BACKGROUND

Field of the Inventions

[0001] Embodiments disclosed herein relate to flashing strips used to create a seal at one or more junctions between construction surfaces and methods of making the same. For example, certain embodiments relate to flashing strips used to create a seal between a roofing panel and a member (e.g., a duct) that projects therefrom.

Description of the Related Art

[0002] Flashing strips or other sealing members can be employed to prevent the passage of water or other matter through an interface of construction surfaces. For example, in some implementations, a flashing strip can be used to "flash" (e.g., seal) a junction or interface between a generally flat roof and a non-planar surface that extends therefrom (e.g., a wall, pipe, or duct).

[0003] A proper flash or seal between construction surfaces is especially important with generally flat roofs where water and/or other liquids can be allowed to stand or collect. Further, a seal formed by a flashing strip can prevent and/or minimize heat transfer through the seal. Accordingly, in roofing implementations, a seal formed by a flashing strip can be important to protect the integrity of the underlayment and/or structure contained below the roof. Such a seal can also help to maintain desirable heat transfer characteristics through the roof.

[0004] Flashing strip installations can be complicated by the use of profiled roofing materials having a corrugated or other non-planar configuration. For example, flashing strips for use with profiled roofing materials must be manipulated to bend and conform to the irregular profile of the roof and must retain that manipulated shape to facilitate the installation (e.g., to allow an installer to fasten the flashing strip to the roof in a desired shape or configuration).

[0005] Existing flashing strips include resilient or elastic materials, for example, resilient rubbers or polymers, that are difficult to stretch and/or otherwise manipulate when installing. Installation of such flashing strips can be burdensome and time consuming. Additionally, such flashing strips can require significant material costs due to their limited elongation capabilities.

SUMMARY OF THE INVENTIONS

[0006] The devices and methods of this disclosure each have several aspects, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the claims, some prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section entitled "Detailed Description of Certain Embodiments," one will understand how the features of the devices and methods disclosed herein provide advantages over other known devices and methods.

[0007] An aspect of at least one of the inventions disclosed herein includes the realization that incorporating a viscoelastic material in a flashing strip can overcome certain problems. For example, existing flashing strips include a body formed of a resilient rubber material that has exceptional memory or recovery characteristics. As such, it can be difficult to manipulate these flashing strips to form certain shapes during installation because of the tendency of the material to recoil or spring back to its initial form.

[0008] Further, materials used in existing flashing strip bodies can have limited elongation characteristics. Thus, when installing these flashing strips it can be difficult to stretch or deform the bodies to cover a desired area. For example, some existing flashing strips can only be stretched or elongated up to a maximum of 25% of their initial form and this can require an exceptional amount of force and effort which can be burdensome and time consuming during installation.

[0009] Therefore, in accordance with at least some of the embodiments disclosed herein, a flashing strip is provided with a viscoelastic material body. By providing such a body, the flashing strip can be more easily stretched to cover larger areas during installation and the strip can be manipulated to form different shapes without the body completely recoiling to its initial form. Therefore, such flashing strips can save time during installation and can save material costs required for manufacturing the body.

[0010] In accordance with other embodiments, a flashing strip is provided for use in forming a seal between a first construction surface and a second construction surface. The flashing strip can include a body and a first reinforcing member embedded at least partially in the body. The body can have longitudinal axis, a lateral axis, and a transverse axis. The body can also be viscoelastically deformable by a manual force along the longitudinal, lateral, and transverse axes between at least a first configuration and a second configuration. The first reinforcing member can include a non-resilient material and can be deformable by the manual force along the longitudinal, lateral, and transverse axes. The first reinforcing member can be configured to maintain a first shape of the body when the body is in the first configuration and when the manual force is not applied to the body. The first reinforcing member can also be configured to maintain a second shape of the body when the body is in the second configuration and when the manual force is not applied to the body.

[0011] In accordance with other embodiments, a flashing strip can include a viscoelastic body and at least one reinforcing member at least partially embedded within a portion of the body. The viscoelastic body can include at least one rubber component and 150 to 300 parts by weight of clay per 100 parts of rubber component(s).

[0012] According to other embodiments, a method of manufacturing a flashing strip is provided. The method can include providing a first layer of uncured viscoelastic material, providing a reinforcing member, providing a second layer of uncured viscoelastic material, and disposing the reinforcing member between at least portion of the first layer and at least a portion of the second layer.

[0013] In accordance with other embodiments, a flashing strip can include a body and a reinforcing member embedded at least partially in the body. The body can have a longitudinal axis, a lateral axis, and a transverse axis, and can be deformable by a manual force along the longitudinal axis between at least a first configuration and a second configuration. The reinforcing member can include a non-resilient material and can be deformable by the manual force along the longitudinal axis. The reinforcing member can be configured to maintain a first shape of the body when the body is in the first configuration and when the manual force is not applied to the body. The reinforcing member can be configured to maintain a second shape of the body when the body is in the second configuration and when the manual force is not applied to the body. The body can have a second maximum longitudinal length in the second configuration that is greater than a first maximum longitudinal length of the body in the first configuration.

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The above mentioned and other features of the inventions will now be described with reference to the drawings. The illustrated embodiments are intended to illustrate, but not to limit the inventions. The drawings contain the following figures:

[0015] Figure 1 is a perspective view of an embodiment of a flashing strip.

[0016] Figure 2 is a top plan view of the flashing strip of Figure 1.

[0017] Figure 3 is a front side view of the flashing strip of Figure 1.

[0018] Figure 4 is a perspective view of an embodiment of a reinforcing member of a flashing strip.

[0019] Figure 5 is a block diagram schematically illustrating a method of making a flashing strip.

[0020] Figure 6 is a perspective view of a flashing strip used to seal a junction between a corrugated roofing panel and a duct that passes therethrough.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

[0021] Embodiments disclosed herein relate to flashing strips used to flash or seal a junction or interface between construction materials and methods of manufacturing the same, although the present inventions are not limited to this application. Flashing strips can include a body and one or more reinforcing members.

[0022] To address the limitations in current flashing strips, new flashing strips and methods of making the same are described herein that incorporate a viscoelastic deformable body and one or more reinforcing members embedded at least partially within the deformable body. As used herein, a viscoelastic material refers to a liquid or solid with both viscous and elastic properties. In contrast to purely resilient or elastic materials, which strain instantaneously when stretched and just as quickly return to their original state once the stress is removed, viscoelastic materials will deform under the influence of an applied shear stress but will slowly recover (e.g., spring back) from only some of the deformation. Viscoelastic materials exhibit stress relaxation, creep, and hysteresis seen in the stress-strain curve. In some embodiments, the viscoelastic deformable body can include, for example, a vulcanized rubber, and the reinforcing member can include a non-resilient material, for example, a metal or alloy wire.

[0023] Flashing strips incorporating a viscoelastic deformable body and one or more shaping members can address the installation and cost problems associated with existing flashing strips stemming from the limited manipulability of the resilient body members. Such problems are especially burdensome during installation when an installer is required to manipulate and/or deform the resilient flashing strip into a desired configuration and then to quickly fasten the manipulated strip to an underlying material before the strip returns to its original shape. Further, the use of resilient materials in a flashing strip body limits the elongation characteristics of the flashing strip and thus, requires more material to flash a given interface or junction.

[0024] Embodiments are described below with reference to the accompanying Figures, wherein like numerals refer to like elements throughout. The terminology used in the description presented herein is not intended to be interpreted in any limited or restrictive manner, simply because it is being used in conjunction with a detail description of certain embodiments of the invention. Furthermore, embodiments of the invention can include several novel features, no single one of which is solely responsible for its desirable attributes or which is essential to practicing the inventions herein described.

[0025] FIGURES 1-3 illustrate an embodiment of a flashing strip 100. To assist in the description of the flashing strip 100, the following coordinate terms are used, consistent with the coordinate axes illustrated in FIGURE 1. A "longitudinal axis" is generally parallel to the flashing strip 100. A "lateral axis" is normal to the longitudinal axis and is generally parallel to the plane of the flashing strip 100. A "transverse axis" extends normal to both the longitudinal and lateral axes. In addition, as used herein, "the longitudinal direction" refers to a direction substantially parallel to the longitudinal axis; "the lateral direction" refers to a direction substantially parallel to the lateral axis; and "the transverse direction" refers to a direction substantially parallel to the transverse axis. [0026] The flashing strip 100 can include a body 102 extending along the longitudinal axis. The body 102 can thus include a maximum longitudinal dimension, a maximum transverse dimension, and a maximum lateral dimension. The body 102 can have a central portion 103 and first and second lateral portions 101a, 101b that are juxtaposed on opposite lateral sides of the central portion 103. In some embodiments, the lateral portions 101a, 101b can have substantially the same maximum transverse dimensions and these dimensions can be about twice as much as a maximum transverse dimension of the central portion 103. For example, the lateral portions 101a, 101b can each have a maximum transverse dimension that is between about 2 mm and about 4 mm and the central portion 103 can have a maximum transverse dimension that is between about 1 mm and about 2 mm.

[0027] As shown in FIGURE 2, in some embodiments, the lateral portions 101a, 101b can each be disposed on opposite lateral margins of the body 102. The lateral portions 101a, 101b can each have a maximum lateral dimension that is about the same as the other lateral portion. For example, the lateral portions 101a, 101b can each have a maximum lateral dimension of between about 1 cm and about 5 cm. In some embodiments, maximum lateral dimensions of the lateral portions 101a, 101b can be less than a maximum lateral dimension of the central portion 103. For example, the central portion can have a maximum lateral dimension of between about 3 cm and about 15 cm.

[0028] As discussed in further detail with reference to FIGURE 6, in some embodiments the body 102 can be generally planar but can be deformable between at least a first configuration and a second configuration to facilitate the sealing of a junction between two or more construction surfaces. For example, the flashing strip 100 can be provided to an installer on a spool and a portion of the spool can then be unrolled to form a generally planar strip (e.g., a first configuration). The unrolled portion can be severed from the spool and used to flash a junction between two construction surfaces. The shape of the flashing strip 100 as installed (e.g., a second configuration) can be different than the shape of the flashing strip 100 in the first configuration. For example, the flashing strip 100 can be generally planar in the first configuration and the flashing strip 100 can be non-planar in the second configuration. Further, as discussed in further detail below, the body 102 can comprise a deformable material such that a surface area of the flashing strip 100 changes between the first configuration and the second configuration.

[0029] In some embodiments, the body 102 can comprise a viscoelastic material, for example, a viscoelastic vulcanizate (e.g., a vulcanized material). Such a material can allow for deformation and manipulation of the body 102 during a flashing installation without the body 102 completely recoiling or springing back to its initial form during the installation. Such a material can also allow the body to be substantially stretched or elongated in the longitudinal and/or lateral directions to further facilitate installation of the flashing strip 100. For example, a flashing strip 100 can comprise a material that can be stretched up to 500% of its original form to allow the flashing strip 100 to wrap and cover a given junction to be sealed. Furthermore, such stretching can be accomplished by applying a manual force or load. In some embodiments, the body 102 can comprise a material that stretches 200% or more in the longitudinal direction when a tensile load of no more than 75 pounds per square inch is applied.

[0030] In some embodiments, the body 102 comprises a viscoelastic material formed with one or more ethylene-propylene-diene M-class ("EPDM") rubber starting materials. That is to say, an EPDM rubber can be used alone as a rubber component of the composition or can be used in combination with other rubbers of the composition. EPDM rubbers provide good aging resistance, for example, desirable resistance to ozone exposure. Such characteristics are desirable in roofing implementations where flashing strips might be routinely exposed to sunlight. Suitable EPDM rubbers for use in the body 102 are not particularly limited, and known EPDM rubbers can be used. Representative examples of commercially available EPDM rubbers are, for example, BUNA 4969, KEP 370, and the like.

[0031] Various additives can be added to the starting material(s) of the body 102, for example, extending fillers, processing fillers, reinforcing fillers, activators, and curing accelerators. Examples of suitable fillers include, for example, silica powder, aliphatic resin, clay, calcium carbonate, and napthenic oil (e.g., pale oil). Representative examples of commercially available fillers include ULTRASIL 360, BLACK 360, WINGTACK 95, NATKA 1200 CLAY, and HUBERCARB Q325. The quantity of a given filler can range from about 5 to about 300 times by weight of the rubber component(s). As clay fillers can limit the resiliency of a resultant material, in some embodiments, the body 102 can include between about 200 and about 300 parts by weight of clay per 100 parts by weight of the rubber component(s).

[0032] Any suitable activators employed for curing or vulcanization of rubbers can be employed, for example, organic peroxides, sulfur, and organic sulfur compounds. Representative examples of commercially available curing agents include WB-16 and CARBOWAX PEG. The quantity of a given activator can range from about 0.1 to about 15 parts by weight, preferably 0.2 to 5 parts be weight, per 100 parts by weight of the rubber component(s).

[0033] Also, any suitable curing agents employed for curing or vulcanizing of rubbers can be employed, for example, aldehyde ammonia compounds, sulfonamide compounds, benzothiazole compounds, guanidine compounds, and thiourea compounds. Representative examples of commercially available curing accelerators include BZX, DPTT, TBBS, and DELTA PM. The quantity of a given curing accelerator can range from about 0.2 to about 10 parts by weight, preferably 0.2 to 8 parts by weight, per 100 parts by weight of the rubber component(s).

[0034] Zinc oxide and stearic acid can optionally be used as activators. In such embodiments, the amount of zinc oxide can range from about 2 to about 10 parts by weight per 100 parts by weight of the rubber component(s) and the amount of stearic acid can range from about 0.5 to about 5 parts by weight per 100 parts by weight of the rubber component(s).

[0035] In one embodiment, the body 102 includes a viscoelastic material formed according to the recipe shown in Table 1.

Table 1

NATKA 1200 240

HUBERCARB Q325 50

Pale Oil 110

Zinc Oxide 7.6

Stearic Acid 3

WB 16 1

CARBOWAX PEG 3

BZX 1.05

DPTT 1.05

TBBS 1.4

DELTA PM 1.33

[0036] The starting material(s) and any various additives can be mixed using any suitable mixing apparatus such as a roll mixer or kneader. Components other than the activator(s) and the curing accelerator(s) can be previously mixed and the accelerator(s) and curing agent(s) can be added thereto. When mixed, the components can be placed in calibrated sheets or plies using a colander before being cured. In some embodiments, the components can be vulcanized by compression molding or roto-curing to produce the body 102.

[0037] With continued reference to FIGURES 1-3, the flashing strip 100 can also include one or more reinforcing members 111a, 111b. In some embodiments, a reinforcing member 111 can be at least partially embedded within at least a portion of a lateral portion 101. The reinforcing members 111a, 111b can be machined or processed to form a ribbon or accordion shape and can comprise a non-resilient deformable material, for example, a metal or alloy. As discussed below with reference to FIGURE 4, a suitable reinforcing member 111 can include a steel alloy, for example, a steel construction wire having a round cross-sectional shape and a diameter of between about 0.03125 inches and about 0.09375 inches. In other embodiments, a reinforcing member 111 can include a plastic, polymer, ceramic, composite, and/or organic material. [0038] The reinforcing members 111a, 111b can be deformable yet non-resilient such that they resist any recoiling of the body 102 upon deformation of the body between a first configuration and a second configuration. In this way, the reinforcing members 111a, 111b can be configured to maintain a first shape of the body 102 when the body is in a first configuration and when no manual force is applied to the body. The reinforcing members 111a, 11 lb can also be configured to maintain a second shape of the body 102 when the body is in a second configuration and when no manual force is applied to the body. That is to say, the reinforcing members 111a, 111b can allow for shaping and/or contouring of the body 102 to conform to a junction between construction surfaces to which the flashing strip 100 is being fitted.

[0039] In some embodiments, the reinforcing members 111a, 111b can optionally be bonded or adhered to the body 102 and the engagement of the body 102 and the reinforcing members 111a, 111b can facilitate manipulation and/or deformation of the flashing strip 100 during installation. In some embodiments, the reinforcing members 111a, 111b can be positioned between two uncured layers of the body 102 and the flashing strip 100 can be cured or vulcanized to embed the reinforcing members 111a, 111b within the body 102. Additionally, the reinforcing members 111a, 111b can also reinforce the lateral portions 101a, 101b such that suitable fasteners, for example, bolts, screws, nails, or rivets, can be used to secure the flashing strip 100 relative to an underlying material.

[0040] In some embodiments, the flashing strip 100 can include a coating disposed over the lateral portions 101a, 101b of the body 102 to seal the reinforcing members 111a, 111b within the body 102. For example, a liquid EPDM compound can be applied to the upper and lower faces of the lateral portions 101a, 101b to inhibit the reinforcing members from penetrating through the outer surfaces of the body 102 during use and/or processing.

[0041] FIGURE 4 illustrates an embodiment of a reinforcing member 411 depicted separate from a body of a flashing member. As discussed with reference to FIGURES 1-3, the reinforcing member 411 can be machined, formed, or otherwise processed to form a ribbon shape or accordion shape. The processed reinforcing member 411 can include alternating radiused arcs to inhibit piercing or puncturing of a flashing strip body by the reinforcing member 411. Thus, the reinforcing member 411 can be shaped to lessen the likelihood of a leak through a flashing strip and/or tearing of a flashing strip body due to a sharp surface or point of the reinforcing member 411.

[0042] With continued reference to FIGURE 4, the shape of the reinforcing member 411 also allows for deformation of the reinforcing member along the longitudinal, lateral, and/or transverse axes. For example, the reinforcing member 411 can be elongated in the longitudinal direction such that the reinforcing member 411 is straightened. Alternatively, the reinforcing member 411 can be compressed in the longitudinal direction such that a maximum longitudinal dimension of the reinforcing member decreases. Additionally, the reinforcing member 411 can be elongated and/or deformed along the transverse axis to form a non-planar shape.

[0043] FIGURE 5 is a block diagram depicting a method a method 500 of manufacturing a flashing strip, according to one embodiment. The method 500 can include the steps of providing a first layer of uncured viscoelastic material 501, providing a reinforcing member 503, providing a second layer of uncured viscoelastic material 505, and disposing the reinforcing member between at least a portion of the first layer and at least a portion of the second layer 507. Performing the method 500 can result in a flashing strip similar to the flashing strip 100 depicted in FIGURES 1-3.

[0044] Still referring to FIGURE 5, in some embodiments, the first and second layers of uncured viscoelastic material can each comprise one or more rubber components (e.g., one or more EPDM rubbers) and between about 150 and about 300 parts by weight of clay per 100 parts by weight of the rubber component(s). In one embodiment, the first and second layers of uncured viscoelastic material can each comprise a composition according to Table 1. In this way, the flashing strip formed by the method 500 can be easy to manipulate, deform, and/or elongate in the longitudinal, lateral, and/or transverse directions.

[0045] In some embodiments, the reinforcing member can be processed to form a ribbon shape, for example, as discussed above with reference to FIGURE 4. The reinforcing member provided can include a metallic wire that has been coated by a suitable adhesive, for example, CHEMLOK 250, such that the reinforcing member can be coupled to the first and/or second layers. The method 500 can further include curing the first layer and the second layer to form a vulcanizate with the reinforcing member embedded at least partially therein. The components of the flashing strip can be cured by any suitable process, for example, compression molding or roto-curing, and the resultant cured flashing strip can be rolled or spooled for transporting or storing. As discussed above, the body of the flashing strip can be coated with a sealant, for example, a liquid EPDM, to inhibit or prevent the reinforcing member from penetrating through the first and/or second layers.

[0046] Turning now to Figure 6, a perspective view of a flashing strip 600 used to seal a junction between a roofing panel 623 and a duct 621 is illustrated. The roofing panel 623 can be a corrugated roofing panel with spaced apart ridges configured to impart strength to the roofing panel 623. The duct 621 can extend through at least a portion of the roofing panel 623 resulting in a junction or interface between the duct and the roofing panel. The flashing strip 600 can be used to seal or flash the junction between the duct 621 and the roofing panel 623 to prevent the passage of fluids, for example, rain water, therethrough. Although, the flashing strip 600 is illustrated as flashing or sealing a junction between a roofing panel and a duct, those of skill in the art will appreciate that any of the flashing strips disclosed herein can be utilized in other implementations. For example, the disclosed flashing strips can be used to seal junctions between dissimilarly dimensioned roofing panels, skylights and roofing panels, pipes and roofing panels, gutters and roofing panels, expansion joints and roofing panels, bullnose interfaces, square ducts and roofing panels, and/or any other junctions between two or more construction surfaces.

[0047] The flashing strip 600 can be similar to the flashing strip 100 discussed above with reference to Figures 1-3 and can include a body 602 having a central portion and opposing lateral portions 601a, 601b. The flashing strip 600 can also include at least one reinforcing member (not shown) embedded at least partially within a portion of the body 602. The body 602 can comprise a viscoelastic material such that the flashing strip 600 can be manually deformed, manipulated, and/or elongated to form and retain different shapes and/or configurations.

[0048] The flashing strip 600 can be provided in a spool and severed therefrom for installation. For example, an installer can cut a length of spooled flashing material to form the flashing strip 600. The installer can then manipulate, deform, and/or elongate the flashing strip 600 to conform to the surface of the roofing panel 623 and the surface of the duct 621 to seal the junction therebetween. Because the body 602 comprises a viscoelastic material, the flashing strip 600 can be manipulated to closely conform to the contours of the roofing panel 623 and the duct 621 without substantial folds or other disturbances between the flashing strip and the roofing panel and duct.

[0049] In some embodiments, the flashing strip 600 can be adhered or bonded to the roofing panel 623 and/or duct 621 by a suitable bonding agent or adhesive, for example, a caulking compound commercially available from SEAL-TITE SYSTEMS, to form a water tight seal therebetween. Once the flashing strip 600 has been shaped to cover the junction between the duct 621 and the roofing panel 623, the first lateral portion 601a can be fastened to the duct 621 and the second lateral portion 601b can be fastened to the roofing panel 623. In some embodiments, the flashing strip 600 can be fastened in place by suitable driving fasteners 625 including bolts, screws, nails, or rivets. The driving fasteners 625 can extend through a reinforcing member that is embedded at least partially within the body 602 to maintain the structural integrity of the body. Further, washers 627 can optionally be disposed between driving fasteners 625 and the body 602. Representative examples of commercially available washers 627 are, for example, MASTER SEAL WASHERS available from Aztec Washer Company, and the like.

[0050] The foregoing description details certain embodiments of the devices, systems, and methods disclosed herein. It will be appreciated, however, that no matter how detailed the foregoing appears in text, the devices, systems, and methods can be practiced in many ways. As is also stated above, it should be noted that the use of particular terminology when describing certain features or aspects of the inventions should not be taken to imply that the terminology is being re-defined herein to be restricted to including any specific characteristics of the features or aspects of the inventions with which that terminology is associated. The scope of the disclosure should therefore be construed in accordance with the appended claims and any equivalents thereof.