Flashings are frequently used to provide weatherproofing at some weather exposed transition between different building envelope claddings (eg; tiles or other roof cladding and/or wall cladding). Frequently, for example, in a roof of a pipe or other entry (eg; chimney) through or around an otherwise weatherproofing surface needs to be flashed.

SUMMARY OF THE INVENTION The present invention recognises an advantage in a self adhesive flashing that is relatively lightweight, preferably has colour options, when being used is conformable to enable installation with little expertise and is more environmentally desirable than lead In a first aspect the present invention consists in a flashing having at least one region thereof (whether planar or of constant thickness or not) (and whether or not having each component coextensive or not with any one or more of the others) provided by a weathering layer of a flexible material, a conformable yet shape retaining layer of a mesh like, perforate or other"open" character material, and a tack retaining adhesive matrix bonding to said conformable layer and to said flexible material and (optionally) providing the flashing underside with a tack retaining adhesive surface, and, optionally, a release sheet releasable from said tack retaining adhesive surface thus to make the same available for adhesive fixing of the thus modified flashing (the release sheet having being removed) underside to an appropriate surface to be flashed.

As used herein"flexible material"in respect of the provision of the weathering layer and/or"weathering layer"covers any single material or multiple materials, whether laminated, mixed or otherwise, to provide a layer (not necessarily planar nor of constant thickness) of which an outer surface is to act as the weathering surface and

another surface of which can act as a surface to be bonded by said adhesive matrix to said conformable layer.

As used herein"adhesive matrix"or indeed any reference to adhesive bonding does not exclude sequential matrices of adhesive connecting directly or indirectly e. g. double sided adhesive sheet or tape.

As used herein"adhesive","adhesive matrix", etc, includes viscous adhesive or tape or sheet carried adhesive or the like. Such adhesive carrying structure can be laid up in a number of different ways to achieve the desired outcome which is an adhesive direct or indirect connection between the flexible material of (I) and the release sheet strip or the like of (III) and thus, upon release of the release sheet strip or the like to allow fixing to a roof or other surface to be clad. For example, a bare minimum may be a suitable tack retaining adhesive applied between the outer layer of a suitable flexible material and said conformable yet shape retaining layer, there being sufficient show through to allow over the regions of said conformable yet shape retaining layer appropriate retention of the item as a flashing optionally with adhesive also available for that purpose on any region (if any) of the flexible material not to be underlaid with said conformable yet shape retaining layer.

As used herein"show through"means not only visual show through but also (whether because of compaction, moulding, extrusion-like flow, etc.) physical showthrough.

As used herein the term"pipe, conduit or the like"is not confined, except where the context does not otherwise allow, to pipes or conduits of circular section, eg; can include electrical cables, pipes, flues, exhausts, chimneys, posts, skylights, etc.

Such flashings can be used to flash dormers into a roof, a parapet into a roof or wall, etc.

Preferably said weathering layer of a flexible material is EDPM or silicone rubber, said conformable yet shape retaining layer is an aluminium mesh and the tack retaining adhesive matrix is one or more of butyl mastic, butyl foam tape or sheet and butyl adhesive tape or sheet.

Preferably said mesh is not co-extensive with the weathering layer of EDPM or silicone rubber.

In one option said weathering layer may include a skirting member to skirt around a member to be flashed into a roof.

Preferably said weathering layer of a flexible material is of a kind capable of being coloured to match a particular roof surface and/or wall surface.

Preferably said weathering layer of a flexible material is of a sheet form (whether planar or otherwise) or has been moulded to a specific shape or is a fabricated item in part of a sheet form and/or a moulded component. In the case of a component having a moulded component adapted to surround directly, for example, a member such as a pipe, conduit or the like through a roof, such moulded component need not have associated therewith said conformable yet shape retaining layer.

Preferably the flashing is of any of the kinds hereinafter described with reference to any one or more of the accompanying drawings which depicts options, forms, methods of manufacture, etc.

In another aspect the present invention consists in a flashing, said flashing being a substantially planar member which is conformable as to shape, said flashing comprising or including a weathering layer of a flexible material, a conformable yet shape retaining layer of a mesh like, perforate or other"open" character material, and a tack retaining adhesive matrix bonding said conformable layer to said flexible material and enabling the flashing to be adhesively fixed therewith as a flashing.

Preferably said adhesive matrix has been applied to one or both of said flexible material and said conformable layer and there is"show through"of said adhesive through the openings of said conformable layer thereby to allow adhesive attachments to, (I) for example, a roofing surface or, if desired, to a release sheet (eg. siliconised paper plastics or the like) and (II) the surface of said flexible material proximate said conformable yet shape retaining layer.

Preferably said tack retainably adhesive matrix is of a butyl adhesive (e. g. double sided tape).

Preferably said flashing has been formed by associating said flexible material and said conformable material together with said adhesive matrix interposed there between.

Preferably the flashing region or the flashing in total which carries the conformable yet shape retaining layer of a mesh like, perforate or other"open" character material has been formed by the procedure: (a) applying an adhesive material to one or both of the flexible material and the conformable yet shape retaining material and bringing the same together, (b) as in (a) but with adhesive"show through"sufficient to at least assist bonding to a substrate to be flashed, (c) as in (a) or (b) but the addition of an application of adhesive on the side of the conformable yet shape retaining material away from the flexible material, (d) the application of adhesive on to the conformable yet shape retaining material on that side thereof that is to be proximate to the substrate to be flashed, reliance being placed upon"show through"of such adhesive (at least in part) through the conformable yet shape retaining material to adhere directly or indirectly to the flexible material.

Preferably any one or more said flexible material, said adhesive matrix, said conformable layer and said release sheet are of a kind as hereinafter defined or described.

In a another aspect the present invention consists in, in a flashing (whether for sealing about a pipe, conduit or the like, or otherwise), (and not necessarily planar nor of constant thickness nor form as hereafter defined). having or being a conformable shape retaining region comprising (I) a more outward or outer layer (e. g. weathering layer) of a suitable flexible material, (II) (a) (i) an adhesive layer, (ii) a conformable yet shape retaining layer, (iii) optionally, a further adhesive layer, or (II) (b) (i) a conformable shape retaining layer, and (ii) an adhesive layer, (III) a release sheet, strip or the like ("release sheet") for any exposed

adhesive.

Preferably the optional further adhesive layer is omitted.

Preferably the shape retaining layer is perforated or mesh-like.

The layer (I) is of a material cut from a sheet, moulded, fabricated from part from a sheet and/or moulded (or otherwise) and preferably is of the same material, but optionally can be a mixture of materials, ie; a different material in one part from a different material in another part.

Preferably the conformable yet shape retaining layer of (II) (a) (ii) or (II) (b) (i) is of a mesh like, perforate or other"open"character material.

Preferably such material is a metal and preferably such metal is aluminium. Other metals may be other malleable metals, eg; zinc, lead, etc.

Preferably said adhesive is such as to provide sufficient"show through"the openings of said conformable yet shape retaining layer, eg; any of the butyl adhesive forms described herein.

In some forms said flexible material provides both an outer ("upper") surface and a peripheral inner ("lower") surface and said adhesive layer provides a lower surface inwardly thereof extending to said shape retaining layer which preferably is perforate or mesh like.

Preferably said adhesive layer also"emerges"or is available to adhere to a substrate (eg; roof) through the perforations or mesh.

Preferably said layers (at least after removal of the release sheet) allow a pipe, conduit or the like ("pipe") to be passed through.

Preferably the passing through is at a zone where said flexible material can provide at least a substantially weatherproof seal with an appropriate pipe.

In still a further aspect the present invention consists in a roof flashing having a moulded weathering layer defining both a conformable region which is substantially planar in form which surrounds a spigot like form adapted to receive therethrough an upstanding member such as a pipe, conduit or the like from a roof, and an adhesive matrix providing a layer (complex or otherwise) which adheres at least to the underside of the conformable region of said weathering layer and which provides a tack retaining surface for attachment in use to a roof, and

a release sheet for the tack retaining surface of said adhesive matrix, wherein said conformable region, at least in part, is rendered conformable yet shape retaining by virtue of said weathering layer at that region being physically associated with a conformable yet shape retaining metal sheet that is mesh-like or perforate in character.

Preferably said spigot like structure is a skirted opening of any of the kinds hereinbefore and/or hereinafter described, for example, preferably is formed as part of a moulding in a suitable EPDM material and preferably is provided with one or more of the following; a) a transition from a generally elliptical form to a circular end form, b) a curved transition from the generally planar form of the conformable region into the spigot form, c) a general axis of about 20° to the vertical from said general plane of the conformable region, d) a distal end which is inclined at approximately 20 °C to said general plane of the conformable region, and e) annular sealing ridges or an annular sealing ridge at an angle of approximately 20° to said general plane of the conformable region, such ridge or ridges being inwardly directed at or adjacent the upper end regions of said spigot..

In yet another aspect the present invention consists in a roof flashing suitable for flashing a roof having a conformable region (i) conformed to or conformable to correspond to a roofing surface about an appropriate upstanding member protruding from the roof, and (ii) surrounding a skirted opening through which said upstanding member of the roof can protrude, and a said skirt opening defined in conjunction with said conformable region, the flashing being characterised in that the conformable region, prior to use, has a conformable shape retaining layer between a weathering layer which extends to provide the skirt of said skirted opening and a release sheet, said release sheet attaching to tacky show through adhesive of an adhesive matrix which connects said weathering

layer to said conformable yet shape retaining layer.

In a further aspect the present invention consists in a roof flashing for flashing a region of a roof, said flashing comprising or including a weathering layer of EPDM, a release sheet, and an adhesive matrix of a tack retaining character interposed between said weathering layer and said release sheet with at least that region of the adhesive matrix contiguous to said release sheet retaining its tack.

Preferably said adhesive matrix includes therein a layer of a shape retaining material of a mesh like, perforate or other"open"form which allows show through of adhesive of the adhesive matrix.

Preferably said conformable shape retaining layer is of an expanded aluminium mesh.

In yet another aspect the present invention consists in a roof flashing having a conformable region (I) conformed to or conformable to correspond to a roofing surface about an upstanding member protruding from the roof, and (ii) surrounding a skirted opening through which said upstanding member of the roof can protrude, the flashing being characterised in that the skirted opening is defined by a fabricated or unitary extension of a flexible and resilient layer forming a weathering layer of said conformable region and said skirt defines a passageway like opening commencing substantially in the plane of said conformable region in substantially an elliptical manner and ending with a substantially circular distal region of less diameter than at least the major axis of its said substantially elliptical commencement, the generally converging form of the skirt from said entrance to said distal region defining a general passageway axis substantially at about 20° from the vertical to the general plane of said conformable region.

In another aspect the invention is a roof flashing having a conformable region (I) conformed to or conformable to correspond to a roofing surface about an upstanding member protruding from the roof, and (ii) surrounding a skirted opening through which said upstanding member of the roof can protrude, the flashing being characterised in that the skirted opening is defined by a

fabricated or unitary extension of a flexible and resilient layer forming a weathering layer of said conformable region and said skirt defines a passageway like opening commencing substantially in the plane of said conformable region in substantially a square or rectangular manner and ending in a square or rectangular manner respectively of lesser dimensions, the skirt from said entrance to said distal region defining a general passageway axis substantially at about 20° from the vertical to the general plane of said conformable region.

In yet another aspect the present invention consists in a roof flashing having a conformable region (I) conformed to or conformable to correspond to a roofing surface about an upstanding member protruding from the roof, and (ii) surrounding a skirted opening through which said upstanding member of the roof can protrude, the flashing being characterised in that a unitary material provides a weathering layer as well as an upwardly converging horn like passageway which is said skirted opening, said conformable region being provided with adhesive which shows through a conformable layer that is shape retaining and not flexible like said weathering layer thereby enabling the conformable region to be conformed to, as well as adhered to, a said roof.

In yet another aspect the present invention consists in a roof flashing having a conformable region (I) conformed to or conformable to correspond to a roofing surface about an upstanding member protruding from the roof, and (ii) surrounding a skirted opening through which said upstanding member of the roof can protrude, the flashing being characterised in that it includes any of the features herein described with reference to any one or more of the accompanying drawings and/or any of the choices of material herein described.

In yet a further aspect the present invention consists in a flashing of any of the kinds hereinbefore described wherein said more outward or outer layer or the weathering layer is of a material coloured to an intended roof. In one preferred form said weathering layer is coloured terracotta or a colour closely matching thereto.

In still a further aspect the present invention consists in a method of flashing a pipe, conduit or the like to upstand or outstand from a support surface (preferably a roof or the like structure) which involves the operative use of a flashing with a

conformable region as hereinbefore defined and/or a flashing in accordance with the present invention.

Preferably said method is performed substantially as hereinafter described with or without reference to any one or more of the accompanying drawings.

The invention also consists in a flashed pipe, skylight, conduit or the like using the present invention method, conformable region and/or flashing.

To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.

BRIEF DESCRIPTION OF THE DRAWINGS Preferred forms of the present invention will now be described with reference to the accompanying drawings in which; Figure 1 is a plan view from the top of a form of flashing having a moulded spigot-like sleeve (not itselfunderlaid by mesh) capable of receiving and preferably self sealing about a pipe that might be passed through a roof, the larger expanse to the right being that part of the surround of the sleeve which preferably is provided upwardly of the sleeve to ensure the effecting of an adequate seal with the roof surface and to present the sleeve with its pipe receiving axis substantially vertically, Figure 2 is a view"A-A"of the flashing of Figure 1, Figure 3 is a cross section at"B-B"but shown in elevation showing the sleeve with an optional O-ring or the equivalent seal at the top most opening thereof to achieve an effective weather seal on a pipe, the sleeve being shown as preferably being formed solely from a flexible and resilient outer weathering layer preferably of EPDM or silicone rubber, Figure 4 is a variation of the form of the sleeve shown in Figure 3 showing multiple O-ring or the form structures which will allow the accommodation with minimal trimming (if any is required at all) of different pipe diameters whilst maintaining a weather seal,

Figure 5 is a view from below of a material such as that shown in Figure 6, there being shown removed on the bottom lefthand region the release sheet to reveal an expanded metal as the conformable yet shape retaining layer embedded into an adhesive providing matrix which in turn is adhered to the flexible material from which the sleeve structure of Figures 3 or 4 is preferably moulded, Figure 5 additional showing with broken lines through the release sheet the perimeter about the sleeve of the adhesive and expanded metal layers, Figure 6 is a assembly to an outer edge of the material of a flashing as shown in Figures 1 and 2, there being an outer layer of preferably EPDM or silicone rubber, a double sided adhesive butyl, an embedded expanded aluminium mesh not fully extensive so as to allow peripheral bonding unfettered on any periphery by mesh, yet enabling where there is mesh some degree of central bonding to a roof or the like surface, and a release sheet, Figure 7 shows an alternative to the material of Figure 6 whereby there might be an additional layer of an adhesive matrix or the like over the expanded metal, Figure 8 is similar to that of Figures 6 and 7 however in this case the expanded aluminium mesh has been positioned adjacent to an outer layer of preferably EPDM or silicone rubber, the adhesive matrix being applied below the mesh in this case, Figure 9 is a similar view to that of Figure 6 showing preferably a layer of a woven material (such as polypropylene, nylon or the like) in the centre of the adhesive matrix as a reinforcement thereof, Figure 10 is a similar view to that of Figure 7 but showing, by the broken line, a similar reinforcement layer to that previously described in respect in Figure 9, for simplicity Figures 9 and 10 not showing the adhesive matrix in the same speckled manner as in Figures 6 and 7, Figure 11 is a similar view to that of Figure 5 but showing a removed region of the release sheet which reveals a similar characteristic to that of Figure 5 thereunder but which has an inner or lower peripheral surface of the flashing being provided by a preferably moulded periphery of the flexible material,

Figure 12 in a manner similar to, for example, Figure 6, shows the arrangement of Figure 11 (just as Figure 6 shows the arrangement in respect of Figure 5), Figure 13A and 13B are perspective views from the underside of another preferred roof flashing, the release sheet being partially lifted to expose an expanded metal layer imbedded into an adhesive providing matrix, Figure 13B showing the show through adhesive or overlying adhesive obscuring more of the aluminium mesh.

Figure 14A and 14B are similar views to those of Figures 13A and 13B where the release sheet has been entirely removed, Figure 15 is a perspective view from above of the roof flashing shown in Figures 13 and 14, there being a moulded lip extending upwardly at the far end of the flashing and a spigot-like sleeve similar to that shown previously although differing in that the plane defining the upper rim of the sleeve is inclined to (rather than parallel to) the plane of the roof flashing, differing also in that moulded rib features are provided for around the outside of the sleeve, Figure 16 is a plan view of the roof flashing of Figures 13 through 14, Figure 17 is a side elevation of the roof flashing of Figures 13 through 16, Figure 18 is a close up view of the spigot like sleeve of Figures 13 through 17, there being shown two internal O-ring or the form structures which will allow the accommodation with minimal trimming (if any is required at all) of different pipe diameters whilst maintaining a weather seal, and also showing two external ribs integrally moulded into the sleeve to provide some guidance or assistance should trimming be required, Figure 19 is a sectional view of the sleeve shown previously in Figure 18, the side view clearly illustrating the angle of inclination the plane defining the top of the sleeve makes with the horizontal plane, Figure 20 shows a flow diagram of one of the preferred ways of manufacturing the flashing, all materials being supplied in spool form and processed continuously (the moulding of the spigot like sleeve (if to be present) may be performed subsequent to the completion of forming (not shown)), Figure 21 shows the process of Figure 20 in schematic form, in this case the mesh and butyl adhesive being supplied initially from the left, then compacted and

consolidated prior to the application of a continuous EPDM layer, there being the means to cut the continuous sheet as it immerges from the process, Figure 22 is a box flow diagram of a similar process in which the mesh and butyl adhesive supplied on spools is processed as before, then subsequently cut to length before a pre-moulded EPDM layer (whether incorporating the spigot like sleeve or not) is then adhered to the aluminium mesh and butyl substrate, Figure 23 shows the schematic layout of the process detailed in Figure 22, the mesh and butyl adhesive sheet being supplied from the left and the pre-moulded EPDM outer layer subsequently adhered or fitted to the expanded aluminium mesh butyl substrate, Figure 24 shows a planar form of flashing in accordance with the present invention, Figure 25 shows a tile roofing region and having positioned thereover the flashing of Figure 24 as it might be conformed to match the form of such roofing tiles, such confirmation preferably being performed whilst the releasable protective sheet for the tact retaining adhesive is still affixed, the release sheet then being removed if desired and the flashing affixed (although in other forms of the present invention there can be some minimal confirmation and further confirmation in conjunction with the final fitment), and Figure 26 shows the fitted flashing of Figures 24 and 25 to the roofing tiles.

In the preferred form of the present invention a roof flashing takes a form substantially as shown in Figures 13 to 19 the drawings.

In the forms of the invention of Figures 1 to 12 the spigot-like sleeve providing structure provided by the region 2 of the outer preferably mouldable resilient material (preferably EPDM or silicone rubber) 1 defines the outer periphery of the flashing to which the adhesive matrix 7 is preferably substantially co-extensive (optionally save for regions inside the perimeter 5) and showing a peripheral region 6 not overlaid or embedding the expanded mesh.

Preferably the sleeve is trimmable (if not sufficiently resilient) to accommodate different diameters of pipe e. g. if provided as a distally converging sleeve as shown, the convergence being of its passage and/or O-ring sequence, if any.

The preferred outer and weathering material is a UV resistant EPDM (eg ROYLENETM of Uniroyal, USA or ESPRENE TI of Cymatium Corp or Japan) or UV resistant silicone rubber (e. g. SILPLUSTI of General Electric, USA). Otherpossibilities are flexible PVC, SANTOPRENETM, NEOPRENETM or similar materials.

The preferred layer 7 is preferably a butyl mastic, butyl foam tape or sheet or butyl adhesive tape or sheet of eg; of Bostik or 3M.

The preferred layer 8 or 11 is preferably a metal mesh (preferably an aluminium "expanded"mesh) (preferably METEXTM of Ipsco, NZ).

The release sheet or patches or strips 13 is preferably SCOTCHCAL SCW-33TM of 3M, USA.

Preferred thicknesses of the layers are as follows- Material 1-0. 5 to 3 mm.

Material 7-0. 5 to 3 mm.

Material 8-0. 5 to 1 mm.

Material 9-0. 1 to 1 mm.

Preferably the flashing, if square or rectangular with sides A and B, has A and B in the ranges: Side A from 20 to 200 cms (most preferably 20 to 100 cms), and Side B from 20 to 200 cms (most preferably 20 to 100 cms).

Preferably the flashing, if round, oval or elliptical, has substantially corresponding dimensions (eg diameter or major axis of from 20 to 200 cms-most preferably 20 to 110 cms).

Each of Figures 9 and 10 show a woven reinforcement layer of, for example, polypropylene, nylon or the like embedded in preferably a centre of an adhesive layer, for example, two layers of double sided butyl metric adhesive tape.

Such reinforcement 15 could, for example, be embedded in the middle of the adhesive layer 10 of the arrangement shown in Figure 7 (now as shown in Figure 10) thereby reducing the prospect of any movement of the shape retaining material in to contact with the upper flexible layer.

Figure 11 and 12 shows an arrangement whereby the moulded flexible material 16 has a periphery 17 that provides a downwardly directed surface in use which borders

the adhesive periphery 18 which extends between the region 17 and the shape retaining layer 19. In the arrangement as shown a release sheet 20 need not extend over the region 17 but can very well do so should that be considered advantageous.

Figures 13A and 13B show the underside of preferred roof flashings where the release sheet has been modified from those depicted in previously shown Figures, there being a hole provided for in the sheet at the sleeve portion, allowing the flashing to be correctly fitted to the protruding pipe and surrounding roof structure prior to the release sheet being removed.

The spigot-like sleeve depicted in Figures 13A through 19 is preferably moulded in unity with outer layer (weather layer). While not shown, the present invention also envisages variants where the sleeve is moulded as a separate component to the weather layer and then subsequently adhered, using a suitable adhesive or the like, to the outer layer upon installation or prior to. The transition of the spigot to the conformable weather layer preferably takes place through curved region where the radius defining the transition is preferably greater than 2 mm but less than 200 mm (and most preferably eg; for pipe flashing less than 100 mm).

The preferred form of the spigot-like sleeve as depicted in Figures 13A through 19 optionally has both internal O-ring features as well as external rib features 21, such ribs providing some degree of visual guidance or assistance should trimming be required. The angle of inclination of the distal end of the sleeve 22 to the plane defining the roof flashing is preferably 20° or thereabouts. Upon installation this angle is thought to provide minimum elongation to the"O"rings and is believed to be aesthetically pleasing and therefore desirable appearance. In the preferred form, the internal sealing ribs or O-ring features 23 are also inclined at an angle substantially similar to that of the distal end of the sleeve.

The upstanding lip 24 shown in the preferred form of the invention (Figures 13 through 19), is preferably moulded as part of the weather layer. The primary purpose of the lip is to prevent water being driven up and over the top edge of the flashing during extreme weather conditions.

The process used to manufacture the flashing is detailed in Figures 20-23. Figure 20 details a more continuous production method in which the EPDM is supplied on a

spool as with the expanded mesh and butyl adhesive. The schematic for this process is shown in Figure 21 where the butyl adhesive spool 25 is shown to the left, the butyl adhesive having at least one release sheet preferably adhered to the underside of the adhesive sheet 26. The expanded mesh is also supplied on a spool 27, both layers coming together and being consolidated at a series of rotating rolls 28. The EPDM layer which ultimately forms the outer surface of the flashing is supplied on a spool 29 and adhered continuously to the mesh and butyl adhesive through compacting rollers shown as 30. The sheet may be further compacted or consolidated, formed and/or punched prior to a cutting operation which is shown as a box 31.

An alternative manufacture method is detailed in Figure 22 where, as before the mesh and butyl adhesive is supplied from the left but where the EPDM layer has been pre-moulded in a separate operation. The EPDM layer is adhered, manually or otherwise, to the expanded mesh and butyl adhesive once it has been cut to the required length.

Figure 23 shows the process detailed in Figure 22 in schematic form, the expanded mesh supplied on a spool 32, and the butyl adhesive with at least one release sheet supplied from below on a spool 33. As before the expanded mesh and butyl adhesive is compacted and consolidated through a series of rolls denoted by 34 prior to being cut to the appropriate length by cutting means 35. The pre-mould EPDM layer may then be adhered to the expanded mesh and butyl adhesive to form the flashing.