"A SEAL DEVICE AND METHOD OF PRODUCING SAME" This invention relates to a seal device for waterproof sealing between a non-planar surface and an elongate member projecting through that surface, and also a method of producing that seal device. The seal device is particularly suitable for sealing about a vent pipe projecting through an outer surface of a tile clad pitched roof, and it will be convenient to hereinafter describe the invention in relation to that application. It is to be appreciated, however, that the seal device is not' limited to that application. Traditionally, metal flashing has been used to waterproof seal between roof tiles and elongate members projecting therethrough, that flashing being fabricated from one or more pieces of light gauge malleable sheet material, such as lead, which is manually deformed to conform to the contour of the tiles for sealing thereto, and is sealingly connected to the elongate member such as by soldering, adhering or with fasteners such as rivets. Such flashings can provide satisfactory sealing, particularly where sealing requires unusually shaped flashing pieces. However, rigid fixing of the flashing pieces, particularly to the elongate member, limits the amount of movement which can be accommodated between the tiles and elongate member without breaking the sealing connection. In addition, a considerable portion of the flashing fabrication is usually conducted at the site of installation, with fabrication requiring considerable skill on the part of the installer to achieve effective installation. As such, fabrication and installation can be relatively time consuming and thus expensive.

In an effort to alleviate these traditional flashing disadvantages, a variety of pre-manufactured sealing devices have been developed. One type of such sealing device includes a base flange adapted to be secured to the outer surface of roof cladding and formed of a non-resilient deformable nature so that, in use, it can be deformed to match the profile of that outer surface; and a sealing sleeve of resilient material integral with the base flange and adapted to receive in sealing engagement the elongate member extending through an opening in the roof, the sealing sleeve usually being flexible to accommodate misalignment between the base flange and the

sealing sleeve. Such sealing devices are generally satisfactory when used on sheet metal clad rooves. However, their use on tile clad rooves necessitates the addition of traditional flashing to the base flange to support the seal device over the opening created by a removed tile. This is because the base flange is often not large enough to fully cover the opening and, in any event, it can be difficult to secure the base flange directly to the roof tiles in a waterproof manner. Thus, on-site fabrication and attendant disadvantages remain. Moreover, addition of flashing to the seal device results in an aesthetically unacceptable sealing of the elongate member.

It is an object of the present invention to alleviate the foregoing disadvantages through the provision of a relatively simple seal device which is particiularly suitable for sealing between an outer surface of a tile clad roof and an elongate member projecting therethrough, and also a method of producing that seal device.

With that in mind, the present invention in one aspect provides a seal device for waterproof sealing between a non-planar surface and an elongate member projecting through that surface, including: a mounting plate having an access aperture therein and being composed of metallic, non- resilient, manually deformable material, the mounting plate in device use being located in a face-to-face relation with the non-planar surface so that the elongate member projects through the access aperture, the mounting plate being deformable to conform to the contour of the surface and at least substantially retain the deformed contour; and, a sealing member waterproof mounted on the mounting plate solely adjacent the access aperture so that the mounting plate substantially projects clear of the sealing member, the sealing member having an access passageway for receiving the elongate member therethrough with the sealing member engaging the elongate member so as to waterproof seal therebetween. In another aspect, the present invention provides a method of producing a seal device for waterproof sealing between a non-planar surface and an elongate member projecting through that surface, including: forming a mounting plate

having an access aperture therethrough and being composed of metallic, non-resilient, manually deformable material, the mounting plate in device use being located in a face-to-face relation with the non-planar surface so that the elongate member projects through the access aperture, the mounting plate being deformable to conform to the contour of the surface and at least substantially retain the deformed contour; and, molding a sealing member onto the mounting plate solely adjacent the access aperture so that the mounting plate substantially projects clear of the sealing member, the sealing member having an access passageway for receiving the elongate member therethrough with the sealing member engaging the elongate member so as to waterproof seal therebetween.

This invention is described with reference to the seal device installed on an outer surface of a roof having an elongate member projecting vertically therethrough, and terms such as "upstanding" should be construed in the light of this orientation. It is to be appreciated, however, that other orientations may be equally possible and that consequential changes in terms such as that above may be necessary in the light of those other orientations for a proper understanding • of the invention.

Preferably, the mounting plate has opposed faces respectively defining an inner and outer face of the plate, and it is the inner face that faces toward the contoured surface during device use. The access aperture is preferably formed in the mounting plate and extends between the opposed faces. That aperture may be offset from a central position in the mounting plate. Preferably, the mounting plate has a connection portion with which the sealing member actually forms a mechanical connection to waterproof seal between the mounting plate and sealing member. Preferably, that connection portion extends continuously about and defines the periphery of the access aperture.

The connection portion is preferably configured to facilitate -the connection between the mounting plate and the sealing member. In that regard, the connection portion preferably at least partially outstands from the inner face of

the mounting plate. That connection portion may be a connection rim outwardly stepped from the mounting plate inner face.

Preferably, in producing the seal device, mounting plate formation includes initially cutting a mounting plate blank from a material supply sheet. That mounting plate formation preferably also includes cutting the access aperture. The cutting of the access aperture creates a peripheral edge region extending about the aperture and the connection portion is preferably provided by that edge region. The connection portion is preferably formed from the edge region either as a result of the access aperture cutting, or separately subsequent thereto such as during formation of the sealing member. Preferably, the sealing member includes a body portion that extends outwardly from the mounting plate and is arranged to sealingly engage the elongate member upon seal device installation. That body portion preferably releasably engages the elongate member, upon installation to facilitate ready removal and replacement of the seal device and elongate member. The body portion preferably sealingly engages entirely about the peripheral extent of the elongate member, at a location spaced axially outwardly of the mounting member upon seal device installation. The sealing member preferably also includes a connection portion which is secured to the mounting plate connection portion to mount the sealing member on the mounting plate. That connection is preferably permanent and, moreover, is achieved by bonding the connection portions together. Preferably, the sealing member connection portion underlies the outstanding mounting plate connection portion. Moreover, the sealing member connection portion preferably extends flush with the inner face of the mounting plate. The connection portion of the sealing member may be a connection flange which may extend in the general plane of the mounting plate when that plate is undeformed.

The sealing member is preferably composed at least partially of flexible and resilient material. Moreover, preferably, that sealing member is shaped and sized relative

to the elongate member so as to enable resilient, interfering engagement between the body portion and the elongate member thereby to waterproof seal therebetween. That flexibility also accommodates misalignment. and movement between the surface and elongate member projecting therethrough.

Preferably, in producing the seal device, the sealing member is molded in situ on the mounting plate so that the sealing member is simultaneously molded and bonded to the mounting plate. Preferably, the mounting plate is initially located relative to a mold so that the sealing member can be moldeld thereonto. That mounting plate is preferably so located that the sealing member will be molded to project from the outer face thereof. The sealing member is preferably then molded onto the mounting plate. During that molding, the body portion and connection portion of the sealing member are preferably formed integral with each other. That molding preferably produces a completed ready-to-use seal device. That completed seal device is then preferably removed from the mold for use. The following description refers to a preferred embodiment of a seal device and production method according to the present invention. To facilitate an understanding of the invention, reference is made in the description to the accompanying drawings where the seal device is illustrated in that preferred embodiment. It is to be understood that the seal device and production method are not limited to the preferred embodiment as hereinafter described and illustrated in the drawings.

In the drawings: Fig. 1 is a perspective view of a seal device according to a preferred embodiment of the present invention;

Fig. 2 is a part cross-sectional side elevational view of the seal device of Fig. 1; and.

Fig. 3 is a perspective view of the seal device of Fig. 1 during use.

Referring initially to Figs. 1 and 2, there is generally illustrated seal device 1. Device 1, includes mounting plate 2, having opposed inner face 3, and outer face 4. Mounting plate 2, is of generally quadrangular shape, and of a size

selected to overlie an opening in the non-planar surface, through which an elongate member extends. Thus, in the example application of device 1, mounting plate 2, will be square and at least large enough to overlap an opening created by a removed roof tile, and through which an elongate member extends.

Mounting plate 2, has circular access aperture 5, extending between inner and outer faces 3,4. Aperture 5, may be centrally located or, alternatively, may be offset as illustrated to provide increased versatility in accommodating various elongate member locations relative to the openings in the contoured surface.

Mounting plate 2, also has connection rim 6, extending about and defining the periphery of access ^" aperture 5. Connection rim 6, may be coplanar with the remainder of mounting plate 2. Alternatively, as in the present embodiment, connection rim 6, outstands from and extends substantially parallel to the remainder of mounting plate 2, and in particular is outwardly stepped from inner face 3. Mounting plate 2, is composed of lead sheet material, although it should be appreciated that other metals such as aluminium may be suitable depending on the intended application of device 1.

Seal device 1, also includes sealing sleeve 7, molded onto mounting plate 2. Sealing sleeve 7, includes sleeve body 8, outstanding from outer face 4, of mounting plate 2, and generally extending about and through access aperture 5. Sleeve body 7, has access passageway 9, arranged coaxial of access aperture 5. Sleeve body 8, has peripheral edge region 10, extending about access passageway 9, remote from mounting plate 2. Peripheral edge region 10, provides a sealing lip for waterproof sealing against an elongate member during use of device 1. Peripheral edge region 10, providing a sealiing lip may be formed during production of device 1. Alternatively, the sealing lip may be formed during installation of seal device 1. That may be achieved by simply cutting or otherwise removing a terminal section of sleeve body 8, so as to form a peripheral edge region 10, providing the sealing lip. That

may be particularly so with the frusto-conical configured sleeve body 8, illustrated since sleeve body 8, could be cut during seal device installation to remove an amount of terminal section sufficient to provide a sealing lip which is shaped and sized to form an effective waterproof seal with the elongate member being sealed. Sealing sleeve 7, may have a series of circumferential ribs 11, extending about sleeve body 8, for guidance during that cutting.

Sealing sleeve 7, also has connection flange 12, formed integral with sleeve body 8. Connection flange 12, extends beneath and is bonded to the underside of outstanding connection rim 6. This bonding between connection rim 6, and connection flange 12, alone provides mounting of sealing sleeve 7, on mounting plate 2. Connection rim 6, outstands from the remainder of mounting plate 2 , an amount replaced by connection flange 12, so that connection flange 12, finishes flush with inner face 3. This particular arrangement between connection rim 6, and connection flange 12, protects the bonding therebetween against damage and deteriorations during use of device 1, particularly in harsh environments. Sealing sleeve 7, is composed of a flexible and resilient, moldable material such as rubber or plastic material.

Flexibility and resilience in sealing sleeve 7, provides seal device 1, with its flexibility to accommodate misalignment and movement between device 1, and the surface and elongate member projecting therethrough. That flexibility may be facilitated and distortion of sleeve body 8, may be minimised by suitable shaping of sleeve body 8. In that regard, sleeve body 8, may be provided with one or more steps 13, or may be circumferentially pleated (not illustrated) at least adjacent mounting plate 2.

In producing seal device 1, mounting plate 2, is cut from a material supply sheet by a guilotining, stamping, punching, or similar cutting operation. Conveniently, access aperture 5, is simultaneously cut with the peripheral outline of mounting plate 2. Connection rim 6, may be left coplanar with the remainder of mounting plate 2, during this cutting operation and then subsequently deformed so as to outstand

therefrom. In that regard, connection rim 6, may be conveniently bent under forces applied to mounting plate 2, as sealing sleeve 7, is molded thereon.

Mounting plate 2, is then positioned within a suitable mold apparatus and sealing sleeve 7, produced in a single molding operation. Prior to molding, connection rim 6, may be treated with a bond promoting material so as to enhance the bond connection between connection rim 6, and connection flange 12. That bond promoting material may be applied to connection rim 6, prior to location of mounting plate 2, in the mold. To further enhance that bond connection, connection rim 6, may be provided with interruptions thereon or therein (not illustrated) . In that regard, connection rim 6, may be provided with ribs or other projections and/or grooves or other depressions formed on inner face 3, about which connection flange 12, is molded. The interruptions may be formed before, or during formation of connection rim 6.

Mounting plate 2, is positioned within the mold.so that connection rim 6, projects into a sealing sleeve mold cavity and adjacent surrounding portions of mounting plate 2, are rigidly clamped or otherwise firmly held against deformation. The mold cavity will include a recess in which connection rirα 6, is located with clearance. In this way, molding material for sealing sleeve 7, entering the recess deforms connection rim 6, by bending it into a final outstanding position, and simultaneously forms connection flange 12, within the recess adjacent connection rim 6. _^ To contain molding material forming connection flange 12, within the recess and adjacent connection rim 6, a rib and/or groove (not illustrated) may extend about connection rim 6, on inner face 3, of plate 2. As will be well recognised by those skilled in the relevant art, the mold may comprise a plurality of mold parts, together defining the mold cavity, and separable to open the mold cavity and permit location of mounting plate 2, and withdrawal of seal device 1. In that regard, the mold parts are initially separated for location of base plate 2, and a quantity of solid sealing sleeve material, such as rubber, in the open mold cavity. The mold parts are then brought together under application of an external force so as

to close the cavity. Heat is applied to the cavity, through one or more of the mold parts to soften the sealing sleeve material so that it flows through the mold cavity, including the connection flange recess to form the sealing sleeve. The mold parts are then again separated to open the mold cavity for removal of the completed seal device 1.

Referring now to Fig. 3, seal device 1, is illustrated installed on pitched roof 14, clad in tiles 15, arranged in traditional overlapped rows. Tiles 15, may be planar or profiled (as illustrated) so that roof 14, presents a non-planar outer surface. One tile 15, is removed to provide opening 16, through which elongate member 17, projects. Seal device 1, is installed so as to waterproof seal between tiles 15, surrounding opening 16, and elongate member 17. In one installation procedure of seal device 1, sleeve body 8, is initially cut as necessary so as to provide peripheral edge 10, with a sealing lip having a shape consistent with and size slightly smaller than elongate member 17. Seal device 1, is then slid along elongate member 17, with mounting plate 2, leading and the sealing lip in frictional engagement with elongate member 17. That sliding continues until inner face 3, abuts the outer surface of tiles 15, in face-to-face relation and overlies opening 16, through which elongate member 17, projects. Mounting plate -2, is then manipulated and defomred as necessary so as to lap beneath at least one tile 15, immediately above opening 16, and lap at least partially over one tile 15, at each- side and immediately below opening 16.

In an alternative installation procedure, seal device 1, is initially installed on roof 14, and elongate member 17, is then projected through access passageway 9, so as to sealingly engage with the sealing lip at peripheral edge 10.

No separate connection or sealing is required or necessary between seal device 1, and either tiles 15, or elongate member 17. However, as an additional precaution against leakage a suitable sealing or caulking compound may be applied. between mounting plate 2, and tiles 15, and between peripheral edge 10, and elongate member 17.

The seal device of the present invention is relatively

simple in both construction and installation. As such, costs of its manufacture and installation can be minimised. In particular, labour costs associated with on-site device preparation prior to installation are negligible. In a preferred embodiment of the seal device, sealing between a tile roof and an elongate member projecting through that roof is both simple and effective when using the device.

Finally, it is to be understood that various modifications and/or alterations may be made without departing from the ambit of the present invention defined in the claims appended hereto.