AU783883B2 - Soaker flashing for aluminium joinery - Google Patents

Description

I

DH Ref: 1317-3AU

AUSTRALIA

PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

Name and Address of Applicant: GRANT MCGREGOR ROBERTSON 19 Ocean View Road, Milford, Auckland 1309, New Zealand Actual Inventor(s): GRANT MCGREGOR ROBERTSON Address for Service: Don Hopkins Associates Spruson Ferguson, Patent Attorneys Level 33, St Martins Tower, 31 Market Street Sydney, New South Wales 2000, Australia SOAKER FLASHING FOR ALUMINIUM JOINERY Invention Title: The following statement is a full description of this invention, including the best method of performing it known to me:- AULP3 This invention relates to improvements in and relating to flashings for aluminium joinery.

It is a known technique with aluminium window and door joinery used in building construction, to weather seal during manufacture, the mitred corner joints and screw hole penetrations in the aluminium framing (joinery) with a silicone or polysulphide sealant. When the joinery is .oo.ei installed in the wall of a building, this sealant is supposed 10 to stop water leaking through the mitre joints or holes in o• the bottom aluminium fabrication section, into the wall structure.

The use of sealant by itself to seal joints and penetrations 5 in joinery can lead to water damage in the walls of building .eo.ei into which aluminium window and door joinery is installed.

This can occur if the sealant is damaged during installation or the joint is stressed during glass or rubber seal replacement. It can also occur as the sealant loses adhesion or gets brittle as it ages.

A previous technique to avoid these problems is to fabricate individual metal sill trays to the dimensions of and to suit each joinery installation. These trays are attached to the SPEC1385 8 MARCH 2002 3 support sill framing before the joinery is fixed into the wall. Full sill trays are subject to damage during joinery installation and unless they are carefully constructed, attached and preserved they do not provide a long-term water management solution.

It is also worthy to note that it is only possible for joinery to leak at the corner joints or where there are penetrations through the aluminium channel sections to locate a mullion or joinery partition bar. As the design of a common sill tray does not stop any leakage water from running sideways along the sill tray and the exact position of the penetrations are not known until the joinery is installed in the fabricated wall, it is necessary to cover the entire sill 15 area with a sill tray to protect the wall structure from water damage.

It is therefore an object of this invention to provide a soaker flashing which is of a simple construction and which a joinery manufacturer can attach in an appropriate position to joinery when it is being manufactured or before it is installed in a fabricated wall.

SPEC1385 8 MARCH 2002 recess in the body for, in use, reception of moisture, mounting means for receiving fasteners for fixing of the body to a reveal element of the fabricated metal joinery and drainage means for, in use, enabling draining of moisture accumulated in said recess.

In a second broad aspect the invention provides a soaker flashing for attachment to a reveal of the fabricated metal joinery the soaker flashing including a body having a water receiving area, a mounting member and drainage means via which water accumulating in the water receiving area can drain.

Preferably the soaker flashing is moulded from a semi rigid plastic. In an alternative embodiment it can be pressed or folded from a corrosion resistant metal or steel which has been coated to resist corrosion.

oooo Preferably the soaker flashing is provided with an attachment flange, which enables it to be firmly attached to the reveal joinery during manufacture or before it is #go installed into the wall structure. This attachment can be oooo by suitable mechanical fasteners, e.g. by stapling or Snailing, through the flange into the typically timber reveal of the joinery.

SPE-C 1288 14 MARCII 2001 wall structure. This attachment can be by suitable mechanical fasteners, e.g. by stapling or nailing, through the flange into the typically timber reveal of the joinery.

The attachment flange is provided at a distance from a water containment part of the soaker flashing so that the attachment process will not affect water tightness. It is also constructed as part of the soaker flashing so that when the flange it is attached to the joinery, it positions the soaker flashing flat and level to aid its water containment capabilities.

In one configuration the soaker flashing is in the form of a corner. When this configuration of soaker flashing is 15 positioned at the corner of an assembled aluminium window or door, attachment will be to both the reveal and sill boards of the joinery. Leak protection will extend a short distance both vertically up the side of the joinery and also along the bottom of the joinery.

In a preferred form the soaker flashing has a raised lip or edge along three sides of the soaker flashing on a face that will be directly below the fabrication joint or penetration in the joinery. This lip or edge defines a water receiving SPEC1385 8 MARCH 2002 6 area which will allow the soaker flashing to contain small amounts of water until it can evaporate harmlessly away. The lip eliminates the necessity for the soaker flashing to be the width of the window or door opening. This is contrary to how a sill tray that is attached to the framing under the window would typically be fabricated to be.

Preferably the soaker flashing is configured to extend the full depth of the aluminium section of the joinery to which it is to be attached and that the edge of the area in which water can be contained or received that is directly behind the window facing does not have the aforementioned raised lip or edge. If the water leakage quantity is greater than the containment area of the soaker flashing can hold, the water will run forward to where there is no raised lip or edge and then run into the recess behind the joinery facing from where it can leak out of the wall in front of the cladding line.

According to a further form of the invention a side of the soaker flashing tray that does not have a lip or fold has a tongue attached to it. This tongue may be angled slightly under square downwards from the containment tray. In use this tongue engages with a recess behind the front face of the joinery to which the soaker flashing is attached. When the SPEC1385 8 MARCH2002 window is installed this tongue will be in front of the front face of the clad wall into which the joinery is positioned.

In the case of recessed joinery, the tongue will direct leaking water forward of the leading edge of any sill flashing which is installed as a normal building practice where a recessed window design is used. This lip ensures that any water running off the soaker flashing cannot run back behind the cladding or sill flashing into the wall e~e 10 construction.

ee e e When the corner soaker flashing is fitted to the corner of aluminium joinery, the water containment or receiving area will align with and be directly below the aluminium side 15 framing. It will therefore catch any water that has weather penetrated to the outer facings of the framing from either above or from the side junctions of the joinery with the wall structure. The soaker flashing will capture this water before it enters the wall structure and guide it forward of the cladding or sill flashing, out of the building.

In the following description of preferred embodiments of the invention, reference will be made to the accompanying drawings in which: SPECI385 8 MARCH2002 8 Figure 1 is a perspective illustration of a type of corner soaker flashing embodying the invention for aluminium joinery that would be attached to and below the corner joint of an aluminium window or door assembly, Figure 2 is a perspective illustration of a type of :.:'-mullion soaker flashing embodying the invention for aluminium joinery that would be attached to and below a mullion bar location screw of an aluminium window or door assembly, Figure 3 is a perspective illustration of a type of S 15 corner soaker flashing for aluminium joinery showing the position in which the soaker flashing would be attached to aluminium window or door assemblies.

Figure 4 is a perspective illustration of the mullion soaker flashing of Figure 2 showing the position in which the soaker flashing would be attached to aluminium door or window assemblies.

SPEC1385 8 MARCH 2002 9 Figure 1 of the drawings shows one form of the present invention where the soaker flashing 10 is intended to fit with the corner of window or door joinery. The soaker flashing 10 comprises a body 11. At one end of the body there is a tongue 12 which extends transverse to the plane of the body. In the preferred form of the invention this tongue 12 is angled slightly away from right angles to the main body.

.eme.: A raised lip or edge 13 extends along those edges of the body 11 which does not have tongue 12. However, as can be seen Figure 1 this raised lip or edge 13 extends at 13a over the tongue 12. The raised lip or edge 13 thus effectively defines the edges of a water containment tray 14.

S Projecting from the sides of the body opposite to those having the tongue 12 is an attachment flange 15. As can be seen in Figure 1 the flange 15 is stepped up from the surface of the lip or edge 13. A wall 15a is thus formed.

As mentioned previously the corner soaker flashing 10 can be formed in one piece from a suitable plastic material or can be fabricated by pressing or folding from a corrosion SPEC1385 8 MARCH 2002 resistance metal or steel or metal that has been coated to resist corrosion.

Figure 3 shows the soaker flashing 10 of Figure 1 in the position it would collect any water that may leak through the corner joint in the joinery and guide it away from the wall assembly to the outside of the cladding line. In this position it would also collect any water that may run down oooeo ":the aluminium reveal of the joinery and guide the water out of the wall structure.

*Figure 3 shows the aluminium profile 16 that forms together with the wooden sill 17 and reveal boards 17a of a window or door assembly. Shown at 18 is the cladding or sill flashing which is present when the aluminium window or door joinery is .:0.Oi installed into a wall construction W. The corner soaker flashing 10 is positioned as shown in Figure 3 with the tongue 12 engaged with the edge of the aluminium profile 16.

The attachment flange 15 locates against the sill 17 or reveal 17a timber of the joinery assembly. It is through this flange 15 that the soaker flashing is attached by e.g.

stapling or nailing. Thus when in position the raised lip or edge 13 of the soaker flashing will contain any water that SPEC1385 8 MARCH 2002 11 leaks on to the top of the flashing and guide the water to the tongue end of the body 11 of the soaker flashing As previously mentioned the flange 15 enables the soaker flashing 10 to be firmly attached to the joinery during manufacture or before it is installed into the wall structure. This attachment can be either by stapling or nailing through the flange 15. Because the flange 15 is located at a distance from the water containment area 14 this attachment process will not affect water tightness.

Because the flange 15 is part of the soaker flashing 10 the soaker flashing is positioned flat and level when attached thereby enhancing the water containment capabilities of the 15 soaker flashing.

Figure 2 shows another form of the soaker flashing 10 which is intended to be attached to and below a location screw for a mullion bar M of an aluminium window or door assembly (see Figure Like features of the soaker flashing of Figure 1 carry the same reference numerals. In the position shown in Figure 4 the flashing 10 will collect any water that may leak through the screw holes that locate the mullion bar M in the SPECI385 8 MARCH 2002 12 joinery and guide it away from the wall assembly to the outside of the cladding line.

The soaker flashing according to the present invention will thus ensure that any water which leaks through the mitred corners or holes in the aluminium joinery will be contained within the leak area 14 from where it can harmlessly evaporate away. If water leakage is excessive the open side of the leak area 14 enables the soaker flashing to 1 mechanically lead the moisture out of the wall structure and beyond the cladding line so that it cannot cause any problems or damage.

S Such a soaker flashing will ensure that any water which leaks through the mitred corners, or holes in the aluminium joinery, will be contained within the leak area from where it can harmlessly evaporate away. If water leakage is excessive this invention is designed to mechanically lead the moisture out of the wall structure and beyond the cladding line so that it cannot cause any problems or damage.

SPEC1385 8 MARCH 2002

Claims (33)

1. A soaker flashing for attachment to fabricated metal joinery, the soaker flashing including a body, a recess in the body for, in use, reception of moisture, mounting means for receiving fasteners for fixing of the body to a reveal element of the fabricated metal joinery and drainage means for, in use, enabling draining of moisture accumulated in said recess.

2. A soaker flashing as claimed in claim 1 wherein the body has first and second parts located substantially at right angles to one another each part having a recess, mounting means and drainage means.

3. A soaker flashing as claimed in claim 2 wherein the recess, mounting means and drainage means of o said first part are respectively connected to the recess, mounting means and drainage means of the second part.

4. A soaker flashing as claimed in claim 1, 2 or 3 wherein the mounting means includes a flange projecting from said body.

SI'EC 1288 14 MARCIH 2001 14 A soaker flashing as claimed in claim 4 wherein the flange has a mounting surface located in a first plane and spaced from a second plane in which a surface of a rim or edge located about the recess.

6. A soaker flashing as claimed in claim 4 or wherein the drainage means includes a tongue which extends from an open portion of the recess.

7. A soaker flashing as claimed in claim 6 when appendant to claim 5 wherein said rim or edge extends at two spaced apart locations along the tongue.

8. A soaker flashing as claimed in claim 5, 6 or 7 wherein the tongue has a surface which communicates with a floor of the recess.

9. A soaker flashing as claimed in claim 8 wherein the tongue surface extends substantially transverse to said first plane. A soaker flashing as claimed in any one of claims :1 to 9 wherein the mounting means is spaced from said recess.

SPEC 1288 14 MARCH 2001

11. A soaker flashing for attachment to fabricated metal joinery the soaker flashing including a body having a moisture receiving area, a mounting member whereby the flashing can be mounted in to a reveal of the fabricated metal joinery and drainage means via which moisture accumulating in the moisture receiving area can drain.

12. A soaker flashing as claimed in claim 11 wherein the moisture receiving area is formed by a surface in part surrounded by a rim or raised edge.

13. A soaker flashing as claimed in claim 12 wherein the drainage means includes a tongue extending from said surface. .o

14. A soaker flashing as claimed in claim 13 wherein ~the rim or raised edge extends along the tongue Sat spaced apart positions. i:

15. A soaker flashing as claimed in claim 13 or 14 oo i: wherein said surface is substantially flat and o*o the tongue projects substantially transverse to said surface. SI'EC 1288 14 MARCHI 2001 16

16. A soaker flashing as claimed in claim 15 wherein the tongue extends at an angle slightly less or greater that right angles to said surface.

17. A soaker flashing as claimed in any one of claims 11 to 15 wherein the mounting member is disposed away from the moisture receiving area.

18. A soaker flashing as claimed in any one of claims 12 to 17 wherein the mounting member is a flange.

19. A soaker flashing as claimed in claim 18 wherein the flange extends from said rim or raised edge. A soaker flashing as claimed in claim 18 wherein o the flange has a mounting surface which lies in a 0. plane spaced from a plane in which lies a surface of the rim or raised edge.

S*

21. A soaker flashing as claimed in claim 20 wherein the flange includes a wall which extends between said planes, said wall being spaced away from S: said moisture receiving area. SPC 12X88 14 MARCIH 2001 17

22. A soaker flashing as claimed in any one of claims 1 to 21 wherein the body includes first and second parts located substantially at right angles each part having a moisture receiving area.

23. A soaker flashing as claimed in claim 22 wherein the moisture receiving areas of each of said first and second parts are connected.

24. A soaker flashing as claimed in claim 23 wherein the rim or raised edge extends about both moisture receiving areas of the first and second parts, these being a drainage means associated with both moisture receiving areas, the drainage means being connected.

25. A soaker flashing as claimed in claim 22, 23 or 24 wherein each of said first and second parts have a mounting member.

26. A soaker flashing as claimed in any one of claims ~1 to 25 when formed in one piece from a plastics "material. SPIC 1288 14 MARCI 2001 18

27. A soaker flashing as claimed in any one of claims 1 to 25 when formed in one piece from non- corrosive metal or metal treated to be non- corrosive.

28. A soaker flashing substantially as herein described with reference to Figures 1 and 3 of the accompanying drawings.

29. A soaker flashing substantially as herein described with reference to Figures 2 and 4 of the accompanying drawings.

Fabricated metal joinery characterised in that at least one soaker flashing as claimed in any one of claims 1 to 29 is attached thereto.

31. Fabricated metal joinery as claimed in claim .wherein a soaker flashing is attached to the reveal at each of lowermost corners of the joinery.

32. Fabricated metal joinery as claimed in claim or 31 wherein at least one soaker flashing is o attached to the reveal to cover a penetration through a part of the joinery. SI'EC 1288 14 MARCIH 2001 19

33. Fabricated metal joinery as claimed in any one of claims 30 to 32 substantially as herein described with reference to the accompanying drawings Dated this 19th day of October 2005 Patent Attorneys for the Applicant/Nominated Person GRANT MCGREGOR ROBERTSON DON HOPKINS ASSOCIATES 14 MARCH 2001 SPEC 1288