Deck Flashing Cleat System for Unobstructed Water Drainage

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Solution Overview

Problem

Existing waterproof deck flashing systems face issues with water seepage due to obstructed flow at the free edge, fastener penetrations, inadequate sealing, and complex installation processes, leading to damage and maintenance challenges.

Innovation Solution

A two-component deck flashing system featuring an 'L' flashing strip with attached cleats using clinch lock joints and a cover plate that eliminates the need for fasteners penetrating the waterproof sheet, provides overlapping and easily sealable components, and simplifies installation by using pre-punched holes for fastener guidance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional T-bar flashing strip is installed with crosshead abutting the free edge to define the outside edge, then the topping surface edge is properly defined, but water flow is blocked at the free edge causing water to seep through fastener penetrations and damage the subfloor

Engineering Contradiction:

Improveedge definition precisionVSAvoidwaterproofing reliability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

Instead of having the flashing crosshead abut the free edge to define the boundary (which blocks water), the invention positions the cleat system to define the edge while leaving the free edge open for water drainage. The cover plate then sits on top of the cleat crosshead, creating a non-abutting configuration that allows water to flow freely over the edge while still defining the topping surface boundary.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The traditional single T-bar flashing strip is segmented into separate components: an L-shaped flashing strip with attached cleats, and a separate cover plate. This segmentation allows the cleat system to perform the edge-definition function while the cover plate provides the waterproofing function, eliminating the conflict between edge definition and water drainage.

Inventive Principle:

Principle #1Segmentation

2Strength

If fasteners are used to secure the T-bar stem through the waterproof sheet and protective sheet, then the flashing components are securely attached, but water can penetrate through the fastener penetrations and damage the subfloor

Engineering Contradiction:

Improveattachment strengthVSAvoidwater penetration through fasteners

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The invention extracts the fastening function from the water pathway. Fasteners are used only to attach the L-shaped flashing strip to the subfloor and to attach the cover plate to the cleat crosshead, but not to penetrate the waterproof sheet at critical water flow locations. This separation of fastening locations from water penetration paths eliminates the harmful effect while maintaining attachment strength.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If multiple separate components (L-shaped flashing strip, T-bar stem, T-bar crosshead, cover plate) are used to create the flashing system, then the system can define the edge and provide waterproofing, but the installation process becomes complex and time-consuming

Engineering Contradiction:

Improvewaterproofing reliabilityVSAvoidinstallation complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention merges the L-shaped flashing strip, cleats, and cover plate into an integrated assembly where the cleats are pre-attached to the L-shaped flashing strip, and the cover plate is positioned on top of the cleat crosshead. This merging reduces the number of separate installation steps while maintaining the functional benefits of multiple components for waterproofing and edge definition.

Inventive Principle:

Principle #5Merging (Combining)

4Manufacturing precision

If the T-bar stem is placed directly on the waterproof sheet to define the edge, then the outside edge of the topping surface is properly defined, but water accumulates at this location and seeps through penetrations in the waterproof sheet

Engineering Contradiction:

Improveedge definition precisionVSAvoidwater accumulation and seepage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The invention introduces the cleat system as an intermediary between the L-shaped flashing strip and the cover plate. The cleat crosshead provides the edge definition function while being positioned to allow water to flow over it freely, and the cover plate sits on top of the cleat crosshead rather than the waterproof sheet, preventing water accumulation and seepage at the edge location.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS8869466B2Waterproof deck flashing system and method

Publication Date: 2014.10.28 RICHARD AVELAR & ASSOC A CALIFORNIA

AI summary

A two-component deck flashing system and method for installing the same. The system utilizes “L” flashing strips with attached cleats utilizing clinch lock joints to alleviate the need for fasteners which might otherwise penetrate and easily damage waterproof sheeting materials. A cover plate is attached to the cleats to define the outside edge of the topping surface. This two component system is designed for installation at wall-to-deck junctures by incorporating a form of a wall “saddle” flashing having one or more wall plates with attached “L” flashing extension with cleats and cover plate extensions. All components are integrated with and overlapping adjacently installed components to provide a flush, easily sealed and maintained, top surface. This two-component deck flashing system can be installed more easily and effectively in the field than prior art systems.