Note: Descriptions are shown in the official language in which they were submitted.
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ELASTOMERIC FLASHING ASSEMBLY AND
METHOD FOR SAME
COPYRIGHT NOTICE
A portion of the disclosure of this patent document contains material that is
subject to copyright protection. The copyright owner has no objection to the
facsimile reproduction by anyone of the patent document or the patent
disclosure, as
it appears in the Patent and Trademark Office patent files or records, but
otherwise
reserves all copyright rights whatsoever. The following notice applies to the
software and data as described below and in the drawings that form a part of
this
document: Copyright Marvin Lumber and Cedar Company, d/b/a Marvin Windows
and Doors; Warroad, MN. All Rights Reserved.
TECHNICAL FIELD
This document pertains generally, but not by way of limitation, to flashing
and moisture diversion for fenestration units.
BACKGROUND
Fenestration units are installed within rough openings (provided by rough
opening frames) in buildings. The interface between the fenestration unit
(e.g., a
window assembly, door assembly or the like) and the rough opening frame
provides
location for the ingress of moisture to the building. Flashing is used in
rough frame
openings to resist the ingress of moisture.
In some example, flashing includes one or more rigid members that are cut
or formed to fit a rough opening. The rigid members are assembled together and
installed in the rough opening. The fenestration unit is installed in the
rough
opening with the assembled rigid members interposed between the rough opening
frame and the frame of the fenestration unit. The one or more rigid members
are
assembled together at one or more seams. For instance, a lineal central member
is
coupled at its ends with left and right hand corner components. The assembled
rigid
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members are then installed within the rough opening, for instance along the
sill and
first and second uprights of the rough opening frame.
In other examples, flexible wrap is coupled along the rough opening frame
along the sill and first and second uprights. The flexible wrap includes a
pleated
surface (e.g., a pleated membrane) that correspondingly provides for a rough
discontinuous (broken) surface when installed in the rough opening. The
flexible
wrap is stretched during installation to fit within the rough opening and
along a wall
panel surrounding the rough opening (e.g., the exterior wall around the rough
opening).
OVERVIEW
The present inventors have recognized, among other things, that a problem
to be solved includes removing seams, wrinkles, pleats or the like from a
flashing
assembly to minimize the ingress of moisture around a fenestration unit or a
rough
opening. In an example, the present subject matter provides a solution to this
problem, such as by providing a flashing assembly including an elastomeric
film
having a rough opening panel and a wall flange coupled with the rough opening
panel. A panel support substrate is coupled along the rough opening panel. The
panel support substrate provides a continuous planar surface to the rough
opening
panel.
In an installed configuration the rough opening panel is coupled along the
rough opening frame and the wall flange is coupled along the wall panel
surrounding the rough opening. The continuous planar surface of the rough
opening
panel (e.g., of the panel support substrate) within the rough opening
facilitates the
diversion of moisture from beneath and around the fenestration unit toward the
wall
flange of the elastomeric film along the wall panel. The panel support
substrate
(e.g., a polymer or the like) provides the continuous planar surface from end
to end
of the assembly and edge to edge (interior to exterior) without any seams.
Further,
wrinkles, pleats and the like are similarly absent (entirely absent or
significantly
minimized) from the continuous planar surface to facilitate diversion of
moisture
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toward the wall flange and away from the rough opening. Accordingly, moisture
is
consistently and reliably diverted toward the wall panel and the exterior
without
pooling along and between wrinkles and pleats and without ingress through
seams.
The present inventors have further recognized that another problem to be
solved includes removing wrinkles, pleats or the like from a flashing assembly
that
arise during manipulation of pliable flashing or are intentionally
incorporated into
the flashing to promote flexibility. Surface features such as wrinkles, pleats
or the
like provide discontinuities in the surface that allow for the pooling and
retention of
moisture between the flashing and the fenestration unit. Additionally,
wrinkles and
pleats are more pronounced (bunched) at rough opening frame corners and along
the
wall panel adjacent to the corners. Wrinkles and pleats fill the rough opening
and
accordingly decrease its dimensions. In some examples, the installation of a
fenestration unit within the decreased rough opening requires significant
labor to
mechanically fit the unit within the opening. Further, installation within the
decreased opening may tear the flashing and frustrate the diversion of
moisture
intended with the flashing.
In another example, the present subject matter provides a solution to this
problem, such as by providing a flashing assembly including an elastomeric
film
having a rough opening panel and a wall flange. A panel support substrate is
coupled along the rough opening panel to provide a continuous planar surface
for
water diversion as described herein. Additionally, the panel support substrate
ensures the rough opening panel has an elastomeric characteristic greater than
that
of the wall flange portion of the elastomeric film. The panel support
substrate still
maintains the elastomeric film in a pliable form, but allows the rough opening
panel
to lay in the planar configuration within the rough opening without wrinkling
or
pleating. In contrast, the wall flange with the lower elastomeric
characteristic
(without the panel support substrate) is more pliable and readily stretches
around the
wall panel at the corners of the rough opening frame. The wall flange lays
substantially flat along the wall panel (it is stretched and not bunched) and
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accordingly provides a good interface for building wrap, decorative wall
coverings
(stucco, siding or the like).
This overview is intended to provide an overview of subject matter of the
present patent application. It is not intended to provide an exclusive or
exhaustive
explanation of the invention. The detailed description is included to provide
further
information about the present patent application.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings, which are not necessarily drawn to scale, like numerals may
describe similar components in different views. Like numerals having different
letter suffixes may represent different instances of similar components. The
drawings illustrate generally, by way of example, but not by way of
limitation,
various embodiments discussed in the present document.
Figure 1 is an exploded view of an exemplary building including a rough
opening, an elastomeric flashing assembly, and a fenestration unit.
Figure 2 is an exploded view of an elastomeric flashing assembly,
according
to an example.
Figure 3 is a perspective view of the elastomeric flashing assembly of
Figure
2 in a folded configuration, according to an example.
Figure 4 is a perspective view of the exemplary elastomeric flashing
assembly
of Figure 2 installed within a rough opening.
Figure 5 is a cross section of an elastomeric flashing assembly in an
installed
configuration interposed between a fenestration unit and a rough
opening frame, according to an example.
Figure 6 is a block diagram of an exemplary method of coupling an
elastomeric flashing assembly along a rough opening frame.
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DETAILED DESCRIPTION
Described herein are various configurations of devices and methods of a
flashing assembly, such as an elastomeric flashing assembly. The following
examples and drawings illustrate the subject matter to enable those skilled in
the art
to practice the subject matter described in the following detailed
description.
Portions and features of some examples may be included in, or substituted for,
those
of other examples.
Figure 1 illustrates an exploded view of a building 100, an elastomeric
flashing assembly 102, and a fenestration unit 104. The exemplary building 100
includes a wall panel 106 on the exterior (or optionally the interior) of the
building
100. In one example, the wall panel 106 includes a vapor barrier installed on
the
building 100. A rough opening 108 is included in the wall panel 106, for
instance,
the rough opening 108 includes, but is not limited to, a rough opening 108 cut
into
the wall panel 106.
The rough opening 108 includes a rough opening frame 110 surrounding the
rough opening 108. The rough opening frame 110, for example, extends
substantially perpendicular of the wall panel 106 toward the interior of the
building
100 (or exterior depending on the desired installation direction) and provides
a
support surface for installation of a fenestration unit 104 within the rough
opening
108. For instance, the rough opening frame 110 includes a frame sill 112
(located
along the bottom of the rough opening 108), a left upright 114, a right
upright 116,
and a header 118 (located along the top of the rough opening frame 110). A
frame
corner 120 is located at each junction between the frame sill 112, the left
upright
114, the right upright 116, and the head 118. Optionally, the frame sill 112
includes
a downward slope from the interior side to the exterior side of the building
100. For
instance the slope includes an angle of 1 to 10 degrees to direct moisture
toward the
exterior of the building 100. The fenestration unit 104 is installed within
the rough
opening frame 110, and in at least some instances, fastened to the rough
opening
frame 110 to retain the fenestration unit 104 on the building 100.
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The fenestration unit 104 includes a fenestration unit frame 122 having a
jamb 124. In one example, the fenestration unit 104 includes one or more
window
panes 126. The window panes 126 are optionally supported within window sashes
128 coupled to the fenestration unit frame 122. The window sash 128 is fixedly
or
moveably attached to the fenestration unit frame 122. In one example, the
fenestration unit 104 includes a door assembly. The door assembly includes a
door
jamb, a header, a sill, and a door. The door can optionally include a window
pane
126. Accordingly, the elastomeric flashing assembly is applicable for use with
various items installed within the rough opening 108 including, but not
limited to,
fenestration units 104, door assemblies, or the like.
The example elastomeric flashing assembly 102 shown in Figure 1 is
configured for installation within the rough opening 108. As shown in Figure
1, the
elastomeric flashing assembly 102 is coupled along the frame sill 112. For
instance,
a rough opening panel 130 of the elastomeric flashing assembly 102 is coupled
along the frame sill 112, and a wall flange 132 of the elastomeric flashing
assembly
102 is coupled along the wall panel 106. The rough opening panel 130 includes
a
panel support substrate (shown in Figure 2 and described herein) having a
substantially planar surface along the rough opening frame 110 (e.g., frame
sill 112,
left upright 114, and right upright 116). The substantially planar surface
facilitates
the diversion of moisture from beneath and around the fenestration unit 104
toward
the wall flange 132 along the wall panel 106. The elastomeric flashing
assembly
provides a contiguous (continuous) water proof barrier for preparation of at
least the
frame sill 112 of the rough opening 108 for the installation of the
fenestration unit
104 or a door.
Figure 2 is an exploded representation of an exemplary elastomeric flashing
assembly 102. The elastomeric flashing assembly 102 includes a corresponding
length and width to fit a desired particular rough opening 108. For instance,
the
elastomeric flashing assembly 102 is provided as a lineal component cut to a
desired
length or is pre-fabricated to one or more lengths. Figure 2 shows a length of
the
elastomeric flashing assembly 102 for illustration purposes.
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. ,
The elastomeric flashing assembly 102 includes an elastomeric film 200
having a front edge 201 and a back edge 203. The elastomeric film 200 is
continuous from the first end to the second end. The elastomeric film 200
includes
the wall flange 132 and the rough opening panel 130 coupled together (as
separate
or integral components). In one example, the wall flange 132 of the
elastomeric
film 200 is coupled to the rough opening panel 130 by a wall flange joint 208.
As
shown in Figure 2, a panel support substrate 204 is laminated along the upper
surface of the rough opening panel 130.
In one example, the elastomeric film 200 includes an optional sill dam 202
(shown in broken lines) extended from the rough opening panel 130. The sill
dam
202 is coupled to the rough opening panel 130 by a sill dam joint 210 (as
separate or
integral components). In another example, a sill dam substrate 206 is
laminated to
the lower surface of the sill dam 202.
The support substrates for the respective rough opening panel 130 and the
sill dam 202 are resistant to deformation, such as stretching, as described
herein.
For instance, the panel support substrate 204 anchors the rough opening panel
130
of the elastomeric film 200 against deformation relative to the wall flange
132 of the
elastomeric film 200 (i.e., the wall flange remains relatively deformable
compared
to the rough opening panel). Similarly, the sill dam substrate 206 anchors the
sill
dam 202 from deformation in a corresponding manner to the rough opening panel
130 with the panel support substrate 204. For instance, the rough opening
panel 130
includes a first elastomeric deformation characteristic. The wall panel 132
includes
a second elastomeric deformation characteristic that is lower than the first
elastomeric deformation characteristic. The panel support substrate 204
includes a
third elastomeric deformation characteristic lower than the first elastomeric
deformation characteristic, but greater than the second elastomeric
deformation
characteristic. Accordingly, the wall flange 132 is more pliable than the
rough
opening panel 130 (at least with regard to stretching) because of the
lamination of
the panel support substrate 204 to the elastomeric film 200 along the rough
opening
panel 130. As described herein, the wall flange 132 stretches over the wall
panel
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106 as the rough opening panel 130 is fit along the rough opening frame 110
(e.g.,
the wall flange 132 stretches to lay over the wall panel 106 at least at the
frame
corners 120 where the rough opening panel 130 is creased or folded).
The elastomeric deformation characteristic (discussed further herein)
includes, but is not limited to, Young's modulus (or the inverse of it),
compliance
(inverse of stiffness) such as the ratio of strain to stress, durometer,
industry or
governing standards for pliability or deformation or the like. Where a
characteristic
of pliability (as opposed to stiffness or Young's modulus) is the elastomeric
deformation characteristic the labeled characteristics herein (e.g., first,
second and
third elastomeric deformation characteristic) are inversed relative to each
other.
The elastomeric film 200 is sized and shaped to fit the rough opening 108.
For instance, the rough opening panel 130 has a width of 1 to 12 inches, for
instance
4.25 inches. The wall flange 132, in another example, has a width of 1 to 12
inches,
for instance 2.75 inches. In one example, the optional sill dam 202 includes a
width
of 0.50 to 4 inches, for instance 1.50 inches in one example. The elastomeric
film
200 has a thickness that permits the elastomeric film to remain pliable (e.g.,
for
fitting within the rough opening frame and folding at corners), such as 0.006
inches
to 0.125 inches. In one example where the elastomeric film 200 includes the
sill
dam 202, the elastomeric film 200 is thicker along the sill dam 202. For
instance,
the sill dam 202 includes an elastomeric film 200 that is twice as thick as
the
elastomeric film 200 of the rough opening panel 130.
The elastomeric film 200 is constructed with a material including, but not
limited to, a synthetic rubber, butyl rubber, asphalt free rubber, or the
like. For
instance, the elastomeric film 200 includes, in an example, a butyl film or
tape. In
one example, the elastomeric film 200 includes a Young's modulus of 160 psi,
210
psi, or any value in between. In another example, the elastomeric film 200 is
tacky.
For instance, the elastomeric film 200 is intrinsically tacky or includes an
adhesive
on one or both sides of the elastomeric film 200 for adhesion to one or more
of the
wall panel 106, the rough opening frame 110, the fenestration unit 104 or the
like.
The elastomeric film 200 is water resistant and provides a barrier against the
ingress
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of moisture through the rough opening 108 in an installed configuration (Shown
in
Figure 4). In other examples, the elastomeric film 200 is resistant to ultra-
violet
radiation to mitigate degradation of the material of the elastomeric flashing
assembly 102 as a result of exposure to sunlight.
The rough opening panel 130 is configured to couple along the rough
opening frame 110. In the example shown in Figure 2, the rough opening panel
130
includes the panel support substrate 204 located on the upper surface of the
elastomeric film 200 and includes a (optional) tacky surface on the lower
surface of
the elastomeric film 200. The tacky surface adheres the rough opening panel
130 to
the rough opening frame 110, specifically the frame sill 112 and at least a
portion of
the left upright 114, the right upright 116, or any combination thereof. As
previously
stated, the rough opening panel 130 includes a first elastomeric deformation
characteristic according to the lamination of the panel support substrate 204
and the
elastomeric film 200. The panel support substrate 204 constrains deformation
of the
elastomeric film 200 along the rough opening panel 130 of the elastomeric
flashing
assembly 102. For instance, a first elastomeric deformation characteristic of
the
rough opening panel 130 is greater than that of the second elastomeric
deformation
characteristic of the wall flange 132 because of the panel support substrate
204. In
other words, the panel support substrate 204 anchors the rough opening panel
130 of
the elastomeric film 200 against deformation relative to the wall flange 132
of the
elastomeric film 200. That is to say, the panel support substrate 204 stiffens
the
rough opening panel 130 with regard to stretching or the like and reduces
wrinkling
along the rough opening panel 130.
When installed the rough opening panel 130 (with the panel support
substrate 204) presents a planar, smooth surface to minimize (e.g., eliminate
or
decrease) pooling of water and improve the fit of the fenestration unit 104
with the
rough opening frame 110. The panel support substrate 204 is constructed with a
pliable (folds, creases or the like) material having a third elastomeric
deformation
characteristic lower than the first elastomeric deformation characteristic,
but greater
than the second elastomeric deformation characteristic. For instance, the
panel
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support substrate 204 is constructed from a material, including but not
limited to, a
polymer sheet, butyl, foil, metal coil sheet, aluminum, copper, galvanized
steel or
iron, biaxially oriented polyethylene terephthalate, or the like. The panel
support
substrate 204 includes, but is not limited to, a thickness between around
0.006" and
0.0625". In one example, the panel support substrate 204 is sufficiently
pliable to
include a minimal bend radius at the frame corner 120. The minimal radius
provides
clearance to accommodate the installation of the fenestration unit 104 within
the
rough opening 108 having the elastomeric flashing assembly 102 installed. For
instance, the panel support substrate 204 includes a bend radius between 0.006
inches and 0.50 inches. On the interior face (e.g., upper surface) of the
rough
opening panel 130, the panel support substrate 204 provides, for instance, a
smooth
(e.g., non-tacky) surface that facilitates the installation of the
fenestration unit 104.
In one example, the material of the panel support substrate 204 is abrasion
resistant.
For instance, the panel support substrate 204 is durable enough to withstand
abrasion and shear caused by installation of the fenestration unit 104.
The wall flange 132 is coupled to the rough opening panel 130 of the
elastomeric flashing assembly 102 by a wall flange joint 208. The wall flange
joint
208 includes the elastomeric film 200, in one example. Optionally, the wall
flange
joint 208 includes a relief in the elastomeric film 200. For instance, the
wall flange
joint 208 includes, but is not limited to, a notch, crease, groove, scoring
line, or the
like. The wall flange joint 208 acts as a hinge for the wall flange 132 and
permits
application of the wall flange 132 to the wall panel 106 of the building 100
while
the rough opening panel 130 is coupled with the rough opening frame 106. The
wall
flange 132 is deformable into a planar configuration and is coupled along the
wall
panel 106 surrounding the rough opening frame 110 (e.g., the installed
configuration). The deformable character of the wall flange 132 (e.g.,
stretchability)
is provided by the elastomeric deformation characteristic of the wall flange
material.
For instance, as previously stated the wall flange 132 has a second
elastomeric
deformation characteristic lower than the first elastomeric defamation
characteristic
of the rough opening panel 130 (including the panel support substrate 204. For
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instance, the wall flange 132 is constructed with a material having a second
elastomeric deformation characteristic (e.g., an elastic modulus of between
around
160-210 psi). The wall flange 132 is installed with a smooth, consistent
surface over
the wall panel 106 according deformable character of the wall flange 132. The
smooth (e.g., substantially unwrinkled) installation minimizes (e.g.,
eliminates or
decreases) the collection of moisture along the wall flange 132.
Optionally, the wall flange 132 includes a wall flange coating 218. The wall
flange coating 218 includes, but is not limited to, a non-tacky butyl rubber,
cotton
liner, nonwoven mesh, paper, or other coating that bonds to the elastomeric
film 200
and resists bonding to the fenestration unit 104 while allowing deformation of
the
wall flange 132, for instance as it is stretched along the wall panel 106 near
the
frame corners 120. The wall flange coating 218 optionally neutralizes an
adhesive
property of the elastomeric film 200. Stated another way, the wall flange
coating
118 minimizes (e.g., reduces or eliminates) any inherent tacky property of the
elastomeric film 200.
An example of the optional sill dam 202 is shown in Figure 2 (in dashed
lines). The sill dam 202 is coupled to the rough opening panel 130 at a sill
dam joint
210. The sill dam joint 210 is optionally formed with the elastomeric film
200.
Optionally, the sill dam joint 210 includes a relief in the elastomeric film
200 to
facilitate folding of the sill dam 202 relative to the rough opening panel
130. For
instance, the sill dam joint 210 includes a notch, crease, groove, scoring
line or the
like. The sill dam 202 is, in one example, constructed with the elastomeric
film 200
used with other components of the elastomeric flashing assembly 102. For
instance,
the sill dam 202 is tacky on one or more of the upper or lower surfaces.
As shown in Figure 2, the sill dam 202 includes a sill dam substrate 206. The
sill dam substrate 206 is coupled along the lower surface of the sill dam 202.
The
sill dam substrate 206 increases the elastomeric deformation characteristic of
the sill
dam 202 along the planar surface of the sill dam substrate 206. Stated another
way,
the sill dam substrate 206 constrains the sill dam 202 from stretching and
reduces
wrinkling along the sill dam 202 when installed along the fenestration unit
frame
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122. The sill dam 202 is installed with a smooth, planar surface that
minimizes (e.g.,
eliminates or decreases) the collection of moisture in a wrinkled surface of a
film.
The sill dam 202 is foldable along the sill dam joint 210 to the installed
configuration (shown in Figure 3). The sill dam joint 210 is a hinge for the
sill dam
202 that permits folding of the sill dam 202 and application to the
fenestration unit
frame 122 (see Figure 1). In an example, the sill dam substrate 206 is
constructed
from a material including, but not limited to, a polymer sheet, paper, foil,
biaxially
oriented polyethylene terephthalate, or the like. As previously mentioned, the
sill
dam 202 optionally includes a portion of the elastomeric film 200 having a
thickness greater than other portions of the elastomeric film 200 (e.g., one
or more
of the rough opening panel 130 or the wall flange 132).
One or more liners are removably coupled to the tacky sides of the
elastomeric film 200. For instance, a wall flange liner 214 is coupled to the
lower
surface of the wall flange 132, a panel liner 212 is coupled to the tacky side
(lower
surface) of the rough opening panel 130, and a sill dam liner 216 is coupled
to the
upper surface of the sill dam 202. Optionally, each of the liners (the panel
liner 212,
the wall flange liner 214, or the sill dam liner 216) is independently
removable. In
one example, two or more liners on the same side of the elastomeric film 200
are
combined into a single liner. For instance, the panel liner 212 and the wall
flange
liner 214 are constructed as a single liner. The liners protect the tacky
surface of the
elastomeric film 200 from collecting debris or adhering to each other. The
liners are
constructed with a carrier having a releasable surface or coating, including
but not
limited to, a wax coated paper, a polymer sheet, or the like.
Figure 3 illustrates the elastomeric flashing assembly 102 arranged in a
folded configuration, for instance as it would appear when installed. The wall
flange
132 is folded along the wall flange joint 208 downward relative to the rough
opening panel 130. Where the elastomeric flashing assembly 102 includes the
sill
dam 202, the sill dam 202 is folded upward along the sill dam joint 210
relative to
the rough opening panel 130. One or more of the liners, such as the panel
liner 212
or the wall flange liner 214, are removable from the rough opening panel 130
and
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the wall flange 132 respectively, as shown in Figure 3. The panel support
substrate
204 is configured to facilitate the flexure (e.g., folding) of the wall flange
joint 208
and the sill dam joint 210. For instance, the panel support substrate 204
extends
from the wall flange joint 208 to the sill dam joint 210 or is absent (e.g.,
one-
sixteenth or one-eighth of an inch gap) at the wall flange joint 208 or the
sill dam
joint 210.
Figure 4 shows an example of the elastomeric flashing assembly 102
installed in the rough opening 108. The panel liner 212 is removed and the
rough
opening panel 130 is applied to (or laid along) the rough opening frame 110.
For
instance, the tacky surface (e.g., on the lower surface of the elastomeric
film 200) is
adhered to the rough opening frame 110. In another example, the tacky surface
bonds to the rough opening frame 110. The rough opening panel 130 is
optionally
applied to the left upright 114, the sill 112 and the right upright 116, or
any
combination thereof. In Figure 4, the rough opening panel 130 is shown coupled
to
the left upright 114 and the frame sill 112 (the right upright 116 is shown in
Figure
1). The panel support substrate 204 constrains stretching in the rough opening
panel
130 while allowing for folding pliability (e.g., at the comers) and provides a
smooth, continuous surface along the panel 130. The panel support substrate
204
reduces wrinkles in the rough opening panel 130 minimizes (eliminates or
decreases) the pooling of moisture along the rough opening panel 130 and
diverts
moisture toward the wall flange 132 (away from the rough opening 108). In one
example, the rough opening panel 130 is sufficiently pliable (while
constraining
stretching) to include a minimal bend radius at the frame comer 120. For
instance,
the rough opening panel 130 includes a bend radius measuring between .006
inches
to 0.50 inches.
In the installed configuration, the wall flange 132 is folded at the wall
flange
joint 208 and stretched around at least one frame corner 120 along the wall
panel
106 of the rough opening 108 in a planar configuration. For instance, along
the wall
flange joint 208, the bend radius of the wall flange 132 is substantially
equal to the
bend radius of the rough opening panel 130 at the frame corners 120. The
length of
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the front edge 201 and the intervening material between the front edge 201 and
the
wall flange joint 208 increases as the wall flange 132 is stretched around the
corner
frame 120. Accordingly, the length of the front edge 201 in the installed
configuration is greater than the length of the wall flange joint 208.
The wall flange 132 is not constrained by a substrate (e.g., like the panel
support substrate 204 constrains the rough opening panel 130). Accordingly,
the
wall flange 132 is deformed around the frame corner 120 (e.g., stretched) to
provide
a smooth surface along the wall panel 106 including at locations adjacent the
frame
corners 120. In contrast, the panel support substrate 204 anchors the rough
opening
panel 130 and minimizes (e.g., prevents or reduces) the stretching of the
elastomeric
film 200. As previously stated herein, the first elastomeric deformation
characteristic of the rough opening panel 130 is greater than the second
elastomeric
deformation characteristic of the wall flange 132 (e.g., that pliably
stretches over the
wall panel 106 at corners).
The wall flange 132 is laid along the wall panel 106 in a planar
configuration. The tacky surface (e.g., on the lower surface of the
elastomeric film
200) is adhered to the wall panel 106. In one example, the tacky surface of
the wall
flange 132 bonds to the wall panel 106 in the planar configuration. In another
example, the wall flange is optionally coupled to the wall panel 106 with
fasteners
in addition to or in place of adhering the tacky surface of the wall flange
132 to the
wall panel 106. Examples of fasteners include, but are not limited to, nails,
screws,
staples, or the like. In one example, the elastomeric film 200 seals (e.g.,
self-seals)
around holes punctured through the elastomeric film 200. For instance, the
elastomeric film 200 expands around the fasteners according to the elastomeric
deformation characteristic of the elastomeric film 200.
Prior to installation of the fenestration unit 104, the sill dam 202 (if
included) extends from the rough opening panel 130. In the example shown in
Figure 4, the sill dam 202 is not folded along the sill dam joint 210. The
sill dam
liner 216 remains attached to the sill dam 202 to protect the tacky surface of
the
elastomeric film 200 from collecting debris or accidentally adhering to other
items.
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. =
,
Figure 5 is an exemplary cross section of the elastomeric flashing assembly
102 in the installed configuration between the rough opening frame 110 and the
fenestration unit 104. The rough opening panel 130 is installed on the rough
opening
frame 110 (the sill 112 as shown in Figure 5) and the wall flange 132 is
folded along
the wall flange joint 208 and attached to the wall panel 106. For instance,
the tacky
surface of the elastomeric film 200 is coupled to the frame sill 112 and the
wall
panel 106. Stated another way, the lower surface of the elastomeric film 200
is
adhered to the frame sill 112 and the wall panel 106 as previously described
herein.
The fenestration unit 104 is supported by the frame sill 112 with the rough
opening
panel 130 in between the fenestration unit 104 and the frame sill 112. The
rough
opening panel 130 is located along the lower surface of the fenestration unit
frame
122. In one example, the rough opening panel 130 has a width that is
substantially
equal to a distance between the wall panel 106 and an interior wall panel 502.
The elastomeric flashing assembly 102 includes a sill dam 202 as shown in
Figure 5. The sill dam 202 is folded along the sill dam joint 210 toward the
fenestration unit frame 122. The tacky side of the sill dam 202 (e.g., upper
surface
of the elastomeric film 200) is adhered along the fenestration unit frame 122.
For
instance, the sill dam 202 is coupled along the fenestration unit frame 122
and
adhered to the fenestration unit frame 122. In another example, the sill dam
202 is
coupled with another mechanism including fasteners extending through the dam
and
into the fenestration unit frame 122.
In the example shown in Figure 5, the sill dam 202 includes a back edge 203
(e.g., opposed to the front edge 201 shown in Figure 2). In another example,
where
the sill dam 202 is not included, the rough opening panel 130 includes the
back edge
203' (see also Figure 2) along the opposite end of the rough opening panel 130
from
the wall flange joint 208. Optionally, the elastomeric flashing assembly 102
includes a continuous surface from the front edge 201 to the back edge 203 (or
203') of the assembly 102. For instance, the elastomeric flashing assembly 102
provides a contiguous elastomeric film 200 (e.g., butyl membrane barrier) to
prevent
water infiltration through the rough opening 108 and to the interior of the
building
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100. In one example, moisture is directed from the back edge 203 of the
elastomeric
flashing assembly 102 toward the front edge 201 of the elastomeric flashing
assembly 102. For instance, where the frame sill 112 includes a downward slope
from the interior to the exterior side of the building 100 the slope is
assumed by the
elastomeric flashing assembly including the rough opening panel 130.
Accordingly,
moisture is directed along the upper surface of the elastomeric flashing
assembly
from the back edge 203 toward the front edge 201 (e.g., toward the exterior of
the
building 100).
Figure 6 shows a diagram of an exemplary method 600 for installing an
elastomeric flashing assembly 102 previously described herein and shown for
instance in Figures 1-5. In describing the method 600, reference is made to
one or
more components, features, functions, and steps previously described herein.
Where
convenient, reference is made to the components, features, steps and the like
with
reference numerals. Reference numerals provided are exemplary and are
nonexclusive. For instance, features, components, functions, steps, and the
like
described in the method 600 include, but are not limited to, the corresponding
numbered elements provided herein. Other corresponding features described
herein
(both numbered and unnumbered) as well as their equivalents are also
considered.
At 602, the method of installing an elastomeric flashing assembly 102
includes coupling the rough opening panel 130 of the elastomeric film 200
along the
rough opening frame 110. The rough opening panel 130 includes the panel
support
substrate 204, and the rough opening panel 130 includes the first elastomeric
deformation characteristic as previously described herein. The panel liner 212
is
removed from the tacky surface (e.g., adhesive side) of the elastomeric film
200
portion corresponding to the rough opening panel 130. In one example, the
tacky
surface of the rough opening panel 130 is located on the lower surface of the
elastomeric film 200. The tacky surface of the rough opening panel 130 is
adhered
along the rough opening frame 110. The rough opening panel 130 is coupled
along
the left upright 114, the sill 112, the right upright 116, or any combination
thereof
where the rough opening panel 130 is a smooth, continuous surface along the
rough
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opening frame 110. For instance, the panel support substrate 204 is a uniform,
smooth exposed surface. In one example, the rough opening panel 130 is coupled
along the rough opening frame 110 in a continuous plane.
At 604, the wall flange 132 of the elastomeric film 200 is coupled along the
wall panel 106 of the rough opening frame 110. Coupling the wall flange 132 to
the
wall panel 106 includes any one, or all, of steps 606 through 610.
At 606, the wall flange 132 is folded at the wall flange joint 208 relative to
the rough opening panel 130. For instance, the wall flange 132 is folded
toward the
wall panel 106. The wall flange liner 214 is removed from the tacky side
(e.g.,
adhesive side) of the elastomeric film 200 portion corresponding toe the wall
flange
132 in preparation for the coupling of the wall flange 132 to the wall panel
106.
At 608, the wall flange 132 is stretched around at least one rough opening
frame corner 120 according to a second elastomeric deformation characteristic
(previously described) of the wall flange 132. The second elastomeric
deformation
characteristic is lower than the first elastomeric deformation characteristic.
The
length of the front edge 201 of the wall flange 132 is stretched to include a
greater
length than the wall flange joint 208. The panel support substrate 204 resists
stretching of the rough opening panel 130. For instance, the wall flange 132
stretches according to the second elastomeric deformation characteristic and
the
rough opening panel is anchored to the rough opening frame 110 as a result of
the
first elastomeric deformation characteristic being greater than the second
elastomeric deformation characteristic.
At 610, the wall flange 132 is laid along the wall panel 106 in a planar
configuration according to the second elastomeric deformation characteristic.
The
tacky surface of the wall flange 132 (e.g., the adhesive side located on the
lower
surface of the elastomeric film 200) is laid along the wall panel 106 and
adhered to
the wall panel 106. For instance, the tacky surface of the elastomeric film
200 of the
wall flange 132 bonds to the wall panel 106, coupling the wall flange 132 to
the
wall panel 106. The wall flange 132 includes a uniform, smooth exposed surface
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,
,
where laid along the wall panel 106. As previously described, the panel
support
substrate 204 resists deformation (stretching) of the rough opening panel 130.
Where the elastomeric flashing assembly 102 includes the sill dam 202, as
previously described herein, the method 600 further includes coupling the sill
dam
202 along the fenestration unit frame 122. The sill dam 202 is folded along
the sill
dam joint 210. For instance, the sill dam 202 is folded toward the
fenestration unit
frame 122. The sill dam liner 216 is removed from the elastomeric film 200 of
the
sill dam 202, exposing the tacky surface of the sill dam 202. The tacky
surface of
the sill dam 202 (e.g., the upper surface of the elastomeric film 200) is laid
on to the
fenestration unit frame 122 and adhered to the fenestration unit frame 122.
Accordingly, the elastomeric flashing assembly 102 includes a continuous
surface
from the front edge 201 to the back edge 203 providing a barrier against
moisture
entering the rough opening 108. The continuous, smooth surface of the rough
opening panel 130, wall flange 132, sill dam 202, or any combination thereof
directs
moisture away from the rough opening 108 and mitigates the pooling of moisture
along the rough opening frame 110. The uniform, smooth surface of the wall
panel
106 provides a good interface for building wrap, decorative wall coverings
(stucco,
siding or the like).
Various Notes & Examples
Example 1 can include subject matter, such as can include an elastomeric
flashing assembly comprising: an elastomeric film including a rough opening
panel
and a wall flange coupled with the rough opening panel at a wall flange joint;
a liner
removably coupled along an elastomeric film adhesive side; and a panel support
substrate coupled along the rough opening panel of the elastomeric film for
installation along a rough opening frame: the rough opening panel having a
first
elastomeric deformation characteristic based on the panel support substrate,
and the
wall flange having a second elastomeric deformation characteristic lower than
the
first elastomeric deformation characteristic, the wall flange with the second
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elastomeric deformation characteristic deformable into a planar configuration
while
coupled along a wall panel surrounding the rough opening frame in an installed
configuration.
Example 2 can include, or can optionally be combined with the subject
matter of Example 1, to optionally include wherein the panel support substrate
is a
continuous plane.
Example 3 can include, or can optionally be combined with the subject
matter of one or any combination of Examples 1 or 2 to optionally include
wherein
the panel support substrate includes a uniform smooth exposed surface.
Example 4 can include, or can optionally be combined with the subject
matter of one or any combination of Examples 1-3 to optionally include wherein
the
panel support substrate anchors the rough opening panel of the elastomeric
film
against deformation relative to the wall flange of the elastomeric film.
Example 5 can include, or can optionally be combined with the subject
matter of one or any combination of Examples 1-4 to optionally include wherein
the
panel support substrate includes a third elastomeric deformation
characteristic
greater than the second elastomeric deformation characteristic, and the first
elastomeric deformation characteristic is based on the third elastomeric
deformation
characteristic of the panel support substrate.
Example 6 can include, or can optionally be combined with the subject
matter of Examples 1-5 to optionally include wherein the elastomeric film
includes
a sill dam coupled with the rough opening panel at a sill dam joint, the sill
dam has
a sill dam thickness greater than a rough opening panel thickness.
Example 7 can include, or can optionally be combined with the subject
matter of Examples 1-6 to optionally include wherein the sill dam is rotatable
at the
sill dam joint into a fenestration coupling configuration, in the fenestration
coupling
configuration the sill dam extends from the rough opening panel to a
fenestration
unit frame above the rough opening panel.
Example 8 can include, or can optionally be combined with the subject
matter of Examples 1-7 to optionally include wherein the wall flange includes
a wall
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flange coating, the wall flange coating neutralizes an adhesive property of
the
elastomeric film.
Example 9 can include, or can optionally be combined with the subject
matter of Examples 1-8 to optionally include wherein the liner includes a
panel liner
coupled along the rough opening panel and a separate wall flange liner coupled
along the wall flange.
Example 10 can include, or can optionally be combined with the subject
matter of Examples 1-9 to optionally include wherein in the installed
configuration,
the rough opening panel extends over the rough opening frame and the wall
flange
is folded at the wall flange joint and stretched around at least one rough
opening
frame corner along a wall panel of the rough opening frame in a planar
configuration.
Example 11 can include, or can optionally be combined with the subject
matter of Examples 1-10 to optionally include wherein the elastomeric film
includes
a butyl tape, and the panel support substrate includes a biaxially oriented
polyethylene terephthalate.
Example 12 can include, or can optionally be combined with the subject
matter of Examples 1-11 to optionally include an elastomeric flashing assembly
comprising: an elastomeric film including: a rough opening panel, a wall
flange
coupled with the rough opening panel at a wall flange joint, and a sill dam
coupled
with the rough opening panel at a sill dam joint; a film liner removably
coupled
along an elastomeric film adhesive side; a sill dam liner removably coupled
along a
sill dam adhesive side; and a panel support substrate coupled along the rough
opening panel of the elastomeric film between the wall flange joint and the
sill dam
joint: the rough opening panel having a first elastomeric deformation
characteristic
based on the panel support substrate, the wall flange having a second
elastomeric
deformation characteristic lower than the first elastomeric deformation
characteristic, and in an installed configuration, the rough opening panel
extends
over the rough opening frame, the sill dam is folded at the sill dam joint and
coupled
along a fenestration unit frame, and the wall flange is folded at the wall
flange joint
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and stretched around at least one rough opening frame corner along a wall
panel of
the rough opening frame in a planar configuration.
Example 13 can include, or can optionally be combined with the subject
matter of Examples 1-12 to optionally include wherein the panel support
substrate is
a continuous plane.
Example 14 can include, or can optionally be combined with the subject
matter of Examples 1-13 to optionally include wherein the panel support
substrate
includes a uniform smooth exposed surface.
Example 15 can include, or can optionally be combined with the subject
matter of Examples 1-14 to optionally include wherein in the installed
configuration
the panel support substrate continuously extends over a sill portion and one
or more
of left and right upright portions of the rough opening frame.
Example 16 can include, or can optionally be combined with the subject
matter of Examples 1-15 to optionally include wherein the panel support
substrate
anchors the rough opening panel of the elastomeric film against deformation
relative
to the wall flange of the elastomeric film.
Example 17 can include, or can optionally be combined with the subject
matter of Examples 1-16 to optionally include wherein the panel support
substrate
includes a third elastomeric deformation characteristic greater than the
second
elastomeric deformation characteristic, and the first elastomeric deformation
characteristic is based on the third elastomeric deformation characteristic of
the
panel support substrate.
Example 18 can include, or can optionally be combined with the subject
matter of Examples 1-17 to optionally include wherein the wall flange includes
a
wall flange coating, the wall flange coating neutralizes an adhesive property
of the
elastomeric film.
Example 19 can include, or can optionally be combined with the subject
matter of Examples 1-18 to optionally include wherein the liner includes a
panel
liner coupled along the rough opening panel and a separate wall flange liner
coupled
along the wall flange.
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Example 20 can include, or can optionally be combined with the subject
matter of Examples 1-19 to optionally include wherein the elastomeric film
includes
a butyl tape, and the panel support substrate includes a biaxially oriented
polyethylene terephthalate.
Example 21 can include, or can optionally be combined with the subject
matter of Examples 1-20 to optionally include a method of installing an
elastomeric
flashing assembly comprising: coupling a rough opening panel of an elastomeric
film along a rough opening frame, the rough opening panel including a panel
support substrate, and the rough opening panel includes a first elastomeric
deformation characteristic; coupling a wall flange of the elastomeric film
along a
wall panel of the rough opening frame, coupling including: folding the wall
flange
at a wall flange joint relative to the rough opening panel, stretching the
wall flange
around at least one rough opening frame corner according to a second
elastomeric
deformation characteristic of the wall flange lower than the first elastomeric
deformation characteristic, and laying the stretched wall flange along the
wall panel
in a planar configuration according to the second elastomeric deformation
characteristic.
Example 22 can include, or can optionally be combined with the subject
matter of Examples 1-21 to optionally include wherein coupling the rough
opening
panel along the rough opening frame includes coupling the rough opening panel
along the rough opening frame and the panel support substrate is a continuous
plane.
Example 23 can include, or can optionally be combined with the subject
matter of Examples 1-22 to optionally include wherein coupling the rough
opening
panel along the rough opening frame includes coupling the rough opening panel
along the rough opening frame and the panel support substrate is a uniform
smooth
exposed surface.
Example 24 can include, or can optionally be combined with the subject
matter of Examples 1-23 to optionally include wherein coupling the rough
opening
panel along the rough opening frame includes resisting stretching of the rough
opening panel with the panel support substrate.
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Example 25 can include, or can optionally be combined with the subject
matter of Examples 1-24 to optionally include coupling a sill dam along a
fenestration unit frame, the elastomeric film includes the sill dam coupled
with the
rough opening panel at a sill dam joint.
Example 26 can include, or can optionally be combined with the subject
matter of Examples 1-25 to optionally include wherein coupling the sill dam
includes: folding the sill dam at a sill dam joint toward the fenestration
unit frame,
affixing the sill dam along the fenestration unit frame.
Example 27 can include, or can optionally be combined with the subject
matter of Examples 1-26 to optionally include wherein laying the stretched
wall
flange along the wall panel in the planar configuration includes the wall
flange with
a uniform smooth exposed surface.
Example 28 can include, or can optionally be combined with the subject
matter of Examples 1-27 to optionally include wherein laying the stretched
wall
flange along the wall panel in the planar configuration includes resisting
stretching
of the rough opening panel with the panel support substrate.
Example 29 can include, or can optionally be combined with the subject
matter of Examples 1-28 to optionally include wherein coupling the rough
opening
panel along the rough opening frame includes: removing a panel liner from an
elastomeric film adhesive side corresponding to the rough opening panel, and
adhering the elastomeric film adhesive side of the rough opening panel along
the
rough opening frame.
Example 30 can include, or can optionally be combined with the subject
matter of Examples 1-29 to optionally include wherein coupling the wall flange
along the wall panel of the rough opening frame includes: removing a wall
flange
liner from an elastomeric film adhesive side corresponding to the wall flange,
and
laying the elastomeric adhesive side of the stretched wall flange along the
wall
panel includes adhering the wall flange along the wall panel.
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Each of these non-limiting examples can stand on its own, or can be
combined in any permutation or combination with any one or more of the other
examples.
The above detailed description includes references to the accompanying
drawings, which form a part of the detailed description. The drawings show, by
way of illustration, specific embodiments in which the invention can be
practiced.
These embodiments are also referred to herein as "examples." Such examples can
include elements in addition to those shown or described. However, the present
inventors also contemplate examples in which only those elements shown or
described are provided. Moreover, the present inventors also contemplate
examples
using any combination or permutation of those elements shown or described (or
one
or more aspects thereof), either with respect to a particular example (or one
or more
aspects thereof), or with respect to other examples (or one or more aspects
thereof)
shown or described herein.
In the event of inconsistent usages between this document and any
documents so incorporated by reference, the usage in this document controls.
In this document, the terms "a" or "an" are used, as is common in patent
documents, to include one or more than one, independent of any other instances
or
usages of "at least one" or "one or more." In this document, the term "or" is
used to
refer to a nonexclusive or, such that "A or B" includes "A but not B," "B but
not
A," and "A and B," unless otherwise indicated. In this document, the terms
"including" and "in which" are used as the plain-English equivalents of the
respective terms "comprising" and "wherein." Also, in the following claims,
the
terms "including" and "comprising" are open-ended, that is, a system, device,
article, composition, formulation, or process that includes elements in
addition to
those listed after such a term in a claim are still deemed to fall within the
scope of
that claim. Moreover, in the following claims, the terms "first," "second,"
and
"third," etc. are used merely as labels, and are not intended to impose
numerical
requirements on their objects.
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The above description is intended to be illustrative, and not restrictive. For
example, the above-described examples (or one or more aspects thereof) may be
used in combination with each other. Other embodiments can be used, such as by
one of ordinary skill in the art upon reviewing the above description. The
Abstract
is provided to comply with 37 C.F.R. 1.72(b), to allow the reader to quickly
ascertain the nature of the technical disclosure. It is submitted with the
understanding that it will not be used to interpret or limit the scope or
meaning of
the claims. Also, in the above Detailed Description, various features may be
grouped together to streamline the disclosure. This should not be interpreted
as
intending that an unclaimed disclosed feature is essential to any claim.
Rather,
inventive subject matter may lie in less than all features of a particular
disclosed
embodiment. Thus, the following claims are hereby incorporated into the
Detailed
Description as examples or embodiments, with each claim standing on its own as
a
separate embodiment, and it is contemplated that such embodiments can be
combined with each other in various combinations or permutations. The scope of
the invention should be determined with reference to the appended claims,
along
with the full scope of equivalents to which such claims are entitled.
Attorney Docket No. 1261.169US1 25
