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Patent Searching and Data


Title:
A SEAL DEVICE AND METHOD OF MANUFACTURE
Document Type and Number:
WIPO Patent Application WO/2009/039562
Kind Code:
A1
Abstract:
The invention relates to a seal device for providing waterproof sealing between a surface (20) and an elongated member (21) which projects through the surface (20). The device includes a sealing member (11) and a mounting plate (12). The mounting plate (12) has an interior opening (13) and the sealing member (11) is moulded to a portion of the mounting plate (12) disposed about the opening (13) in a manner which secures the sealing member (11) to the mounting plate (12) and provides a waterproof seal between the sealing member (11) and the mounting plate (12). The sealing member (11) extends from the mounting plate (12) to an opening (15) through which the elongated member (21) extends.

Inventors:
SCHALLE WERNER ERNST (AU)
Application Number:
PCT/AU2008/001404
Publication Date:
April 02, 2009
Filing Date:
September 23, 2008
Export Citation:
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Assignee:
AQUARIUS RUBBER AUST PTY LTD (AU)
SCHALLE WERNER ERNST (AU)
International Classes:
E04D13/147; E04D13/14; F16L5/02
Foreign References:
US4864782A1989-09-12
GB1355517A1974-06-05
FR2672626A31992-08-14
US4526407A1985-07-02
US4265058A1981-05-05
US5018748A1991-05-28
AU778763B22004-12-23
Attorney, Agent or Firm:
PHILLIPS ORMONDE & FITZPATRICK (22 & 23367 Collins Stree, Melbourne Victoria 3000, AU)
Download PDF:
Claims:

CLAIMS:

1. A seal device for providing waterproof sealing between a surface and an elongated member which projects through the surface, the device including a sealing member and a mounting plate, the mounting plate having an interior opening, the sealing member being moulded to a portion of the mounting plate disposed about the opening in a manner which secures the sealing member to the mounting plate and provides a waterproof seal between the sealing member and the mounting plate, the sealing member extending from the mounting plate to an opening through which the elongated member can extend.

2. A seal device according to claim 1 , wherein the portion of the mounting plate disposed about the opening includes a plurality of openings through which the sealing member is moulded.

3. A seal device according to claims 1 or 2, wherein the portion of the mounting plate disposed about the opening includes a flange and the sealing member is moulded to the flange.

4. A seal device according to claim 3, wherein the flange has a free edge and includes a plurality of free-edge openings that extend through the free edge to define tab portions between each free-edge opening, at least part of the tab portions extending transverse to the portion of the flange from which they extend.

5. A seal device according to claim 4, wherein the free-edge openings are substantially equidistantly spaced apart.

6. A seal device according to claim 5, wherein the flange is formed continuously about the interior opening.

7. A seal device according to any one of claims 3 to 6, wherein the flange is shaped to define a recess into which a portion of the sealing member is moulded.

8. A seal device according to claim 7, wherein one portion of the flange extends transverse to another portion of the flange to define the recess.

9. A seal device according to claim 8, wherein the flange is formed into a generally U-shaped profile.

10. A seal device according to claim 8 or 9, wherein the flange is formed to extend in a direction away from the inner opening of the mounting plate.

1 1. A seal device according to any one of claims 3 to 10, wherein the sealing member is substantially fully moulded about the flange.

12. A seal device according to any one of claims 3 to 11 , wherein the flange has an inner surface facing inwardly toward the opening and the sealing member is moulded to cover at least a portion of the inner surface.

13. A seal device according to any one of claims 3 to 12, wherein the flange is formed integrally with the mounting plate.

14. A seal device according to claim 13, wherein the mounting plate is formed from a pliable material.

15. A method of forming a seal device which provides waterproof sealing between a surface and an elongated member, the method including securing a sealing member to a mounting plate having an interior opening by moulding the sealing member to a portion of the mounting plate disposed about the opening to provide a waterproof seal between the sealing member and the mounting plate.

16. A seal device according to claim 15, wherein the portion of the mounting plate disposed about the opening includes a plurality of openings through which the sealing member is moulded.

17. A method according to claims 15 or 16, wherein the portion of the mounting plate disposed about the opening includes a flange and the sealing member is moulded to the flange.

18. A method according to claim 17, wherein one portion of the flange extends transverse to another portion of the flange to define a recess and the sealing member is moulded into the recess.

Description:

A SEAL DEVICE AND METHOD OF MANUFACTURE

The present invention relates to a seal device for providing waterproof sealing between a surface and an elongated member which projects through that surface. The present invention also relates to a method of manufacturing a seal device.

The present invention has been developed principally for waterproof sealing between a roof surface and an elongated member in the form of a pipe, flue or conduit. It will therefore be convenient to describe the invention in relation to that form, although it should be appreciated that the invention could have wider application, such as when the surface is a wall rather than a roof, or when it is an outdoor floor.

It is a normal requirement for commercial and domestic buildings, that where a pipe or flue is required to penetrate through a roof, it is necessary to ensure that water cannot penetrate from the outside to within the roof through the opening in the roof through which the pipe or flue penetrates. This can be achieved with the use of metal flashing that is fixed to the outside roof surface through which the pipe or flue extends and a sealing member such as a flexible cone that is attached to the flashing and which seals against the outside surface of the pipe or flue to prevent water ingress to within the cone. To ensure that the flashing can be applied to a non-planar surface, such as a corrugated or tiled roof, the flashing can be made from a pliable material to allow it to be deformed complementary to the shape or profile of the surface to which it is applied.

In some arrangements, the sealing member has been bonded to the flashing with an adhesive. To ensure a successful bond between the flashing and the sealing member, the region of the flashing to which the sealing member is adhered usually first undergoes some form of surface preparation. Thereafter, the adhesive is applied to the flashing and then the sealing member is attached to the flashing by the adhesive.

There are several disadvantages associated with using adhesive to attach the sealing member to the flashing. Firstly, if the adhesive is not uniformly applied to the flashing, an incomplete seal may be created between the flashing and the sealing member, enabling water penetration through the seal. This is a particular issue where it is necessary to deform the flashing over a non-planar surface. Secondly, the adhesive bond can deteriorate over time. This might be the result of inadequate preparation of the flashing surface prior to the application of adhesive, or because the adhesive was applied incorrectly or was not allowed to cure under the correct conditions. Adhesive bond failure might also be the result of weathering, or it might occur as a result of the bond region being subjected to excessive mechanical force, i.e. wind loading or hail.

It would be desirable to overcome or at least alleviate one or more of the disadvantages associated with the prior art.

According to the present invention there is provided a seal device for providing waterproof sealing between a surface and an elongated member which projects through the surface, the device including a sealing member and a mounting plate, the mounting plate having an interior opening, the sealing member being moulded to a portion of the mounting plate disposed about the opening in a manner which secures the sealing member to the mounting plate and provides a waterproof seal between the sealing member and the mounting plate, the sealing member extending from the mounting plate to an opening through which the elongated member can extend.

According to the present invention there is also provided a method of forming a seal device which provides waterproof sealing between a surface and an elongated member, the method including securing a sealing member to a mounting plate having an interior opening by moulding the sealing member to a portion of the mounting plate disposed about the opening to provide a waterproof seal between the sealing member and the mounting plate.

By moulding the sealing member to the mounting plate, the use of a separate adhesive can be eliminated because the mounting plate is configured to mechanically interlock with the sealing member.

The mounting plate is usually a generally planar or flat plate, although it can be profiled complementary to the surface of the roof or other substrate to which it is fixed. For example, the mounting plate could be profiled to rest flush against a tiled corrugated roof surface, or the plate can be pliable so that it can be formed on site to the appropriate profile.

In a preferred embodiment, the portion of the mounting plate disposed about the opening includes a plurality of openings through which the sealing member is moulded. Preferably, the openings are equidistantly spaced apart.

The mounting plate may include both a flange and a body. The body, in use, at least partially overlies the surface to which the seal device is attached. In a preferred arrangement, the flange extends transverse to, or is upstanding from the body portion and for example, the flange could extend upwardly and away from the body at any suitable angle. In a preferred arrangement, the flange extends initially away from the body at about 90° to the body.

The moulded connection between the flange and the sealing member can be achieved in any suitable manner. Preferably there is a waterproof mechanical interlock between the sealing member and the flange and in one preferred arrangement, the flange is shaped to define a recess into which a portion of the sealing member can be moulded. In this arrangement, by moulding a part of the sealing member into the recess, a mechanical interlock is formed between the flange and the sealing member.

The flange recess is preferably formed by one portion of the flange extending transverse to another portion of the flange. This can be achieved by folding a portion of the flange over itself. Preferably, the flange is folded into a generally U-shaped profile, although alternative profiles which define a recess are acceptable. Thus the recess could be V-shaped, or otherwise shaped.

In the preferred arrangement, the flange extends fully about the interior opening of the mounting plate. In a preferred arrangement, the flange continues uninterrupted about the interior opening, although in one arrangement, the flange includes a plurality of openings. Preferably the openings are formed through the flange substantially equidistantly spaced apart. The openings can be formed completely within the flange, or can extend through a free edge of the flange. It is also possible to have a plurality of openings both completely within the flange and extending through a free edge of the flange. Where the openings extend through the free edge of the flange, they are preferably formed part circular, although the circumferential extent of the openings can vary, as can the circumferential extent of the portions which remain between the openings. In that arrangement, the flange includes a portion which extends from the body of the mounting plate and tab portions between the openings. The tab portions can be folded over to define the recess into which the sealing member can be moulded. The openings can help to promote the flow of moulding material into the recess when the sealing member is moulded to the mounting plate.

Where the flange is folded over, preferably it is folded in a direction away from the inner opening of the mounting plate.

Where the openings are formed fully within the flange, the sealing member can be moulded to extend or bridge through the openings so as to form a mechanical interlock with the flange.

In an alternative embodiment, a plurality of openings may be provided in both the mounting plate and in the flange about which the sealing member can be moulded to provide a mechanical interlock between the mounting plate and the sealing member.

The flange is preferably formed integrally with the mounting plate. Thus the mounting plate would normally be formed from a sheet metal, and the flange can be a portion of that metal sheet. Preferably the mounting plate and flange is formed from a pliable material.

It is preferred that the sealing member is substantially fully moulded about the flange. In one embodiment, the sealing member is moulded about the flange and is in resting contact with a surface of the mounting plate which is adjacent the flange.

For a better understanding of the invention and to show how it may be performed, embodiments thereof will now be described, by way of non-limiting example only, with reference to the accompanying drawings.

Figure 1 shows an exploded isometric view of one embodiment of the seal device according to the present invention.

Figure 2 shows one embodiment of the seal device according to the present invention installed on a roof.

Figure 3 shows a sectioned view of one embodiment of the seal device according to the present invention.

Figure 4 is an enlarged view of the flange region of the seal device shown in Figure 3.

Figure 1 shows a seal device 10 according to the present invention. The seal device 10 includes a sealing member 11 and a mounting plate 12.

The mounting plate 12 can be of any suitable shape or size. However, typically the mounting plate 12 will be of square or rectangular shape, and will be large enough to cover an opening through which an elongated member is required to extend.

The mounting plate 12 has an interior opening 13. The interior opening 13 is shown centrally located of the mounting plate 12, although it may alternatively be offset with respect of the centre of the mounting plate 12 as required. The interior opening 13 is shown as having an elliptical shape, but it is also possible for the opening to be circular, square, or any other appropriate shape.

The mounting plate 12 can be manufactured from a variety of materials, although it is preferable that a pliable material be used so that it can be deformed during installation to conform to the profile of a non-planar surface. The material for the mounting plate 12 should also be weather resistant. Thus, for example, the mounting plate 12 could be manufactured from sheet metal composed of aluminium or galvanised steel.

The sealing member 1 1 has a body 14 which, when assembled to the mounting plate 12, extends from the mounting plate 12. The body 14 terminates in a first opening 15 through which an elongated member can extend when the seal device 10 is installed on a surface, such as a roof. The sealing member 1 1 has a second opening which is not shown in Figure 1 , but which is generally opposite the first opening 15.

The mounting plate 12 also has a body 16, from which a flange 25 (to be described later herein) extends.

Figure 2 shows the seal device 10 fixed in place on a roof 20 and with an elongated member 21 extending through the opening 15 of the sealing member 1 1. In Figure 2, the sealing member 1 1 is fixed to the mounting plate 12 in a waterproof manner, while the mounting plate 12 is deformed to define a step 22 to conform to the profile of the tiled roof 20.

Figure 3 shows in side cross-section, the arrangement of Figure 2 but without the roof 20 and the step 22 being illustrated. Thus, Figure 3 shows the elongated member 21 extending through the sealing member 1 1 and the mounting plate 12 and into a roof space 23. The elongated member 21 extends through the first opening 15 of the sealing member 1 1 , and through the second opening 24, which is generally opposite the first opening 15. Likewise, the elongated member 21 extends through the interior opening 13 of the mounting plate 12.

The edge of the interior opening 13 of the mounting plate 12 is formed by a flange 25 which extends from the body 16 of the mounting plate 12. In the

illustrated embodiment of Figure 1 , the flange 25 defines a plurality of tab portions 26 separated by free-edge openings in the form of notches 27. Reference will now be made to Figures 3 and 4, which show in more detail, the flange 25 and the tab portions 26 of the mounting plate 12.

The flange 25 extends generally perpendicular to the plane of the body 16 of the mounting plate 12. The tab portions 26 are folded over, so that they extend transverse to the portion of the flange 25 from which they extend, and in the orientation shown, the ends of the tab portions 26 generally point towards the mounting plate 12. It is to be noted that the shape of the flange 25 and tab portions 26 shown in Figures 3 and 4 is an ideal illustration, and it is likely that in practice, the shape of the flange 25 and the tab portions 26 may be less perfectly formed.

The step of moulding the sealing member 11 to the mounting plate 12 ensures that the rim 30 flows fully about the flange 25 and the tab portions 26 and fills the space between them and the mounting plate surface, thus providing a secure mechanical interlock between the sealing member 11 and the mounting plate 12. The moulding step additionally ensures that there is complete waterproof engagement between the rim 30 of the sealing member 1 1 and the flange 25. Moreover, by moulding the sealing member 1 1 to the mounting plate 12, advantageously there is no requirement for adhesive to be employed and thus the problems and added expense associated with the use of adhesive can be avoided.

By forming the flange 25 in the manner shown in Figures 3 and 4, the tab portions 26 can securely mechanically lock the sealing member 1 1 to the mounting plate 12. This is achieved by moulding the base rim 30 of the sealing member 1 1 about the flange 25 and the tab portions 26 and as shown in Figures 3 and 4, a portion 31 of the rim 30 is captured between the flange 25, the tab portions 26 and the facing surface of the mounting plate 12. As will be apparent from Figure 1 , this mechanical interlock will occur completely about the entire opening 13.

Figure 4 shows the rim 30 flush against the facing surface of the body 16. In practice, a gap may exist between the surface of the body 16 and rim 30, although the moulding process can minimise that gap. The existence of a gap is acceptable, given that the rim 30 engages the flange 25 in a waterproof manner, so precluding ingress of water past the flange 25.

It will be appreciated by a person skilled in the art, that by manufacturing the mounting plate 12 from a pliable and thin metal sheet material, the flange 25 and the tab portions 26 can easily be formed by punching or stamping and then deformed into the shapes shown in Figures 3 and 4. Finger pressure could be employed to deform the flange 25 and tab portions 26, or more preferably, it would be part of a machine process either during or following punching or stamping.

The notches 27 can facilitate folding over of the tab portions 26.

The sealing member 11 can be manufactured from a variety of materials, although it is preferably of a flexible polymeric material such as rubber or plastic. This enables the sealing member 1 1 to accommodate movement and/or misalignment of the elongated member 21 within the sealing member 1 1.

The sealing member 1 1 can be moulded into a variety of suitable shapes, although it is preferable that the sealing member 1 1 be moulded into the shape of a truncated cone as illustrated. The shape can be such that the plane of the first opening 15 is not parallel to the plane of the second opening 24. The purpose of this configuration is to accommodate the installation of the seal device 10 on a roof, where the elongated member 21 extends vertically whilst the roof is slanted at some angle with respect to the vertical.

The sealing member 1 1 is provided with at least one, and preferably a plurality of surface markings 32 (Figure 1 ) which are disposed on the exterior surface of the sealing member 1 1. These are to provide a guide for cutting away a section of the sealing member 1 1 , such as during installation of the seal

device, for the accommodation of an elongated member of a particular size.

Preferably, the surface markings take the form of circumferential ribs that sit proud of the adjacent surface, but they can take any other appropriate form of protrusion, depression or marking.

To manufacture the seal device, the mounting plate 12 can be cut from stock material such as metal sheet either by stamping, punching or some other suitable cutting operation. The interior opening 13 and corresponding flange 25, tab portions 26 and notches 27 are preferably formed during the cutting operation. The plurality of tab portions can then be deformed with respect to flange 25.

The next stage in manufacturing the seal device 10 is to mould the sealing member 11 onto the previously formed flange 25. The mounting plate 12 is positioned within a suitable moulding apparatus and the sealing member 1 1 is moulded from suitable moulding material in a single moulding operation.

It is to be noted that Figure 4 shows the base rim 30 extending only slightly down the interior surface 33 of the flange 25. In practice, the material of the sealing member 11 may extend further, or even fully along the interior surface 33. This can provide for a more secure mechanical interlock between the rim 30 of the sealing member and the flange 25 and can improve the waterproofing between the sealing member 11 and the mounting plate 12.

It is also to be noted that the thickness of the wall of sealing member 1 1 within the vicinity of tab portions 26 can be larger or smaller than what is shown in Figure 4. For example, if the mounting plate material is particularly thin or pliable, the step of moulding sealing member 11 to mounting plate 12 may cause excessive deformation of tab portions 26, in which case a smaller wall thickness may be desirable.

The invention described herein is susceptible to variations, modifications and/or additions other than those specifically described and it is to be

understood that the invention includes all such variations, modifications and/or additions which fall within the spirit and scope of the present disclosure.