rippling (i.e., around corners). Transitions between the varying thickness may be gradual or abrupt. The groove may also be a constant thickness. A groove with a constant thickness may be approximately ⅛ inch thick. These dimensions may be adjusted to accommodate flashing of various thickness. 
     Other embodiments may include an angle that is adjustable to preset degrees. The adjustable angles allow available space on the plate to be conserved. The angle may be adjustable for acute, substantially right and obtuse angles. The adjustment could be set by a variety of ways. For example, block inserts may be added to a portion of the groove, which is shaped to the desired bend. Another example of an adjustable angle may include a pinned guide that assists the flashing in bending only at a certain preset angle. 
     The present invention also includes a method of forming flashing comprising the steps of (1) obtaining a plate having at least one groove having at least one angle, and a length of flashing; (2) securing the plate; (3) threading the first end of the flashing into the groove by bending the first end to fit the groove, and placing the first end at least partially through the groove; and (4) pulling the first end through the groove and away from the plate, until the desired length of flashing has been formed. After the desired length of flashing has been formed, the flashing would be cut just before or after the plate. Thus, the flashing is bent along the entire length of the piece. The step of cutting the length of flashing after a formed portion has been created to release the length of flashing from the plate is a further step which may be further included to the method of forming flashing. The flashing may also be cut before inserted into the device so that the bend is formed on a precut length. 
     The step of securing the plate could be further defined as fixedly attaching the plate to a stationary structure. However, other means for securing the plate may be achieved. For example, the plate may be attached to a temporary support, persons holding the plate or some other means for supporting the plate known to one skilled in the art. 
     Another embodiment may include a guide for assisting the placement of the flashing in the groove. Additionally, the method would further comprise the step of placing a guide slidably attached to said groove against said length of flashing. This guide allows the bend in the flashing to be an even distance from one edge of the sheet metal. 
     Another embodiment of the present invention includes a step of adjusting an angle on the groove to acquire a desired shape of the flashing. For example, an angle may be adjusted by inserting preshaped blocks in the device to obtain a desired angle, moving a guide to assist the flashing through a certain angle, or adjusting the angle by some other means known to one skilled in the art. 
    
    
     Further objects and advantages of this invention will be more clearly apparent during the course of the following description, references being had to the accompanying drawings which illustrate a preferred form of the device of the invention and wherein like characters of reference designate like parts throughout the drawings. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective front view of a device for forming flashing that is constructed in accordance with the present invention. 
     FIG. 2 is a front view of another embodiment of a device for forming flashing that is constructed in accordance with the present invention. 
     FIG. 3 is a front view of another embodiment of a device for forming flashing that is constructed in accordance with the present invention. 
     FIG. 4 is a sectional view of the device in FIG.  3 . 
     FIG. 5 is a front view of another embodiment of a device for forming flashing that is constructed in accordance with the present invention. 
     FIG. 6 is a front view of another embodiment of a device for forming flashing that is constructed in accordance with the present invention. 
     FIG. 7 is a front view of the device in FIG. 6 illustrating an alternative setting for adjusting an angle. 
     FIG. 8 is a perspective front view of another embodiment of a device for forming flashing that is constructed in accordance with the present invention. 
     FIG. 9 is a front view of a block for adjusting the angle in the device shown in FIG.  8 . 
     FIG. 10 is a front view of another block for adjusting the angle in the device shown in FIG.  8 . 
     FIG. 11 is a front view of another block for adjusting the angle in the device shown in FIG.  8 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     For the purposes of promoting an understanding of the principles of the invention, references will now be made to the preferred embodiment of the present invention as illustrated in FIGS.  1 - 11 , and specific language used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. The terminology used herein is for the purpose of description and not limitation. Any modifications or variations in the depicted method or device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. 
     Referring now to FIG. 1, there is shown a front view of a preferred embodiment of the device  10  for forming flashing. The device  10  is a plate  12  having grooves  14 ,  20 , and  26  cut through it. The plate  12  may be manufactured from a material having a sufficiently hard surface to allow the flashing to bend when passed through the groove (e.g., metallic, composite, wood or metallic lined material). The first groove  14  is connected to a second groove  20  at their corresponding ends to form a first bend line  16 . The second groove  20  is connected to a third groove  26  also at their ends at a second bend line  24 . A first jut groove  38  creates an angle perpendicular to and extending outward from the second groove  20 . This first jut groove  38  is located near the second bend line  24 . A second jut groove  36  creates a perpendicular angle extending outward from the third groove  26  near the second bend line  24 . An extension groove  32  extends out perpendicular to the third groove  26  at a third bend line  30 . A third jut groove  34  is located at the end of, and extends outwardly from the extension groove  32  to create a perpendicular angle. Apertures  46  are located around the perimeter of the plate  12  for securing the device  10  to a frame structure. 
     The first and second groove,  14  and  20  respectively, form an angle β to form a first V-shaped bend in the flashing. The second groove  20 , the bend line  24 , and the second jut groove  36  form a first Z-shaped bend in the flashing used to fit freeze boards. The second groove  20  and third groove  26  form an angle β to form a second V-shaped bend. The third groove  26 , second bend line  24 , and the first jut groove  38  form a second Z-shaped bend in the flashing used to fit another type of freeze board. The third groove  26 , the third bend line  30 , the extension groove  32 , and the third jut groove  34  form a third Z-shaped bend in the flashing also used to fit another type of freeze board. 
     A first guide  40  slides along the third groove  26 , and is used to force the flashing to remain within the second or third Z-shaped bend when pulling the flashing through the device  10 . A second guide  42  slides along the second groove to force the flashing against the second Z-shaped bend. A third guide  44  slides along the first groove  14  to force the flashing against the second guide  42  to remain within a relative position of the first V-shaped bend. Guides  40  and  42  may be used against each other to force the flashing to remain within the second V-shaped bend. 
     The thickness of the grooves around the first bend line  16  is reduced at a first reduction area  18 . Additionally, a second reduction area  28  reduces the thickness of the grooves around bend line  30 . The reduction areas  18  and  28  prevent wrinkling from occurring in the flashing around the bend areas  16  and  30 , respectively, by allowing less room for the flashing to move or flow. 
     Turning now to FIG. 2, another embodiment of a device for forming flashing  50  is shown from a front view. The device  50  consists of a plate  52  having grooves  54  and  58  cut through the thickness. A first groove  54  is connected to a second groove  58  at a bend line  56 . The first and second grooves,  54  and  58  respectively, create an angle Φ about the bend line  56 . The first groove  54  and second groove  58  form a V-shaped bend used for forming a single angle along the length of flashing. 
     Referring now to FIGS. 3 and 4, a front and sectional view of another embodiment of a device for forming flashing is shown. The device  60  comprises a plate  62  having a groove  64  and a guide  70 . An extension groove  66  is connected substantially perpendicularly to the groove  64  on one end, and a jut groove  68  on the other end. The grooves  64 ,  66 , and  68  are cut through the plate  62 . The guide  70  is slidably attached to the groove  64  in such a way that the flashing is forced against grooves  66  and  68  when the guide  70  is positioned next to the flashing. The guide  70  is illustrated as a bolt  72  extending through the plate  62  and attached with a nut  74 . A washer  76  allows the guide  70  to be adjusted along the groove  64  without catching. The guide  70  may be loosened or tightened against the plate  62  by adjusting the nut  74 . Other guides, having substantially round dimensions and having greater width than a standard bolt head, such as guide  78 , may be used. These guides provide additional support for the flashing, especially when forming angles in the flashing having small segments. 
     Referring to FIG. 5, a front view of another embodiment of a device for forming flashing is shown. The device  80  is illustrated as a plate  82  having a first groove  84  connected to a second groove  88  at a bend line  86 . The grooves  84  and  88  are aligned to create an angle θ, which forms a V-shaped bend. A first guide  90  slides along the first groove  84 . Likewise, a second guide  92  slides along the second groove  88 . The guides  90  and  92  are used to align a length of flashing in a position about the bend line  86 . A scale  94  is attached substantially parallel to the length of the groove  84 . A bend crease is measured using the scale  94  to achieve a desired distance from the crease to the edge of the flashing. 
     Now turning to FIGS. 6 and 7, another embodiment of a device for forming flashing having an adjustable angle is illustrated in perspective front views. The device  100  comprises a plate  102  having adjustable angle grooves. A main groove  104  is connected to a first groove  108  about a first bend line  106  to create an angle A. Additionally, the first groove  108  is connected to a second groove  112  about a second bend line  110  to create an angle B. Furthermore, the second groove  112  is connected to a third groove  116  about a third bend line  114  to create an angle C. The grooves  104 ,  108 ,  112 , and  116  are positioned in a fan shaped arrangement having angles A, B and C. 
     An adjustment guide  118  is attached to the plate  102  with a pinned connection  120 . The adjustment guide  118  assists the flashing when using the first and second grooves,  108  and  112  respectively. A removable pin  122  is placed in a first aperture  128 , as shown in FIG. 6, when using the first groove  108 . The pin  122  is placed in a second aperture  130  (hidden view) when using the second groove  112 , as shown in FIG.  7 . When using the third groove  116 , the pin may be placed in a third aperture  126  to store the adjustment guide  118 . A guide  124  is attached to the main groove  124 , and slides up against the flashing to hold it in place. 
     Referring now to FIGS.  8 - 11 , another embodiment of a device for forming to flashing having adjustable angles is illustrated in FIG. 8 as a front view. FIGS.  9 - 11  show block inserts for the device  200 . The device  200  comprises a plate  202  having adjustable angle grooves. A main groove  204  is connected to a first groove  208 , a second groove  212 , and a third groove  216  at one point forming a fan-like arrangement. The main groove  204  is connected to a first groove  208  about a first bend line  206  to create an angle X. Additionally, the first groove  208  is connected to a second groove  212  about a second bend line  210  to create an angle Y. Furthermore, the second groove  212  is connected to a third groove  216  about a third bend line  214  to create an angle Z. A guide  218  is attached to the main groove  204 , and slides up against the flashing to hold it in place. 
     A first block  220  consists of an insert  226  and a web  224 . The first block  220  is arranged to fit into the first groove  208  and the main groove  204 , whereas an insert groove  228  is substantially the same. An insert bend line  222  is substantially the same as the first bend line  206 . Thus, an angle X is achieved in the first block  220  which follows the angle X on the plate  202 . A second block  230  also consists of an insert  236  and a web  234 . The second block  230  is arranged to fit into the second groove  212  and the main groove  204 , whereas an insert groove  238  is substantially the same. An insert bend line  232  is substantially the same as the second bend line  210  added to the first bend line  206 . Thus, an angle V is achieved in the second block  230 , which follows the angle X, plus Y on the plate  202 . A third block  240  also consists of an insert  246  and a web  244 . The third block  240  is arranged to fit into the third groove  216  and the main groove  204 , whereas an insert groove  248  is substantially the same. An insert bend line  242  is substantially the same as the third bend line  214  added to the first and second bend line,  206  and  210  respectively. Thus, an angle W is achieved in the third block  240 , which follows the angle X, plus Y and Z on the plate  202 . Each insert must be used independent of the others. The inserts may be used as a wear piece and replaced as a separate unit. 
     Although a specific form of the invention has been illustrated and described, it will be apparent that various modifications can be made without departing from the spirit and scope of the invention.