Patent Publication Number: US-11655637-B2

Title: Sealing gasket, flashing arrangement, and method of sealing a gap between flashing members for a roof window

Description:
A sealing gasket for use between flashing members, a flashing arrangement for a roof window including at least two flashing members and at least one sealing gasket, and method of sealing a gap between flashing members for a roof window 
     TECHNICAL FIELD 
     The present invention relates to a sealing gasket for use between flashing members, comprising a compressible sealing section and an attachment section comprising at least two legs configured for engagement with a flashing member, said sealing gasket having a length direction and a width direction extending perpendicular to the length direction, and said sealing section and said attachment section both extending over substantially the entire length of the sealing gasket when seen in the length direction. Furthermore, the invention relates to a flashing arrangement for a roof window including at least two flashing members and at least one sealing gasket and to a method for sealing a gap between flashing members for a roof window. 
     BACKGROUND ART 
     It is known to ensure a watertight transition between a window installed in a roof and the surrounding roofing. Traditionally, a flashing arrangement comprising a number of flashing members is installed such that the flashing members overlap. At places where the flashing members do not come into tight contact with each other, the gap between them is shaped such that wind entering will be slowed down, thereby hindering air and dirt penetration into the structure. Such a specially shaped gap is also known as a labyrinth seal. 
     Labyrinth seals have been found to work very well, often even better than physical seals, such as sealing gaskets and joint fillers, but the dimensions of the gap need to be within certain limits for the labyrinth seal to work. As a consequence, the possibility for changing the relative angle between flashing members is limited, and different flashing arrangements therefore often have to be provided for roof window installations in roofs with different inclinations. This problem is particularly relevant when roof windows are installed in a so-called ridge structure, where the top frame members of two windows are arranged next to each other and the panes inclining in different directions. In such cases it is common to cover the gap between the top frame members by one common ridge flashing member, and a change of the angle of inclination of a window will result in a change in the distance between the ridge flashing member and the part of the window, which it overlaps, typically a top cover member arranged on the top frame member, and/or in a change in the extent of the overlap. 
     In the following, reference will be made only to flashing members, but it is to be understood that in this context this term is used for all of the sheet material components used for weather-proofing the transition between a window installed in a roof and the surrounding roofing, i.e. including also what is traditionally referred to as covering members and cladding members. 
     As an alternative or supplement to labyrinth seals, sealing gaskets have been used, but these too have been suitable only for very specific relative positions of the flashing members. 
     SUMMARY OF INVENTION 
     With this background, it is an object of the invention to provide a sealing gasket, a flashing arrangement, and method for sealing a gap between flashing members for a roof window, which allow the same flashing members and the same sealing gasket to be used for a wide range of roof window inclinations. 
     In a first aspect of the invention this and further objects are achieved with a sealing gasket of the kind mentioned in the introduction which is furthermore characterised in that the at least two legs of the attachment section project from a base section of the attachment section in a height direction, which is perpendicular to the length direction and the width direction, that each leg has a free edge furthest from the base section, and that the at least two legs project substantially in parallel, so that a first recess extending in the length direction is defined between the two legs, and that said attachment section comprises a second recess extending in parallel with the first recess, said first and second recesses being configured for engagement with a flange, ridge, or leg on a flashing member. 
     The provision of two recesses, each of which are suitable for a flange, ridge, or leg on a flashing member, allows the sealing gasket to be attached to one of the flashing members in two different positions, thus allowing it to be optimally positioned for two different inclination angles. 
     The second recess may be delimited on one side by a leg of the attachment section and on the other side by the sealing section. 
     The fact that the recesses are not just local but extending in the length direction allows a continuous engagement between the sealing gasket and a flange, ridge, or leg extending over the length of the flashing member, thereby contributing to an uninterrupted weather-proofing. It is presently preferred that the recesses extend over the entire length of the sealing gasket, thereby also making the sealing gasket suitable for manufacture by extrusion. It may, however, be advantageous that the recesses have closed ends so as to prevent water, air and dirty from penetrating into the recesses from the ends. For this purpose, it is also possible to provide the sealing gasket with one or more end plugs. 
     Similarly, a cavity provided in the sealing section in order to provide compressibility may extend over the entire length of the sealing gasket as is well-known from other gaskets, and it may be closed at the ends. 
     Alternatively, the sealing section may be made from a soft material, such as for example a polymer foam, in order to provide compressibility. 
     In order to allow adaptation to even more different inclinations, the attachment section may comprise at least one further leg extending in parallel with the at least two legs, and at least one further recess extending in parallel with the first and second recesses, which is delimited by the at least one further leg. 
     In one embodiment, the first recess, the second recess, possible further recesses, and the cavity of the sealing sections are arranged on a row when seen in the width direction. This allows the sealing section to be positioned where the gap between the two flashing members opens towards the exterior, while the attachment section extends inwards underneath one of the flashing members. By choosing one recess over another the sealing gasket can be moved inwards or outwards relative to the flashing members in order to achieve a proper positioning of the sealing section. 
     Even though the invention is here described with reference to embodiments where only one recess is used at a time it is to be understood that it is within the scope of the invention to provide the flashing member with two flanges, ridges, or legs, or combinations thereof and for these to engage with different recesses. This may even result in the formation of a labyrinth seal within the sealing gasket. 
     In one embodiment, the sealing section comprises two cavities arranged next to each other when seen in the width direction. As described with reference to the recesses above, this too provides increased versatility to the sealing gasket in that one or the other cavity may be compressed between the two flashing members, thereby allowing at least two different relative inclinations without having to use another recess of the attachment section. 
     As the sealing gasket will usually project slightly from the gap between the flashing members, the side of the sealing section furthest from the attachment section when seen in the width direction may have an inclined outer surface configured for draining off water. For the same reason, at least the sealing section of the sealing gasket should preferably be made from a material, which is resistant at least to exposure to UV radiation and water and which is preferably also resistant to temperatures in the range from −40 degrees Celsius to +80 degrees Celsius. 
     In an embodiment, the legs and/or the recesses project in the height direction from an interior surface of the sealing gasket, the interior surface extending in the width direction. An exterior surface of the sealing gasket is positioned opposite to the interior surface in the height direction. All legs, recesses, cavities, walls between cavities and the inclined outer surface, if any, extend below a plane that is defined by the exterior surface of the sealing gasket in the mounted state. In other words, the legs and the recesses project from the interior surface of the sealing gasket away from the exterior surface in the height direction and all parts of the sealing gasket are located on the same side of the exterior surface when seen in the height direction. 
     The legs may be formed integrally with the base section, and/or the attachment section may be integrally formed with the sealing section. This applies to all embodiments unless otherwise stated. 
     In one embodiment, at least one leg of the attachment section is provided with a thickening or projection so that a width of each recess at the free edges of the legs is smaller than a width of the respective recess closer to the base section. This may improve the connection between the sealing gasket and the flashing member as the smaller width at the free edges may allow a tight fit, so that they are kept in engagement by friction. Alternatively, or as a supplement, the flashing member and the attachment section may come into a snap-locking engagement, for example by the flashing member being provided with at least one recess or opening matching the size and shape of a projection on a leg of the attachment section. 
     The width closer to the base section may allow movement of the free edge of the flashing member, which may potentially reduce the wear on the sealing gasket which might otherwise result from a relative movement of the two, for example caused by temperature gradients. It is, however, also within the scope of the invention that the recesses have substantially the same width over the entire height. This width may correspond to the thickness of the part of the flashing member extending into the recess, thereby achieving a tight fit, but the width may also be bigger, allowing a certain sideways relative movement, which may for example be used for compensating for tolerances and variations. 
     In one embodiment, at least the legs of the attachment section are made from a resilient material allowing the legs to bend about and axis, which is substantially parallel to the length axis, and automatically return towards their original position. This may facilitate a tight fit and/or a snap-locking engagement between the sealing gasket and the flashing member. 
     In a second aspect of the invention the object of the invention explained above and further objects are achieved with a flashing arrangement including at least one sealing gasket of the type described above which is characterised in that the sealing section of the sealing gasket contacts both flashing members and closes a gap between them and where a flange, ridge, or leg on a flashing member projects into a recess of the attachment section. The embodiments and advantages described with reference to the first aspect of the invention above also applies to this aspect unless otherwise stated. 
     In one embodiment, a flange, ridge, or leg on a flashing member contacts a surface section of sealing section at a position above a cavity therein, and at least the surface section of the sealing section is made from a resilient material allowing the cavity to be deformed. The flange, ridge, or leg on the flashing member ensures that the contact with the sealing gasket is well-defined and the resilience of the material means that the sealing gasket presses back against the flashing member thus contributing to ensuring that the sealing gasket stays in contact with the flashing member at all times. 
     In a third aspect of the invention the object of the invention explained above and further objects are achieved with a method including the use of at least one sealing gasket of the type described above which is characterised in that in the sealing gasket used, at least two legs of the attachment section project from a base section of the attachment section in a height direction, which is perpendicular to the length direction and the width direction, that each leg has a free edge furthest from the base section, and that the at least two legs project substantially in parallel, so that a first recess extending in the length direction is defined between the two legs, and that said attachment section comprises a second recess extending in parallel with the first recess, and in that the sealing gasket is arranged such that a flange, ridge, or leg on a flashing member projects into a recess of the attachment section. 
     The embodiments and advantages described with reference to the first and second aspects of the invention above also applies to this aspect unless otherwise stated. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       In the following description embodiments of the invention will be described with reference to the schematic drawings, in which 
         FIG.  1    is a perspective view of ridge structure including twelve roof windows, 
         FIG.  2    is a partially cut-away cross-sectional view along the line II-II in  FIG.  1   , 
         FIG.  3    a partially cut-away cross-sectional perspective view corresponding to the detail marked III-III in  FIG.  2   , 
         FIG.  4    corresponds to  FIG.  3    but seen directly from the end in the direction indicated by the arrow IV in  FIG.  1    and showing an embodiment where the windows are mounted with a low inclination angle, 
         FIG.  5    corresponds to  FIG.  4    but showing an embodiment, where the two roof windows are installed with different inclination angles, 
         FIG.  6    is a perspective view of an end of a sealing gasket seen slightly from below, and 
         FIG.  7    corresponds to  FIG.  6    but showing the sealing gasket slightly from above. 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     Referring initially to  FIG.  1   , a ridge structure including twelve roof windows  1  and a gable  20  is shown. A flashing arrangement  3  provides a watertight transition between windows, between the windows and the gable, and between the windows and a surrounding roofing (not shown) as is well-known to the skilled person. 
     Turning now to  FIG.  2    a cross-section along the line II-II in  FIG.  1    illustrates how a single ridge flashing member  31  overlaps top flashing members  32  on both roof windows  1  so that rain water etc. landing on the ridge flashing member will drain off onto the top flashing members and from there onto the panes  11  of the roof windows. The ridge flashing member  31  and the top flashing members  32  are mounted on connector brackets  33 ,  34 , which are mounted on mounting brackets  21 ,  22  used for connecting the roof windows  1  to a load-bearing beam  23  of the ridge structure. 
     As is more clearly seen in  FIGS.  3 - 5   , sealing gaskets  4  are arranged in the gap between the ridge flashing member  31  and each top flashing member  32 . 
     Referring now also to  FIGS.  6  and  7   , each sealing gasket consists of a sealing section  41  and an attachment section  42 . 
     The sealing section is resting on an exterior surface  322  of the top flashing member  32  and a flange  311  of the ridge flashing member  31  projects downwards so that its free edge  312  rest on top of the sealing section. 
     In  FIGS.  2 - 5    the sealing gaskets are shown in their initial undeformed state, but it is to be understood that the sealing gasket will be deformed by the downwards pressure exerted by the flange  311 . In order to allow this deformation, the sealing section comprises two cavities  411 ,  412 , but it would also be possible to make the sealing section from a soft material, such as for example a polymer foam, in which the cavities would not be needed. How the compressibility of the sealing section  41  is achieved has no bearing on the embodiment of the attachment section  42 , except possibly influencing the choice of the material used, as it may be considered advantageous to make the entire sealing gasket  4  from the same material. 
     The wall  413  between the two cavities is here made with a V-shaped cross-sectional shape allowing it to yield when pressure is applied to the upper side of the sealing section  41 , but it is understood that this need not be the case. 
     As may be seen, the side  414  of the sealing section  41  furthest from the attachment section  42  when seen in the width direction W projects slightly from the gap between the ridge flashing member  31  and the top flashing member  32  and will thus be exposed to rain water etc. In order to lead water away from the gap, the exposed side  414  of the sealing section  41  has an inclined outer surface configured for draining off water. 
     Both cavities  411 ,  412 , the wall  413  between them, and the inclined outer surface  414  are extending in the length direction L over the entire length of the sealing gasket  4  as is also seen in  FIGS.  6 - 7   . 
     In the embodiment shown, the entire sealing gasket  4  in made from a resilient material and this allows even the attachment section to give way for other members. In this case the ridge flashing member  31  is provided with an insulating member  313  on the interior side which will force the end  421  of the attachment section furthest from the sealing section downwards. The apparent overlap of the sealing gasket  4  and the insulating member  313  will thus not be present in real life. 
     The attachment section  42  of the sealing gasket  4  shown in the drawing has six legs  422  projecting from a base section  423  and forming six recesses  424 , a first recess  424 ′ being formed between a first leg  422 ′ and the sealing section  41 . Each leg and each recess is extending over the entire length of the sealing gasket  4  as is also seen in  FIGS.  6 - 7   . 
     As is best seen in  FIGS.  3 - 5   , each top flashing member  32  is here provided with a flange  321  projecting substantially perpendicular to the exterior side  322  of the main section of the top flashing member and the sealing gasket  4  is mounted on this flange in a manner so that the flange projects into one of the recesses  424 . In this embodiment the flange  321  is made by bending the sheet material, from which the top flashing member is made, twice, so that the flange is twice as thick as the rest of the top flashing member, but it is to be understood that this need not be the case. It may also have the same thickness or be replaced by a separate member (not shown) attached to a main body of the top flashing member. 
     In this embodiment, each leg  422  has a bulge  4221  at its free edge so that the distance d between the legs at the free edges and hence the width of each recess is smaller than the distance D between the legs closer to the base section  423 . In this embodiment this feature simply reduces the risk of dirt entering the recesses  424 , but in other embodiments it may mean that there is a tight fit between the projecting part, such as a flange, of the flashing member  32  and the attachment section  42 . 
     The sealing gasket  4  on the left-hand side of  FIGS.  2  and  3    is mounted with the flange  321  of the top flashing member  32  projecting into the first recess  424 ′ closest to the sealing section  41  while the sealing gasket  4  on the right-hand side is mounted using the second recess from the sealing section. As is best seen in  FIG.  4    this means that for roof windows  1  mounted with the same angle of inclination A the flange  311  on the ridge flashing member  31  contacts the sealing section  41  at different places. By choosing the right recess  424  it is thus possible to achieve an optimal positioning of the sealing gasket  4  in relation to the ridge flashing member  31 . This applies independently of how the sealing gaskets and the flashing members are embodied, only the engagement between one of a plurality of recesses in the sealing gasket and a flange, ridge, or leg on the flashing member is required. 
     Turning now to  FIG.  5    a situation, where the roof windows  1  are mounted with different angles A of inclination is shown. The left-hand window is mounted with the same angle inclination as in  FIG.  4   , i.e. approximately 5 degrees, while the right-hand roof window is mounted with an angle corresponding to that in  FIGS.  1 - 3   , i.e. approximately 25 degrees. As may be seen, the different angles means that both the distance between the ridge flashing member  31  and the top flashing member  32  and the extent of the overlap in a horizontal direction are different. This is characteristic of ridge structure where the angle is changed by rotation about a fixed point, here the connection between mounting brackets  21  and  22 . In other embodiments only one of them will be change as the angle changes. 
     In order to compensate for these differences the sealing gasket  4  on the left-hand side in  FIG.  5    is mounted using the recess  424  furthest from the sealing section  41 , thus arranging the sealing section as far onto the exterior surface  322  of the top flashing member as possible, while the sealing gasket on the right-hand side is mounted using the second recess as described above. The provision of the row of recesses  424  thus enables the use of the same flashing members  31 ,  32  and the same sealing gaskets  4  for a wide range of inclination angles. 
     The sealing gasket  4  shown in the drawing is intended for use with angles of inclination of 5-25 degrees, but it is to be understood that the relative dimensions of the sealing section and the attachment section and parts thereof may be adjusted so that it may be used in other angle intervals. Likewise, it is to be understood that the number of cavities, legs and recesses may be changed. Changes to the specific configuration of the sealing gasket  4  may be made in order to allow the use with flashing members which are different from those shown in the drawing. 
     LIST OF REFERENCE NUMERALS 
       1  Roof window 
       11  Pane 
       20  Gable 
       21  Mounting bracket 
       22  Mounting bracket 
       23  Load-bearing beam 
       3  Flashing arrangement 
       31  Ridge flashing member 
       311  Flange 
       312  Free edge 
       313  Insulating member 
       32  Top flashing member 
       321  Flange 
       322  Exterior surface 
       33  Connector bracket 
       34  Connector bracket 
       4  Sealing gasket 
       41  Sealing section 
       411  Cavity 
       412  Cavity 
       413  Wall between cavities 
       414  Side furthest from attachment section 
       42  Attachment section 
       421  End furthest from sealing section 
       422  Leg 
       4221  Bulge 
       422 ′ First leg 
       423  Base section 
       424  Recess 
       424 ′ First recess 
     A Angle of inclination 
     d Distance between legs at free edges 
     D Distance between legs away from free edges 
     L Length direction 
     W W direction