System for Flashing End Joints of Siding

This application is a continuation-in-part of U.S. patent application Ser. No. 18/134,468, filed Apr. 13, 2023, which claims benefit of and priority to U.S. Provisional App. No. 63/330,365, filed Apr. 13, 2022, both of which are incorporated herein in their entireties by specific reference for all purposes.

This invention relates to a flat siding product with a unique end-joint flashing treatment.

Flat siding is an exterior cladding product that may be installed in horizontal, vertical or diagonal orientations. It may be installed fully flush with the wall. It may come in various dimensions (e.g., ½″ thick×8″ wide×16′ long), with various surface textures (e.g., smooth, cedar, and the like). It may be fashioned of various materials, including, but not limited to, sawn wood, engineered wood composites of various types, cellulose fiber cement, or combinations thereof. Oriented, multilayer wood strand boards of the above-described type, and examples of processes for pressing and production thereof, are described in detail in U.S. Pat. Nos. 3,164,511, 4,364,984, 5,435,976, 5,470,631, 5,525,394, 5,718,786, 6,461,743, and U.S. patent application Ser. No. 17/747,930, all of which are incorporated herein in their entireties by specific reference for all purposes.

Installation of flat siding products present a unique challenge when the aesthetic desire for a “blind nail” attachment (i.e., the nail head is not visible and does not penetrate the outer surface of the siding) is coupled with the engineering need to withstand local building code requirement for specified wind loads (i.e., so that adjacent pieces remain fully flush on the wall and resist being pulled away or detached from the wall). Various modifications of a shiplap or tongue-and-groove joint profile with locking edges may be used to secure the two adjacent products. However, the locking flanges or profile elements of the respective joint edges prevent prior-art flashing devices from directing water out and away from the end joint, which typically is a flat or butt joint with respect to the siding boards meeting end-to-end.

In various exemplary embodiments, the present invention modifies the ends of the siding, during manufacture or in a factory setting, to adjust the locking flange profile. This allows the ends and edges to precisely mate with a unique piece of factory-produced or pre-made flashing of similar or matching profile. Thus, the flashing piece fits with the ends of the adjacent siding boards and aligns with the profile of the locking edges so the system sheds water effectively and prevents water from penetrating behind the siding. In addition, the factory-modified siding and the pre-manufactured flashing pieces are supplied as a ready-to-install system that simplifies the siding installation process and shortens the time and cost of installation.

In several exemplary embodiments, the present invention comprises a system, method, and associated flashing device(s). Portions of the lower edge proximate the ends of siding piecesL,R (for the left piece and right piece, respectively) are modified as discussed below, and the joints between the ends are backed by a unique flashing piece during installation. The upper edgesand lower edgesof each siding piece form corresponding profiled portions of a locking flange joint. The locking flange joint is formed when an upper siding piece(or row of upper siding pieces) is installed above a lower siding piece(or row of lower siding pieces). The terms “upper” and “lower” are used with the respective vertical positioning of two adjacent siding pieces or two adjacent rows of siding pieces, and a siding piece or row may be described as “upper” with respect to a lower piece or row, and as “lower” with respect to a higher piece or row.

An example of a locking flange joint system with a modified shiplap joint is described in U.S. patent application Ser. No. 18/097,447, filed Jan. 16, 2023, published Jul. 20, 2023 as Pub. No. 2023-0228099, which is incorporated herein in its entirety by specific reference for all purposes. That reference discloses a unique modified shiplap joint with matching or corresponding reverse curves (S-curve), where two simple curves turn in opposite directions (e.g., a first curve followed immediately by a second curve in the opposite direction). The opposing edges or ends of a piece of flat siding comprise one-half of the modified shiplap joint: an underlap edge, and an overlap edge. In a horizontal configuration, the underlap is the top edge of the siding, and the overlap is the lower edge of the siding, so that when two siding pieces are assembled, any water or moisture on the exterior of the siding will run down the exterior side or face of the siding, and not enter or flow into the joint and thus potentially get behind the siding. The ends of the siding pieces on the same row form vertical butt joints, often with a gap between the ends. While the present invention may be used with the locking flange joint system with a modified shiplap joint as described in U.S. patent application Ser. No. 18/097,447, the present invention may be used other form of joint systems with adjustments made to match the adjusted joint profiles.

According to several embodiments of the present invention, the profiled joint portion along the lower edgeof the siding pieces is adjusted or modified during manufacture of the siding piece in the factory, or after manufacture but in a factory setting. As seen in, a portion of materialis absent, not present, or removed from the profiled joint section, for a modified sectionproximate the end. As seen in, approximately 2.5 inches of the locking tab or spline for the “underlap” or “lower” component of a locking joint at the ends of the siding has been removed, although the actual distance may vary, as described below. Doing this at the factory or during the manufacturing process has the advantage of allowing a precise removal or cut. An improper cut, such as a joint flange being too deeply or improperly cut, could weaken the siding product and affect its performance.

In several embodiments, the top cutof the modified sectionmay be orthogonal to the rear siding face, or angled downward (from back to front, so the front of the cut is lower). The angle of the topof the (i.e., “dog-leg”) double-bent portionof the flashing is selected to fit within this modified section. The angle of the topmay match the angle of the top cut, or may be larger or smaller, thereby providing a space between the top cut and the top of the dog-leg to help prevent water from being trapped therein.

When two ends are placed adjacent to other, the respective modified sectionof each end match, and together form a flashing space or areaof sufficient length to receive the double-bent (i.e., “dog-leg”) portionof the flashing piecelower edge, and allow the double-bent portion to fit within the siding pieces and in front of the corresponding profiled joint portion along the upper edgeof the siding piece or piecesbelow.

In some alternative embodiments, the flashing may be made of flexible and/or molded material, such as, but not limited to, gasket material as described below, in whole or in part, particularly in the dog-leg section, so that the dog-leg portion, or the bottom of the flashing, can conform to or is molded to conform to the underlying profile, without necessitating adjustment or modification of the profiled joint portion along the lower edgeof the siding pieces (e.g., no material is removed from the siding). Thus, for example, the dog-leg portionmay comprise a flap or section of flexible material or molded material (molded to match the respective sections of the profiled joint) that fits between respective portions of the profiled joint without modification.

While the distances the modified sections extend from their respective ends may differ, in a preferred embodiment the distances are the same so that the flashing pieceis effectively centered on the vertical butt joint. The distances are chosen such that they are sufficient when the siding is installed, including an appropriate gap in the butt joint, to precisely accommodate the width of the flashing piece comfortably but without allowing lateral movement, or significant lateral movement, of the flashing when in place.

During installation, a lower row of siding is installed by driving or inserting a nail or other fastenerinto the top flange of the upper edge, which may have a groove or channel, when each piece of siding is mounted on a building or structure frame or sheathing. This forms a “blind nail” attachment when the overlap end of the vertically adjacent piece of siding is placed over this area (and thus the nail headcannot be seen). The depth of the groove or channel is such as to accommodate the nail or fastener head(i.e., the top of the nail or fastener head does not extend above the front faceof the underlap), and allows the overlap portion, and thus the adjacent pieces of siding, to lie flat when the jointis formed.

The next (upper) row of siding is installed above the previous row by each upper piece of siding placed above the lower pieces and moved downward so the profiled joint portion along the bottom edge enters and engages the corresponding profiled joint portion along the upper edges of the lower pieces of siding. During this process, the flashing piecesare inserted at the ends of the upper piece so that the lowermost legof the “dog-leg”fits over some or all of the front faceof the underlap portion of the upper edge joint profile. The lowermost legmay extend partially or completely over the nail or fastener headand/or channel. In a preferred embodiment, the lowermost legat least downward past the point where the upper edge of the lower piece of flashing in that area extends. The upper siding pieces are then nailed or fastened into place, in the same manner described above.

As shown in, the upper siding pieces are installed such that the vertical butt joints of a row are offset from one or more vertical butt joints of the adjacent rows. However, in some installations, the vertical butt joints for two or more adjacent rows may be aligned.

In some embodiments, the flashing piece may not be fastened to any siding piece or to the building or structure frame or sheathing. The lack of penetrations in the flashing help prevent water or moisture from penetrating into the frame or sheathing behind the siding. In other embodiments, the flashing piece may be fastened proximate its upper edge by nails or fasteners as described above. In a preferred embodiment, where the flashing piece extends to or near the height of the back edge of the respective piece of siding, the “blind nail” used to fasten the siding also acts to fasten the flashing piece, as seen in.

throughshow another embodiment of the flashing. In this embodiment, the dog-leg portiondoes not extend the full width of the bottom edge of the flashing, but instead extends only across a center portion, while two tabsparallel to and continuous with the main flashing section extend downward. The tabsextend downward behind the profiled upper edge of the adjacent lower pieceof siding, which increases stability of the flashing and eases placement and installation, thereby reducing time and expense of installation. The tabs are shown as being ½″ in width, but may be of any suitable width and configuration.

show a further embodiment where some (i.e., partial) or all of the flashing is corrugated(i.e., wavy, alternating curves, or with sine waves in cross-section).shows the corrugation on the dog-leg and extending upward therefrom to the upper edge of the flashing.shows the corrugation on the entirety of the flashing. The corrugation helps create a series of channels or space between the flashing and siding faces, thereby promoting the flow of water down the flashing and outward in the butt joint area. The width and depth of the channels may vary as needed, depending on the configuration.

shows another embodiment where some (i.e., partial) or all of the outward face of the flashing has a plurality of diagonal, slanted, or angled depressions or channels. In several embodiments, there are two sets of diagonal channels that form a “herringbone” pattern, where each channel is angled downward from the outer end, and leading to an inner endthat opens into a vertical channellocated between the two sets of channels. The depth of the diagonal channels may be the same for all diagonal channels, although in other embodiments the depth may vary between diagonal channels, or along the length of a channel (e.g., shallower at the outer end, and deeper at the inner end). In one embodiment, the outer end of the channel may be level with the face of the flashing and increasing in depth moving inwards. In the embodiment shown, the vertical channelis centrally located on the flashing, and of the same depth as the diagonal channels, or the depth of the inner endof the diagonal channels where they open into the vertical channel.

The diagonal channels and vertical channel are designed to catch water or moisture behind the joint, and direct the water or moisture toward the center of the flashing, and then downward and outward, over the dog-leg and onto the outer face of the lower piece of siding, as discussed above.

The width of the vertical channelmay be the same as the diagonal channels, although in a preferred embodiment the vertical channel is wider than some or all of the diagonal channels. In several embodiments, the vertical channel has the same width as the designed or required installation gap between the ends of the pieces of siding, and the vertical channel thus provides a spacing guide at the siding butt joint to make installation easier. For example, the vertical channel may be 3/16″, or slightly wider (e.g., ¼″ or 5/16″) for installations where a 3/16″ gap is required or used.

The width of the diagonal channels may be the same for all diagonal channels, although in alternative embodiments some or all of the diagonal channels may vary in with from each other. Similarly, the diagonal channels may be spaced evenly or variably. The number, side, and configuration of the diagonal channels may be varied depending on the engineering need for moisture/water management in a particular area or for a particular structure.

Similarly, the angle of the diagonal channels with respect to the vertical channel may be the same for all diagonal channels in a set, although in some embodiments the angles may vary. The angle(s) of the diagonal channels may be chosen and/or varied based on the engineering need for moisture/water management in a particular area or for a particular structure. In the embodiment shown in, the diagonal channel angles are constant at 30 degreesfrom a line orthogonal to the longitudinal axis of the vertical channel (e.g., the top of the “dog-leg” section).

shows the “herringbone” channels ofwith two vertical linear gasketsadded at the outer sides or edges of the diagonal channels and attached to the face of the flashing. The gaskets help ensure that no rain or other wind-blown moisture can be blown through the joint and behind the siding beyond the flashing (the arrowsshow the direction of water/moisture flow during a rain or similar event).

The gasketmaterial may be flexible, and factory-applied to the face of the flashing. This flexible gasket material, when overlapped with adjacent shiplap panels, provides a weather resistive seal to limit both water and air penetration. As the gasket material is flexible, it accommodates thickness and other variances that are typical in the siding and/or wall assembly. In several embodiments, the gasket or sealing material may comprise a variety of components, including, but not limited to, caulk, rubber, foam, silicone, polyurethane foam, urethane foam, and/or thermoplastic coatings (e.g., acrylics, polyvinyl acetates, polyvinyl esters, and the like). In several embodiments, the gasket material may comprise a compressible, water-resistant or water-impermeable material, such as foam, rubber or the like. In several embodiments, the gasket material may comprise ethylene propylene diene monomer rubber or foam (EPDM). The gasket material may be sprayed or brushed on as a liquid, or affixed or attached to the respective faces and sides as a solid material. In one exemplary embodiment, the gasket material (e.g., EPDM) on a face has a thickness of at least 1/32″. In additional embodiments, the gasket material may comprise fire resistant materials, e.g., an intumescent fire-resistant caulk.

shows a front partial perspective view of the flashing piece ofinstalled behind the joint between the ends of two upper pieces of siding, and above a continuous portion of a lower piece of siding.

shows the flashing piece ofwith a central vertical linear gasketadded in the vertical channeland attached to the face of the flashing. This gasket may be made of the same or similar material, and may be similarly attached to the flashing (including factory-installed), as that for the gasketsdescribed above. The central gasketas shown is wider than the side gaskets, and serves the same purpose in helping to ensure that no rain or other wind-blown moisture can be blown through the joint and behind the siding. In particular, the width of the central gasket helps seal the gap in the joint by underlying the gap. The central gasket also helps divide and direct the water flow downward through two drainage channels formed to either side of the central gasket (as indicated by the arrows). In an exemplary embodiment, the width of the central gasketmay have the same width as the designed or required installation gap between the ends of the pieces of siding, and thus provides a spacing guide at the siding butt joint to make installation easier. For example, the central may be 3/16″ to match a required or desired 3/16″ gap. In other embodiments, the width of the central gasket may match, or be slightly smaller than, the width of the vertical channel.

shows a front partial perspective view of the flashing piece ofinstalled behind the joint between the ends of two upper pieces of siding, and above a continuous portion of a lower piece of siding.

Accordingly, this system allows the ends and edges of the adjacent pieces of siding (horizontally and vertically) to precisely mate with a piece of factory-produced or pre-made flashing of similar profile. Thus, the flashing piece fits with the ends of the adjacent siding boards and aligns with the profile of the locking edges so the system sheds water effectively and prevents water from penetrating behind the siding. The bottom edge of the flashing piece is twice bent, as described above, forming a sloped profile that may match the slope of the top cut. The “leg” section past the sloped profile is generally parallel to the main section and extends downward along the outer face of the “underlap” component, and between it and the inner face of the “overlap” component. In one exemplary embodiment, the flashing piece is 6¾″ in length for the main pan section, the sloped section is ¼″ long, and the leg section is ½″ long. In addition, the factory-modified siding and the pre-manufactured flashing pieces may be supplied as a ready-to-install system that simplifies the siding installation process and shortens the time and cost of installation.

In several embodiments, the prefabricated flashing piece comprises corrosion and fire-resistant metal flashing, configured to align with the modified bottom edge of the siding, and the profile of the top edge of the adjacent piece of siding (typically the lower piece of siding). Flexible, fabric-style flashing is not suitable for open joints that expose the flashing to UV and fire. In one embodiment, the flashing piece is approximately 4 inches in width, which allows it to fit within the total of approximately 5 inches of flashing gap (2½″ inches per piece, plus a gap between the ends, which may be approximately 3/16″).

In alternative embodiments, the flashing piece comprises one or more of metal, copper, aluminum, galvanized steel, stainless steel, flexible metal fabric, and/or an adhesive-based metal foil. As noted above, the flashing may include gaskets with fire-resistant gasket material (e.g., intumescent caulk), and thus reduce exposure of flexible and/or fabric-style flashing to fire and/or UV radiation. In other embodiments, the flashing comprises one or more of a molded plastic polymer, high impact polystyrene (HIPS), polypropylene, polycarbonate, and/or a polymer coated fiberglass, some or all of which may be fire-resistant and UV resistant. Flashing also may comprise various combinations of the materials described above.

Thus, it should be understood that the embodiments and examples described herein have been chosen and described in order to best illustrate the principles of the invention and its practical applications to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited for particular uses contemplated. Even though specific embodiments of this invention have been described, they are not to be taken as exhaustive. There are several variations that will be apparent to those skilled in the art.