Flexible flashings and associated method of manufacture

Abstract

A flexible flashing and method for manufacturing and installing the flashing at a window or other portal in a wall opening is provided. The flashing includes a base member with a plurality of channels that are structured to direct water therefrom, and a face plate extends from the base member. The flashing can be formed, e.g., by a molding operation, and then supported and cooled in a curved configuration. For example, the flashing can be supported in a jig in a configuration that is curved about a first axis that is perpendicular to an axis about which the flashing is curved during installation.

1 . A method for manufacturing a flexible flashing for use in a portal installation in a curved opening of a wall, the method comprising: 
 forming the flashing, the flashing comprising: 
 a base member defining opposite first and second surfaces extending from a first edge to a second edge; and  
 a face plate extending from the base member generally perpendicular to the base member, the face plate defining a first edge proximate the first edge of the base member and extending therefrom to a second distal edge;  
   supporting the flashing in a curved configuration while heated and such that the first edge of the base member defines a first radius of curvature extending from an axis which is generally parallel to the face plate and the second edge of the base member defines a second radius of curvature from said axis, the first radius of curvature being greater than the second radius of curvature; and    at least partially cooling the flashing in the curved configuration such that the flashing is structured to be installed with the face plate in a substantially planar configuration against the wall, the base member curved to correspond to the curved opening of the wall, and the base member disposed at a desired angle relative to the face plate.    
   
   
       2 . A method according to  claim 1  wherein said forming step comprises molding the flashing in a die.  
   
   
       3 . A method according to  claim 2  wherein said cooling step comprises at least partially cooling the flashing in the die, the die being structured to support the flashing in the curved configuration.  
   
   
       4 . A method according to  claim 1  wherein said forming step comprises molding the flashing as a unitary member of molten plastic.  
   
   
       5 . A method according to  claim 1  wherein said forming step comprises forming the flashing with each of the face plate and the base member in a substantially planar configuration, and further comprising bending the flashing to the curved configuration of said supporting step.  
   
   
       6 . A method according to  claim 1  wherein said supporting step comprises disposing the flashing in a jig subsequent to said forming step, the jig defining the curved configuration and being structured to restrain the flashing in the curved configuration.  
   
   
       7 . A method according to  claim 1  wherein said supporting step comprises supporting the flashing with the first radius of curvature being between about ⅙ of a major length of the flashing and about 6 times the major length of the flashing.  
   
   
       8 . A method according to  claim 1  wherein said supporting step comprises supporting the flashing with the first radius of curvature being between about ⅓ of a major length of the flashing and about a distance equal to the major length of the flashing.  
   
   
       9 . A method according to  claim 1  wherein said supporting step comprises supporting the flashing with the first radius of curvature being less than about 6 feet.  
   
   
       10 . A method according to  claim 1  wherein said supporting step comprises supporting the flashing with the first radius of curvature being less than about 3 feet.  
   
   
       11 . A method according to  claim 1 , further comprising installing the flashing at the opening of the wall with the face plate disposed in a generally planar configuration and the base member disposed in a curved configuration corresponding to the curved opening of the wall, the base member being substantially perpendicular to the face plate and thereby configured to direct water in a direction from the first edge of the base member to the second edge of the base member.  
   
   
       12 . A method according to  claim 1 , further comprising forming a plurality of channels in the first surface of the base member, the channels being configured to direct water in a direction from the first edge of the base member to the second edge of the base member and thereby direct water on the base member outward from the wall.  
   
   
       13 . A method according to  claim 1 , further comprising forming a plurality of slots in the face plate, the slots extending from the second edge of the face plate toward the first edge of the face plate.  
   
   
       14 . A method according to  claim 1  wherein said supporting and cooling steps comprise cooling the flashing in the curved configuration such that the base member is structured to be disposed substantially perpendicular to the face plate when the face plate is installed in a planar configuration with the base member curved to correspond to the curved opening of the wall.  
   
   
       15 . A flexible flashing for use in a portal installation in a curved opening of a wall, the flashing comprising: 
 a base member defining opposite first and second surfaces extending from a first edge to a second edge; and    a face plate extending from the base member in a plane generally perpendicular to the base member, the face plate extending from the first edge of the base member to a distal edge, such that the face plate is structured to be disposed against the wall with the base member disposed against the curved opening of the wall,    wherein the flashing in an unloaded condition defines a curved configuration with the first edge of the base member defining a first radius of curvature extending from an axis which is generally parallel to the face plate and with the second edge of the base member defining a second radius of curvature extending from said axis that is lesser than the first radius of curvature such that the base member is structured to be disposed at a desired angle relative to the face plate when the flashing is installed with the face plate in a substantially planar configuration and the base member curved to correspond to the curved opening of the wall.    
   
   
       16 . A flexible flashing according to  claim 15  wherein the flashing is a unitary member formed of plastic.  
   
   
       17 . A flexible flashing according to  claim 15  wherein the first radius of curvature is between about 1 times a major length of the flashing and about 10 times the major length of the flashing.  
   
   
       18 . A flexible flashing according to  claim 15  wherein the flashing is structured to be installed with the face plate disposed in a generally planar configuration and the base member disposed in a curved configuration corresponding to the curved opening of the wall such that the base member is substantially perpendicular to the face plate and thereby configured to direct water in a direction from the first edge of the base member to the second edge of the base member.  
   
   
       19 . A flexible flashing according to  claim 15  wherein the flashing defines a plurality of channels in the first surface of the base member, the channels being configured to direct water in a direction from the first edge of the base member to the second edge of the base member and thereby direct water on the base member outward from the wall.  
   
   
       20 . A flexible flashing according to  claim 15  wherein the flashing defines a plurality of slots in the face plate, the slots extending from the edge of the face plate toward the base member.