NZ767780A - Skylight weatherproofing flashing tray and method - Google Patents

Abstract

The difficulty with the prior art is that the flashing tray for tiled roofs and corrugated panel roofs are different and specific to each, requiring suppliers to stock both and requiring skylight installers to have access to both. The present invention aims to provide a flashing tray suitable for both tiled roof and corrugated panel roof installation. A weatherproofing flashing tray 10 comprises a generally flat rectangular body 12 which has a central square, round or rectangular opening 14. A structure 16 of the flashing tray body 12 extends upwardly from the opening 14 for a skylight. The upper portion 20 comprises a distal upper edge section 21 which is bent upwardly and back towards the upper surface 26 of the flat proximal portions of the upper portion 20. The upwardly bent top edge section 21 forms part of the waterproofing formation of the upper portion of 20. The side portions 24 each comprise a distal side edge section 25 which is bent downwardly at an angle of between 8° and 90° (preferably 10°) relative to the horizontal proximal portions of the side portions 24. The downwardly bent side edge sections 25 form a first part of the waterproofing formation of the side portions 24. Each side portion 24 further includes a second waterproofing formation, being raised elongate strips 32 extending generally parallel and adjacent to the side edge section 25 thereof. oth tiled roof and corrugated panel roof installation. A weatherproofing flashing tray 10 comprises a generally flat rectangular body 12 which has a central square, round or rectangular opening 14. A structure 16 of the flashing tray body 12 extends upwardly from the opening 14 for a skylight. The upper portion 20 comprises a distal upper edge section 21 which is bent upwardly and back towards the upper surface 26 of the flat proximal portions of the upper portion 20. The upwardly bent top edge section 21 forms part of the waterproofing formation of the upper portion of 20. The side portions 24 each comprise a distal side edge section 25 which is bent downwardly at an angle of between 8° and 90° (preferably 10°) relative to the horizontal proximal portions of the side portions 24. The downwardly bent side edge sections 25 form a first part of the waterproofing formation of the side portions 24. Each side portion 24 further includes a second waterproofing formation, being raised elongate strips 32 extending generally parallel and adjacent to the side edge section 25 thereof.

Description

SKYLIGHT WEATHERPROOFING FLASHING TRAY AND METHOD Field of the Invention The Invention relates to weatherproof flashing for skylights. The invention is however not limited to this application and can also be used for other roof installation applications with a roof opening such as skylights, roof windows, whirlybirds, roof ventilation, solar roof ventilation, and other roof products that are larger than a single roof tile.

Background of the Invention ional methods for rproof flashing of larger skylights is roof specific.

There are three main types of roofs in use in Australia and each calls for a specific ng method; the Industry standards generally are: a. TILE roof skylights have a flashing tray that has a small 10-20mm wide gutter folded up to about 160 degrees angle at each side edge and at the top edge.

This flashing tray usually includes a soft over-flash along the lower edge; b. CORRUGATED roof skylights have a flashing tray that has about 15mm wide side edge sections folded down at about 15 degrees on both side edges of the tray; c. DECK roofing skylights have a tray that has . 30mm skirt folded down at 90 degrees around the full perimeter.

The first two are the most common roof types in Australia and the aim of this invention is to provide a tray and methodology that can be applied to both roof types whilst utilizing the same basic components contained in a single product kit.

Traditional skylight assemblies are manufactured in thin sheetmetal, typically 0.55 zincalume or colorbond. (smaller hts can be stamped from more malleable materials such as aluminium).

The present invention seeks to overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an ion that the information forms part of the common general knowledge in the art, in Australia or any other country.

Summary of the ion According to a first aspect, the t invention a flashing tray for a roof lation, the flashing tray comprising: a generally flat body having an upper e and a lower surface, a structure extending upwardly from a central section of the body to define an g for the roof installation, the flashing tray body comprising an upper n, a lower portion, and side portions extending from a periphery of the ure, the upper portion, the lower n, and the side portions together g a continuous peripheral band around the structure, wherein the side portions comprise a first downwardly extending waterproofing formation and a second upwardly extending waterproofing formation.

In a preferred embodiment, the first waterproofing ion comprises a distal side edge section of the side portions which is bent downwardly at an angle of between 8° and 90° relative to the horizontal proximal portions of the side portions.

In another preferred embodiment, the side edge sections are bands which extends across the full length of the side portions.

In another preferred embodiment, the second waterproofing formation comprises at least one raised elongate strip extending along the upper surface of each side section, each strip being generally parallel and adjacent to the respective side edge section.

In another preferred embodiment, the strips extend substantially the full length of the side portions.

In another preferred embodiment, each side n comprises a pair of parallel spaced strips, with the strips forming a channel therebetween.

In another preferred embodiment, the strips are ed unattached to the side portions, and attachable thereto by the user in use.

In another red embodiment, the strips can be attached to lower surface of the side portions generally parallel and adjacent to the respective side edge section.

In another preferred embodiment, the side portions include markings for attachment of the strips.

In another preferred embodiment, the upper portion comprises a distal upper edge section which is bent ly and back towards the upper surface of the flat proximal portions of the upper portion.

In another preferred embodiment, the upper edge section is a band which extends across the full length of the upper edge of the upper portion, and is at an angle of about 10° relative to the horizontal proximal portions of the upper portion.

In another preferred embodiment, the lower portion ses a soft flashing ing from the lower edge thereof.

In another preferred embodiment, the soft flashing is made from softer malleable material and extend across the full length of the lower portion.

In another preferred embodiment, the strips are made from flexible foam material and are mounted to the upper surface via a roof adhesive.

The present invention also provides a method of installing the flashing tray of claim 4 for a tiled roof installation, the method comprising: disposing the upper portion and the side portions under respective adjacent tiles and sealing therewith, wherein the strips prevent water from reaching the outer edges of the side portions and direct water to the lower portion.

The present invention also provides a method of installing the flashing tray of claim 8 for a ated roof installation, the method comprising: disposing the upper portion into a cut portion of a corrugated roof panel to be disposed under a section of the corrugated roof panel, sealing the upper portion to the corrugated roof panel via a suitable sealant, disposing the side portions on top of the corrugated roof panel and sealing therewith using a suitable sealant, wherein the downwardly bent side edge sections direct water to the adjacent corrugated roof panels.

In a preferred embodiment, the method of r comprises attaching a strip to the lower e of each side portion, each strip being generally parallel and adjacent to the respective side edge section.

Other aspects of the invention are also disclosed.

Brief Description of the Drawings hstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the present invention will now be described, by way of es only, with nce to the anying drawings in which: Figure 1 shows a rproof flashing tray according to a red embodiment of the present invention where (a) is a front end elevation view, (b) is a closeup view of encircled portion A, (c) is a top view and (d) is a top perspective view, Figure 2 is a front top perspective view of the flashing tray, Figure 3 is a closeup perspective view of the right side of the flashing tray, Figure 4 is a closeup perspective view of the right side and top edge of the flashing tray, Figure 5 is a closeup view of the right side and front edge of the flashing tray, Figure 6 is a closeup perspective view of the top edge of the ng tray..

Description of ments It should be noted in the following description that like or the same reference numerals in different ments denote the same or similar features.

Figures 1 to 6 show a weatherproofing flashing tray 10 according to a preferred embodiment of the present invention. The flashing tray 10 comprises a generally flat rectangular body 12 which has a central , round or rectangular opening 14. A structure 16 of the flashing tray body 12 extends ly from the opening 14 for a skylight. The structure 16 can be shaped in many forms and does not form part of this invention. The present invention relates to the features of the body 12 extending around the g 14.

As is known, an opening is formed in a roof of a structure, and a flashing tray (such as the flashing tray 10 or similar) with a skylight opening 14 is positioned therein. The skylight opening 14 in use is covered by a translucent panel or dome, to allow light through the opening 14 and into the interior of the structure. The panel or dome is made from plastic or glass material and is weatherproof sealed with the structure 16. The panel or dome may or may not be openable. The flashing tray needs to be weatherproof sealed against the roof components to avoid water from leaking etween and into the interior of the structure.

The difficulty with the prior art is that the flashing tray for tiled roofs and corrugated panel roofs are different and ic to each, requiring suppliers to stock both and requiring skylight installers to have access to both. The present invention aims to provide a flashing tray suitable for both tiled roof and corrugated panel roof lation.

The flashing tray body 12 comprises an upper portion 20, a lower portion 22, and side portions 24 extending from a periphery of the opening 14. The upper portion 20, lower portion 22, and side portions 24 are generally flat and together form a continuous peripheral band having an upper surface 26 and a lower surface 28. The structure 16 extends upwardly from the upper surface 26 at a central section of the body 12.

As best seen in Figure 6, the upper n 20 comprises a distal upper edge section 21 which is bent upwardly and back towards the upper surface 26 of the flat proximal portions of the upper portion 20. The upper edge section 21 is a peripheral band 10 to 15 mm wide (preferably 10 mm) which s across the full length of the upper edge of the upper portion . The upper edge section 21 is at an angle of about 10° relative to the ntal proximal portions of the upper portion 20. The upwardly bent top edge section 21 forms part of the waterproofing formation of the upper portion of 20.

The side portions 24 each comprise a distal side edge n 25 which is bent downwardly at an angle of between 8° and 90° (preferably 10°) relative to the horizontal proximal portions of the side portions 24. The side edge ns 25 are peripheral bands 10 to 15 mm wide rably 10 mm) which extends across the full length of the side portions 24. The downwardly bent side edge sections 25 form a first part of the waterproofing formation of the side portions 24.

Each side portion 24 further es a second waterproofing formation, being raised elongate strips 32 ing generally parallel and adjacent to the side edge section 25 thereof. The strips 32 are attached to the upper surface 26 of the respective side portion 24 and thus extend upwardly from the upper surface 26. The strips 32 extend substantially the full length of the side portions 24 from the upper edge section 21 to the edge of the lower n 22. In the embodiment shown, each side portion 24 comprises a pair of parallel spaced strips 32, with a first strip 32a adjacent the side edge section 25 and a second strip 32a inwardly spaced from the first strip 32a. The strips 32 form a channel 33 therebetween.

The lower portion 22 in the embodiment shows comprises a soft flashing 38 ing from the lower edge thereof. The soft flashing 38 is made from softer malleable material and extends across the full length of the lower portion 22.

The strips 32 are made from an inert, ultraviolet stable, semi-closed-cell flexible foam al, and are mounted to the upper surface 26 via a waterproof adhesive for fixing direct to the metal surface of the flashing tray. The body 12 is lly made from substantially rigid metal.

The actual location and application of the foam material strips 32 can vary according to the roof type which is the subject of the application method.

In use, for a corrugated roof installation, the upper portion 20 is tucked into a cut portion of a corrugated roof panel to be disposed under a section of the corrugated roof panel. The upper portion 20 is then sealed to the corrugated roof panel via suitable sealant with the bent upper edge section 21 providing additional waterproofing. The side portions 24 are disposed on top of the corrugated roof panel and also sealed using a suitable sealant. The downwardly bent side edge sections 25 direct water to the adjacent corrugated roof panes by providing a ”drip edge”. The soft flashing 38 of the lower portion 22 can be bent and moulded to follow the contours of the ated roof panel if desired. For a corrugated roof, the strips 32 are not used in the manner shown in figure 2 (being on the upper surface 26). For corrugated roof, these strips 32 are optional. r, a different arrangement of the strips 32 is recommended for lower pitch roof. In that case, one strip 32 can be used on the tray lower e 28, d with and opposite of strip 32b; and a second strip 32 can by attached to the corrugated roof sheet, in the valley t to the cut-out for g 14.

For a tiled roof installation, the strips 32 are to be applied on the upper surface 26 as shown in Figures 1 to 6. The upper portion 20 and the side portions 24 are all disposed to be under their respective adjacent tiles and are sealed therewith. The upper n 20 and side ns 24 will all be concealed by tiles except for the lower section 22 which will be visible over tiles across the lower n 22. The upper edge section 21 provides additional waterproofing and directs water rdly to the remainder of the flashing tray 10. The strips 32 and channel 33 also prevent any water from reaching the outer edges of the side portions 24 and direct water to the lower portion 22. The soft flashing 38 of the lower portion 22 is similarly bent moulded to follow the contours of the upper surface of the roof tiles.

The present invention thus provides a flashing tray for a skylight with a commercial advantage which is that it will halve the number of products held as stock by resellers, and consolidate the sales into ONE model only, thereby increasing the performance on that ONE model and g up available retail (shelf) space to accommodate a larger range or increased stock levels.

The invention ates the risk of the customer picking the incorrect model, leading to returns or installation issues later, and reduces the number of models for production, leading to further economies of scale.

The dual purpose flashing tray in the preferred example shown has a smaller downturn on the sides only: 10mm and at 10 degrees only, at the correct spacing as to match up with Australian standard Corrugated sheets / profile. Due to the reduced flange size and d angle, the flashing tray can still be used for a tile roof, without kicking the tile up too much.

To waterproof the installation for a corrugated roof, the foam can be used on the actual roof-sheet: in the valley next to the roof cut-out, running down each of the sides Although a preferred embodiment of the present invention has been described, it will be apparent to skilled persons that cations can be made to the embodiment shown.

For e, the soft flashing can be omitted. Also, the bent upper edge portion can be replaced with a strip of foam. The strips along the side portions can also be replaced by bent ions of the side portions formed for example via roll forming.

The strips 32 can be provided in the product packaging unmounted to the side portions 24. The user can then mount the strips 32 to the side portions 24 along the top surface 26 as required for a tiled roof installation, or one strip 32 along the lower surface 28 for a corrugated roof installation as described above. The side portions 24 preferably e markings for the placement of the strips 32.

Claims

Claims (17)

The claims defining the invention are as follows:

1. A flashing tray for a roof installation, the flashing tray comprising: a generally flat body having an upper surface and a lower surface, a structure ing upwardly from a central section of the body to define an opening for the roof installation, the flashing tray body comprising an upper portion, a lower portion, and side portions extending from a periphery of the structure, the upper portion, the lower portion, and the side portions together g a continuous peripheral band around the structure, wherein the side portions comprise a first downwardly extending waterproofing formation and a second upwardly extending roofing formation.

2. The flashing tray of claim 1 wherein the first waterproofing formation comprises a distal side edge section of the side portions which is bent downwardly at an angle of between 8° and 90° relative to the horizontal proximal ns of the side portions.

3. The flashing tray of claim 2 wherein the side edge ns are bands which extends across the full length of the side portions.

4. The flashing tray of claim 2 n the second waterproofing formation comprises at least one raised te strip extending along the upper surface of each side section, each strip being generally parallel and adjacent to the respective side edge section.

5. The flashing tray of claim 4 wherein the strips extend substantially the full length of the side portions.

6. The flashing tray of claim 4 each side portion comprises a pair of parallel spaced strips, with the strips forming a channel therebetween.

7. The flashing tray of claim 4 wherein the strips are provided unattached to the side portions, and able thereto by the user in use.

8. The flashing tray of claim 7 wherein the strips can be ed to lower surface of the side portions generally parallel and adjacent to the respective side edge section.

9. The flashing tray of claim 7 n the side portions include markings for ment of the strips.

10. The flashing tray of claim 1 wherein the upper portion comprises a distal upper edge section which is bent upwardly and back towards the upper surface of the flat proximal portions of the upper portion.

11. The ng tray of claim 10 wherein the upper edge section is a band which extends across the full length of the upper edge of the upper portion, and is at an angle of about 10° relative to the horizontal proximal portions of the upper portion.

12. The flashing tray of claim 1 wherein the lower portion ses a soft flashing extending from the lower edge thereof.

13. The flashing tray of claim 12 wherein the soft flashing is made from softer malleable material and extend across the full length of the lower portion.

14. The flashing tray of claim 4 wherein the strips are made from le foam material and are mounted to the upper surface via a waterproof adhesive.

15. A method of installing the flashing tray of claim 4 for a tiled roof lation, the method comprising: disposing the upper portion and the side portions under respective adjacent tiles and sealing therewith, wherein the strips prevent water from ng the outer edges of the side portions and direct water to the lower portion.

16. A method of installing the flashing tray of claim 8 for a corrugated roof installation, the method comprising: disposing the upper portion into a cut portion of a corrugated roof panel to be disposed under a section of the corrugated roof panel, sealing the upper portion to the corrugated roof panel via a le sealant, ing the side portions on top of the corrugated roof panel and sealing ith using a suitable sealant, wherein the downwardly bent side edge ns direct water to the adjacent corrugated roof panels.

17. The method of claim 16 further comprising attaching a strip to the lower surface of each side portion, each strip being generally parallel and adjacent to the respective side edge section. ABSTRACT A weatherproofing flashing tray 10 comprises a generally flat rectangular body 12 which has a central square, round or gular opening 14. A structure 16 of the flashing tray body 12 extends upwardly from the opening 14 for a skylight. The upper portion 20 comprises a distal upper edge section 21 which is bent upwardly and back towards the upper surface 26 of the flat proximal portions of the upper portion 20. The upwardly bent top edge section 21 forms part of the waterproofing formation of the upper portion of 20. The side portions 24 each comprise a distal side edge section 25 which is bent rdly at an angle of between 8° and 90° rably 10°) ve to the horizontal proximal portions of the side portions 24. The downwardly bent side edge sections 25 form a first part of the waterproofing formation of the side portions 24. Each side portion 24 r includes a second waterproofing formation, being raised elongate strips 32 extending generally parallel and adjacent to the side edge section 25 thereof. 32b 33 (b) 32a 26 21 28 25 38 22 38 22 12 (c) (d)