Patent Description:
Skirt flashing elements, which typically comprise a skirt member adapted for resting on the outer surface of the roofing material and a plate or rail member to be attached to the roof penetrating structure, are used for sealing joints between building structures penetrating a roof surface, for example a joint between the frame of a roof window and the surrounding roofing material, particular at the lower horizontal member of the main frame of the roof window. The skirt member is important with regards to securing a well-fitting, stable and secure sealing of the joint between a roof penetrating structure and a roof surface, particularly when using an undulated roofing material such as tiles. The skirt member shall ideally provide for an easy mounting procedure, which ensures that the skirt member is firmly and closely mounted onto the roof surface and stays in this position for the entire lifetime of the flashing. In order to achieve this, the skirt member is made of a material, which is easy to bend, preferably by hand, and which has a relatively high weight and a low elasticity.

Skirt flashing elements have traditionally been made from lead plates with a thickness of approximately <NUM>. Lead as a flashing material has a number of advantages as it is very easy to deform with only a very limited elasticity, i.e. the lead plate substantially stays in the form into which it is initially bend without any elastic bouncing back. This inherent feature of lead is of great advantage when a lead-skirt is shaped directly onto for example an undulated roof surface, since such skirts cannot be bent in excess in order to compensate for possible elastic re-bouncing. Although lead is virtually non-elastic, there may be a minimal re-bouncing, but as lead is a very heavy material, gravity will keep the lead-skirt in close contact with the roof surface. The high weight also prevents the skirt from being lifted and bent backwards by heavy winds. Lead, however, is environmentally harmful and has therefore been forbidden for use in construction work in many countries.

Different kinds of skirt flashing elements having a sandwich structure with a stress damping and stabilizing layer of ductile material covered by a foil sheeting has been suggested as alternatives to lead. The core layer has typically been made out of a polymeric material or bitumen product, and the foil has typically been a thin metal foil, preferably aluminium foil.

For use on roof surfaces in the form of undulated tiles with very deep troughs these sandwich structures are typically wave-corrugated or pleated giving them a surplus of material, which allows them to stretch so that a good fit between the flashing and roofing may be obtained.

An example of a prior art document showing a wave corrugated flashing is <CIT>. A flashing assembly is furthermore known from <CIT>.

Practice, however, has shown that wave-corrugated or pleated skirt flashing elements can result in the undulated roof covering resting on the flanges of wave-corrugated skirt member, being lifted, because the corrugated surface makes it impossible for the undulated roofing elements to rest flat on the undulated roofing elements, which it overlaps. It is considered a problem with roof windows having a small width, where the width of the two flanges together is of the same or almost of the same width as the skirt member. Not only does the overall appearance of the flashing assembly suffer with such a dominant configuration of the flanges but it also becomes hard to fit the skirt and flanges to highly undulated roof coverings. The object of the invention is therefore to make an improved flashing assembly without the above-mentioned drawbacks.

This is achieved by a flashing assembly according to claim <NUM>, wherein a flange member is adapted to lay flat and follow the surface of the roof covering element, the flange member being formable for substantially permanent deformation, and comprising an elastomer being plastic and/or a textile.

The deformed flange member may be kept in place by the roof covering elements resting on top of it. For example, if the flange member is lightweight, such as a textile or does not comprise metal or a minimal amount of metal.

What is meant by plastic is that the material is able to be deformed without rupture by the action of a force and remain deformed after the force is removed. It may have plastic properties similar to modelling clay or similar materials with ductile or like properties. The flange member may be plastic.

It may alternatively or additionally be viscoelastic such that a faster deformation results in a higher degree of elasticity.

The flange member may be adapted to lay flat and follow the surface of the roof covering element(s) by being elastic, but still maintain its shape after being modelled or by having surplus material. For example, the flange member may be flared such the flange member is progressively wider towards the bottom and/or being pleated and/or stretchable.

The flashing assembly is particularly suitable for undulated roof covering elements, such as tiles, but may also be used for flat roof covering elements.

Textile may include anything made from fibrous materials. The term includes fabrics made of adhered fibers like felt, items made of relatively unmodified plant materials like materials used for baskets and mats, fabrics made of spun yarns such as knitted and woven cloth, and items made of synthetic linear elements such as for nylon window screens. The textile may be woven, non-woven, spun or molded.

The flange member has an inner surface, adapted to face in an interior direction towards an interior of the building.

The inner surface of the flange member may have adhesive properties to provide at least a temporary attachment to the roof covering elements until roof covering elements have been positioned on top of the flange member, to provide an easier installation. The flange member may be repositionable even with adhesive properties. The inner surface may be provided with a release liner to protect an adhesive inner surface.

According to an embodiment, the textile is impregnated and/or laminated and/or vulcanized. The purpose of this is to repel water.

The flange member and/or the skirt member may be made without any metal or a minimum amount of metal. For example, the flange member and/or the skirt member may comprise less than <NUM>% metal by volume, less than <NUM>% metal by volume, less than <NUM>% metal by volume or less than <NUM> % metal by volume. The minimum amount of metal could be a thin metal foil or metal particles in the flange and/or skirt member.

By using a flange member that has both plastic and elastic properties, it is possible to stretch the flange member, so it adapts to the shape of the roof covering elements, e.g. such that conforms to the shape of the roof covering elements and stays in place after being mounted. It is thus possible to position the tiles or roofing material closely to the flashing and a closer fit is provided, in particular in low roof inclinations. When the tile or roofing material is brought closer together a possible corrugated part of the skirt member will also be pushed further down towards the roof. What is meant by corrugated, is that surplus material is available in the form of corrugations or pleats, so the material can reach down into the troughs of the roof covering elements. The skirt member may be plane as well, without corrugations. It may also be plastic and/or elastic.

The flange member may comprise a main layer comprising an elastomer being plastic.

The flange member may comprise a second layer comprising an elastomer being elastic and preferably adhesive.

The flange member may comprise sailcloth, where the material(s) for the sailcloth is preferably selected from a group consisting of flax, hemp, cotton, nylon, polyester, aramids, and carbon fibers.

The flashing assembly may comprise a sealing member attachable to the bottom of the roof penetrating structure and the skirt member.

The sealing member may be in the form of a rail or a plate material, usually metal, such as aluminum, adapted to cover a part of the space between the roof penetrating structure and the roof covering elements.

The flashing assembly may comprise a skirt member of a corrugated sheet material having a first edge attached to the sealing member in the mounted condition, and a fourth edge, opposite the first edge, and a second and a third edge connecting the first edge with the fourth edge, preferably the second and the third edges are substantially perpendicularly to the first edge. The skirt member may comprise metal, preferably aluminium.

The flange member may comprise metal particles, such as iron oxide.

The main layer may comprise mainly short chained elastomer. The second layer may comprise mainly long chained elastomer.

In an embodiment at least <NUM>%, more preferably at least <NUM>% of the volume of the flange member may consist of an elastomer. The elastomer may also be synthetic. The surface of the main layer facing the exterior may be covered by a thin foil, e.g. less than <NUM> thick, or provided with UV protection, e.g. a form of paint, or another exposure protection.

The elasticity of the second layer contributes to distributing the forces in the main layer when the flange member is being molded into place clinging to the roof covering elements.

The elasticity also depends on the speed with which you pull the flange member. The faster you pull and/or provide an impulse to the material, the more elastic it will feel. If you slowly press on the material it will leave a mark and be permanently deformed.

The second layer or bottom layer may be adhesive.

The adhesiveness of the second layer contributes to holding the flange member in place during mounting, before a roof covering element may be placed on top of it, and subsequently holds it in place.

The flange member is preferably flexible or pliable or formable.

What is meant by being flexible is that the flange member is able to bend, preferably up to <NUM> degrees, more preferably up to <NUM> degrees, without breaking.

The flashing assembly is either delivered on site in one piece or is assembled on site. For example, the skirt member may be attached to the flange member or they may be attached to each other on site.

The inclination of the roof is preferably between <NUM> degrees and <NUM> degrees.

The roof covering elements may be tiles or other undulated roof covering elements.

The top, bottom and side members may have an interior side for facing in an interior direction towards an interior of the building in a mounted condition and an exterior side for facing in an exterior direction opposite the interior direction in the mounted condition.

The skirt member may be used for covering the remaining space between the roof penetrating structure and the roof covering elements and part of the roof covering elements facing the roof penetrating structure, at the bottom of the roof penetrating structure.

The skirt member may be a laminated sheet material comprising a layer of aluminum, cobber or zinc or alloys thereof, and a polymer layer or bitumen layer. It may be coated or include fillers and/or adhesives. It may also be made of the same materials as the flange member.

A second and/or third edge of the skirt member may be positioned in continuation of a length of the first and/or second side member of the roof penetrating structure, when mounted. The second and/or third edge of the skirt member may be positioned in continuation of the edge of the roof covering elements facing the first or the second side of the roof penetrating structure.

The flange member is preferably free from metal. It may include fillers such as chalk.

The flange member may have a break elongation of more than <NUM>%, preferably more than <NUM>%. When pulling the flange member over the roof covering elements, some areas of the flange member will be more exposed to being pulled than others. The break elongation makes it possible to stretch the material were needed, so the flange member can be moulded according to the roof covering elements.

The flange member may be around <NUM>-<NUM> wide and <NUM> - <NUM> long. It is preferably rectangular but may be semi-circular.

The main layer or flange member may comprise material selected from a group consisting of Ethylene Propylene Diene Monomer (EPDM) and butyl and a second layer preferably comprising butyl and/or resin. The flange member may comprise a rubber suitable for the purpose when it comes to its plastic and elastic properties. The butyl in the main layer is preferably substantially made from short chained butyl. The butyl of the second layer is preferably substantially made from long changed butyl or another long-chained rubber material, which contributes to the elasticity. The resin, or other tacky material, contributes to adhering the flange member to the roof covering elements. The second layer or bottom layer facing towards the interior of the building is preferably covered by a release liner, such that it is easier to handle the flange member during mounting.

The flange member may be configured to be positioned at least partly between the roof covering elements. A part of it may extend from between the roof covering elements on the outside of the roof.

The flange member may have a thickness between <NUM>-<NUM>, preferably between <NUM>-<NUM> in a pre-mounted, non-stretched, condition. When the flange member is mounted it may be formed or stretched such that is conforms to the shape of the roof covering elements. When it is mounted, the thickness may be reduced to between <NUM> and <NUM> as the material is stretched. Because the flange member has a limited thickness, the roof covering elements is able to be positioned close to each other, as opposed to a corrugated or thicker material. The flange member may also be <NUM>-<NUM> thick in the pre-mounted, non-stretched, condition.

In an embodiment the main layer has preferably a thickness between <NUM> - <NUM>, more preferably around <NUM> in the pre-mounted, non-stretched, condition. The second layer has preferably a thickness between <NUM> - <NUM>, preferably around <NUM> in the pre-mounted, non-stretched, condition.

In an embodiment the flange member and the skirt member constitutes one piece or at least share a layer of material. They may be made from the same material as described for either the flange member or the skirt member in this application.

The flange member and the skirt member may be attached to each other in the mounted condition. They may be disconnected from each other before being mounted.

The flange member and the skirt member may be attached to each other by means of a connection means such as a snap fitting and/or an adhesive or welded together. They may also be laminated together.

The flange member may be provided with an attachment flange adapted to engage with gripping means, for example formed like an omega shape, on the skirt member.

The flange member or main layer may comprise a filler, preferably chalk, which contributes to the materials plasticity.

The flange member may have a bottom edge extending across the inclination direction, wherein the bottom edge may be substantially in line with the roof covering element resting upon the flange member in the mounted position. Thereby the flange member becomes almost invisible in the mounted position, such that visually the width of the skirt member and flange member corresponds to the width of the window. In order to have a bottom edge of the flange member being in line with the overlaying roof covering element, the flange member is preferably adapted such that the piece of flange member that extends out between the roof covering elements is cut off after the roof covering elements has been mounted.

Using a flashing assembly with a skirt and flange member of the above-mentioned configuration, may also allow the installer to make a trimming of the flange member. For instance, if a very overall slim design look of the roof window and the flashing assembly all together is wanted, it can be done by trimming of the flange member by for instance cutting away any excess material coming out under the overlaying roof covering elements. In this way, looking at the roof window, the flashing assembly and the roof covering all in their mounted positions, you would get the impression that the skirt so to speak just makes a continuation of the roof penetrating structure, e.g. the roof window and leaving the two flange members invisible underneath the roof covering elements. The flange member may be adapted to be cut across the inclination direction when in the mounted position, with pocket-knife or similar tool. For example, when there is little or no metal present and the flange member is formable, such as pliable, and relatively thin, for example less than <NUM> thick, the material is easy to cut with a hand tool.

According to a second aspect a method of mounting a flashing assembly is disclosed. The method comprises the steps of mounting the flashing assembly according to the first aspect in the roof, mounting the roof covering elements, such that the at least one flange member is at least partly covered by the roof covering elements and removing a part of the flange member that extends out from between the roof covering elements, thereby aligning a bottom edge of the flange member with a bottom edge of the roof covering element positioned on top of the flange member. The removal of the part of the flange member that extends out from between the roof covering elements is a lot easier, when metal is not forming part of the flange member but instead is being mainly made from an elastomer or textile. The person mounting the flashing assembly can easily cut of surplus material, that does not contribute to sealing the roof. Furthermore, a more harmonious look of the roof is obtained.

The method may further comprise the step of attaching a sealing member to the bottom of the roof penetrating structure.

According to a third aspect a roof structure is disclosed, the roof structure comprising roof covering elements and a flashing assembly according to the first aspect.

In the roof structure the flange member of the flashing assembly may be positioned between the roof covering elements and a bottom edge of the flange member may be substantially aligned with a bottom edge of the roof covering elements covering the flange member. Any element mentioned above in relation to the flashing assembly and/or method may be included in the roof structure.

The invention will now be explained in closer detail with reference to embodiments shown in the drawings, in which.

In the embodiment shown in <FIG>, only a half section of the flashing assembly <NUM> is shown, and a corresponding mirror inverted image may be positioned in extension of the skirt member and the rail member. The flashing assembly <NUM> comprises a sealing member in the form of a rail element <NUM> and a skirt member <NUM>. The rail element <NUM> is attached to the skirt member <NUM> along a first edge <NUM> thereof and serves as a connecting element between the skirt member <NUM> and, for example, the frame of a roof window (not shown) installed in an inclined roof. A flashing member <NUM> is attached to a flange member <NUM> and a number of sub-elements <NUM>, <NUM>, <NUM> are intended for being connected to the window and/or roof in a manner known per se.

The skirt member <NUM> is corrugated to provide a surplus of material in a direction along the skirts first edge <NUM> and fourth edge <NUM>. In this embodiment the skirt member <NUM> is laminated. The skirt member <NUM> comprises first layer made from sheet aluminium with a thickness of <NUM>,<NUM>, which has been lacquered, which layer faces the exterior. The second cover layer is a cross-laminated foil of a polyolefin, preferable polyethylene, such as the one sold under the trademark Valeron® and with a thickness of <NUM>,<NUM>. The third cover layer is made from as polymer, such as polypropylene or polyethylene, or silicone coated paper. Other thicknesses may be used as well.

The skirt member <NUM> comprises a second edge <NUM> and a third edge (not shown) connecting the first edge <NUM> and fourth edge <NUM>. A flange member <NUM> is attached both at the second edge <NUM> and the third edge (not shown) by a snap fitting. The skirt member <NUM> and the flange member <NUM> may be integrally formed. The flange member <NUM> is flexible and comprises mainly an elastomer. The flange member is abutting both the skirt member <NUM> and flashing member <NUM>. The flange member <NUM> comprises a main layer <NUM> comprising butyl being plastic in its ability to be modelled according to the shape of the roof, and a second layer <NUM> comprising a butyl and resin, however with the abilities of being adhesive and elastic.

<FIG> shows the flashing assembly in the mounted condition. Here the roof penetrating structure <NUM> in the form of a window is mounted in the roof <NUM>. The window comprises a first <NUM> and a second side member <NUM>, connected by a bottom <NUM> and a top member (not shown). The roof <NUM> is covered by undulated roof covering elements <NUM> in the form of tiles. The flange member <NUM> is easily formed according to the shape of the tile, and the tile resting above the flange member <NUM> is brought close to the tile the flange member rests upon. The flange member may be stretched so that it can reach over the undulated roof covering elements <NUM>. The flange member is not corrugated but is a flat piece of material. A close-fitting flashing assembly is thereby provided.

<FIG> shows another embodiment of the flashing assembly in the mounted condition. In addition to the features mention under <FIG>, the flange member <NUM> has been cut off after being mounted, such that the flange member substantially does not extend out from between the roofing elements <NUM>, but instead is in line with the bottom edge of the roof covering element <NUM> resting upon the flange member <NUM>. The flange member <NUM> has a bottom edge <NUM> extending across the inclination direction ID, perpendicularly to the second edge <NUM> of the skirt member. That way the flange member is substantially invisible in the mounted position.

<FIG> shows an embodiment of a cross section of the flange member <NUM>. The main layer <NUM> makes up about <NUM>% of the volume of the flange member. The main layer <NUM> is in this embodiment is butyl rubber. The main layer <NUM> may be made out of EPDM instead or another rubber with similar plastic properties. The top layer <NUM> facing the exterior is a layer of UV protection. This could be dispensed with, in particular in cases were the bottom part of the flange member is cut off, so that it is in line with the roof covering element. A second layer <NUM> comprising butyl rubber and resin is positioned below the main layer <NUM>. This layer is elastic and has adhesive properties. The third layer <NUM> is a release liner, so the flange member <NUM> is easier to work with during mounting, as the second layer <NUM> is somewhat sticky. The third layer <NUM> is removed before mounting of the flange member <NUM>. The third layer <NUM> could be dispensed with as well.

<FIG> shows a cross section of a snap fitting <NUM> between the flange member <NUM> and the skirt member <NUM>. The snap fitting comprises a protrusion <NUM> on the flange member <NUM>, preferably extending along the edge of the flange member <NUM> facing the skirt member, and an omega shaped engagement means <NUM>, enclosing the protrusion <NUM>. The layers of the flange member and the skirt member is not shown.

<FIG> shows another embodiment of the flashing assembly in a semi mounted condition. Here it can clearly be seen how the flashing member <NUM> are modelled according to the roof covering elements and stays in place after it has been stretched into position. The plastic properties of the flange member help to keep it in place.

<FIG> shows an embodiment of the flashing assembly in a mounted condition. Here it can in particularly be seen how the whole window appears, when the bottom edges <NUM> of the flange members is in line with the overlaying roof covering elements <NUM>.

<FIG> shows an embodiment of the flashing assembly in a mounted condition. Here the skirt member <NUM> and the flange member <NUM> are in one piece and comprising a layer of the same material. They may be made of the same material throughout. The flange member <NUM> has been cut such that the bottom edge of the flange member <NUM> is substantially aligned with the bottom edge <NUM> of the roof covering element <NUM> positioned on top of the flange member <NUM>.

Claim 1:
Flashing assembly (<NUM>) for use for a roof penetrating structure (<NUM>), preferably a window, in an inclined roof (<NUM>) of a building, the inclined roof (<NUM>) having an inclination direction and having roof covering elements (<NUM>), the roof penetrating structure (<NUM>) comprising a top member and a bottom member (<NUM>) extending across the inclination direction, and a first side member (<NUM>) and a second side member (<NUM>) connecting the top member with the bottom member (<NUM>) extending in the inclination direction, the flashing assembly (<NUM>) comprising:
- a skirt member (<NUM>) configured for at least partly covering the roof covering elements (<NUM>) facing the bottom of the roof penetrating structure (<NUM>), the skirt member (<NUM>) has a first edge (<NUM>) and a fourth edge (<NUM>) for extending across the inclination direction, the fourth edge (<NUM>) being opposite the first edge (<NUM>),
- a rail element (<NUM>) attached to the skirt member (<NUM>) along a first edge (<NUM>) thereof and serving as a connecting element between the skirt member (<NUM>) and the roof penetrating structure (<NUM>),
- a flange member (<NUM>) positioned in extension of the skirt member (<NUM>) and the first (<NUM>) and the fourth edge (<NUM>), such that the flange member (<NUM>) is for being positioned at the first (<NUM>) and/or the second (<NUM>) side member of the roof penetrating structure (<NUM>) respectively,
- a flashing member (<NUM>) attached to the flange member (<NUM>) and a number of sub-elements (<NUM>, <NUM>, <NUM>) intended for being connected to the roof penetrating structure (<NUM>),
- the flange member (<NUM>) has an inner surface, adapted to face in an interior direction towards an interior of the building, the flange member (<NUM>) is adapted to lay flat and follow the surface of the roof covering elements (<NUM>), the flange member (<NUM>) being formable for substantially permanent deformation characterized in that the flange member (<NUM>) comprises an elastomer being plastic and/or a textile, and in that the flange member (<NUM>) is not corrugated but is a flat piece of material.