U.S. patent application number 10/411305 was filed with the patent office on 2004-10-14 for exterior building cladding having rigid foam layer with drain channels.
Invention is credited to Schilger, Herbert K..
Application Number | 20040200183 10/411305 |
Document ID | / |
Family ID | 33130944 |
Filed Date | 2004-10-14 |
United States Patent
Application |
20040200183 |
Kind Code |
A1 |
Schilger, Herbert K. |
October 14, 2004 |
Exterior building cladding having rigid foam layer with drain
channels
Abstract
A novel building construction is described for exterior building
walls. The construction comprises an interior frame formed of a
plurality of laterally spaced studs or beams, a layer of rigid
insulation adjacent to the exterior side of this steel frame,
exterior building cladding adjacent the exterior side of the rigid
insulation and a plurality of non-thermal conducting plastic
connectors extending through the layer of rigid insulation and
connecting together the exterior cladding and the interior steel
studs or beams. Vertical channels are formed adjacent both the
inside and outside faces of the insulation layer to remove
moisture. This provides the required structural strength with a
minimum of thermal conductivity from the warm side to the cold side
of the building envelope, while providing exterior drain channels
and interior moisture removing channels.
Inventors: |
Schilger, Herbert K.;
(Calgary, CA) |
Correspondence
Address: |
KIRBY EADES GALE BAKER
BOX 3432, STATION D
OTTAWA
ON
K1P 6N9
CA
|
Family ID: |
33130944 |
Appl. No.: |
10/411305 |
Filed: |
April 11, 2003 |
Current U.S.
Class: |
52/782.1 ;
52/506.01 |
Current CPC
Class: |
E04C 2/205 20130101 |
Class at
Publication: |
052/782.1 ;
052/506.01 |
International
Class: |
E04B 002/00 |
Claims
1. A building wall construction comprising an interior frame formed
of a plurality of laterally spaced studs or beams, a layer of rigid
foam insulation adjacent the exterior side of said frame and an
interior wall connected to the interior side of the frame with the
rigid insulation layer and interior wall forming a wall cavity
therebetween, vertical venting channels formed on the interior side
of said rigid insulation layer for collecting and removing moisture
from the wall cavity and vertical venting channels formed on the
exterior side of said rigid foam insulation for collecting and
removing rain water, exterior building cladding adjacent the
exterior side of said rigid foam insulation and a plurality of
non-thermal conducting plastic connectors extending through said
layer of rigid foam insulation and connecting said exterior
cladding to said studs or beams.
2. A wall construction according to claim 1 wherein the interior
frame is formed of wood or steel studs.
3. A wall construction according to claim 2 wherein the rigid foam
insulation is in the form on panels having a thickness of about 1
to 3 inches.
4. A wall construction according to claim 3 wherein the rigid foam
insulation panels are joined edge to edge by means of edge slots
containing plastic splines.
5. A wall construction according to claim 4 wherein screws extend
through the splines and into the studs.
6. A wall construction according to claim 4 wherein the vertical
venting channels are laterally spaced by a distance of about 2 to 4
inches.
7. A wall construction according to claim 3 wherein the plastic
connectors are flexible plastic straps.
8. A wall construction according to claim 3 wherein the plastic
connectors are rigid plastic strips.
9. A wall construction according to claim 8 wherein the rigid
plastic connectors are strips having sharp points capable of
piercing the rigid insulation.
10. A wall construction according to claim 3 wherein the plastic
connector is formed of polyolefin.
11. A wall construction according to claim 10 wherein the
polyolefin is polypropylene or polyethylene.
12. A wall construction according to claim 11 wherein the plastic
connectors are joined to studs by means of screws.
13. A wall construction according to claim 3 wherein the exterior
cladding is stucco on metal mesh lath and the plastic connectors
have loop portions which hook onto the metal mesh.
14. A wall construction according to claim 3 wherein the exterior
cladding is bricks and the plastic connectors are joined to the
brick wall by means of metal brick ties extending from the outer
ends of the plastic connectors into the brick mortar joints.
15. A wall construction according to claim 3 wherein the exterior
cladding is siding connected to vertical furring strips which are
connected to horizontal plastic splines.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates to building construction and more
particularly to a building wall construction having an interior
frame work and exterior cladding.
[0002] Particularly in colder climates, it has been a common
building technique for many years to construct an interior support
frame, with an exterior wall cladding or shell fixed to the
exterior side of the frame and an interior wall fixed to the
interior side of the frame. Many different materials have been used
for the exterior wall cladding, including brick veneer, aluminum
siding, vinyl siding, wood siding, stucco, concrete, glass, metal,
etc. Such constructions may be made with or without insulating
materials.
[0003] The frame is typically made of wood or steel and frames made
of steel studs and beams are now becoming more commonplace even for
home construction. It is also commonplace to use metal connectors
for connecting the exterior wall cladding to the frame and these
may be in the form of screws, bolts, clips, protruding lugs, etc.
Particularly when a steel frame is used, when there is a difference
between exterior and interior temperatures, there tends to be
condensation and subsequent corrosion along the connector from the
cold exterior cladding to the warm interior wall cavity of the
building. Even when rigid thermal insulation is used between the
exterior cladding and the structural frame, this problem of
condensation and corrosion may continue through the insulation
along the structural connector.
[0004] It is an object of the present invention to provide a
thermally non-conducting connection between the exterior cladding
and the interior frame of the building wall to thereby break the
bridge between the different temperature areas and also to remove
any interior condensation and collected rain water.
SUMMARY OF THE INVENTION
[0005] The present invention in its broadest aspect relates to a
building wall construction comprising an interior frame formed of a
plurality of laterally spaced studs or beams, a layer of rigid
insulation adjacent the exterior side of the frame and an interior
wall connected to the interior side of the frame with the rigid
insulation layer and interior wall forming a wall cavity
therebetween, vertical channels formed in the rigid insulation
layer adjacent the interior side thereof for collecting and
removing moisture from the wall cavity and vertical channels formed
in the rigid insulation adjacent the exterior side thereof for
collecting and removing rain water. An exterior building cladding
is provided adjacent the exterior side of the rigid insulation and
a plurality of non-thermal conducting (insulating) plastic
connectors extend through the layer of rigid insulation and connect
the exterior cladding to the interior frame.
[0006] The frame is typically made with wood or metal studs, e.g.
galvanized sheet steel channels. The rigid insulation is typically
made of plastic foam, e.g. polystyrene foam.
[0007] The exterior wall cladding may be any of the exterior wall
claddings that are traditionally used. These may include, for
example, brick veneer, wood siding, aluminum siding, vinyl siding,
stucco, concrete, glass, metals, etc.
[0008] The non-thermal conducting (insulating) plastic connectors
can be made from a variety of plastic materials having high
strength and an ability to withstand high variations in
temperature. High strength polyolefins, such as polyethylene or
polypropylene are particularly useful. The connectors are typically
made of plastic material having a form of relatively thin bands.
The material may be either flexible or rigid.
[0009] In passing through the rigid insulation layer, the plastic
connector should fit snugly within an opening in the rigid
insulation through which it passes. This can conveniently be
accomplished by providing the connector with a sharpened tip which
can simply be pushed through the insulation, creating its own
opening.
[0010] The inner end of each plastic connector can be connected to
a frame component by a variety of means and can be very simply
connected by means of screws. The outer end of each plastic
connector may be connected to the building cladding in a number of
different ways which will be described hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] In the drawings which illustrate certain preferred
embodiments of this invention:
[0012] FIG. 1 is an isometric view of a wall construction according
to the invention;
[0013] FIG. 2 is a sectional elevation of a wall construction
according to the invention;
[0014] FIG. 3 is a horizontal section through a rigid foam panel of
the invention;
[0015] FIG. 4 is an elevation view of a valid form panel;
[0016] FIG. 5 is an elevation showing a detail of connector slot in
the rigid form panel;
[0017] FIG. 6 is a perspective view of a plastic connector for
brick facing;
[0018] FIG. 7 is a perspective view of a plastic connector passing
through a foam panel;
[0019] FIG. 8 is a perspective view of a plastic connector for
stucco lath; and
[0020] FIG. 9 is a perspective view of a general purpose plastic
connector.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] As seen in FIGS. 1 and 2, this construction according to the
present invention includes an interior framework formed of steel
studs 10. Each stud has an inner flange 11, an outer flange 12 and
a central web 13. Floor beams 14 intersect the wall frame
portions.
[0022] A standard wall paneling 15 is connected to inner flanges 11
of studs 10 and panels of rigid foam insulation 16 are placed
adjacent the outer face of the outer flange 12 of studs 10. The
inner wall panels and the foam panels form therebetween the wall
cavity 17 is fill with commercial insulation, e.g. glass fiber
batts.
[0023] The rigid foam panels 16 are connected to the studs 10 by
way of plastic connectors 20 one type of which can be seen in FIG.
1. In the particular embodiment of FIGS. 1 and 2, a metal mesh
stucco lath 23 is applied over the rigid foam panels 16 and over
the lath is applied an exterior stucco coating 24.
[0024] The wall structures are horizontally separated at each floor
level of a structure as can be seen in FIG. 2. A downwardly sloping
metal flashing 25 is installed between the two sections for
draining away any water.
[0025] Details of the rigid foam panels 16 can better be seen from
FIGS. 3, 4 and 5 and these are preferably formed from panels having
a thickness of about 2 inches. Vertical channels 21 are formed in
the foam panels adjacent both the interior and exterior sides of
the rigid foam panels 16 and connect to the exterior by way of thin
channels 22.
[0026] The vertical channels in the exterior face of the rigid foam
panels provides a rain screen at the interface between the stucco
and the rigid insulation. Exterior water penetration drains to the
bottom of the channel and exists via a drain wick 28 and flashing
25.
[0027] Vapour that may collect in the wall cavity is vented by way
of the channels on the inside face of the rigid insulation panels.
This vaporizes up through the channels and exits through the vents
26 as well as through weep holes 27.
[0028] The solid insulation panels also have grooves or slots 30
cut into the edge faces to allow a positive connection all around
each panel by means of plastic splines inserted between the panels.
These plastic splines may also be made from a polyolefin plastic
such as polyethylene or polypropylene. A combination of the rigid
foam panels, the plastic connectors extending through the foam
panels and the plastic splines connecting the foam panels edge to
edge together create a complete insulating envelope free of any
thermal bridging between the interior and exterior of the building.
The plastic splines when inserted in the slots 30 form a rigid
lateral support between the studs. As part of this lateral
strengthening, screws may extend through the splines and into the
studs.
[0029] Details of some forms of plastic connectors can be seen in
FIGS. 6 to 9. The plastic connector 36 of FIG. 6 is in the form of
a wedge with a sharp tip 37 for penetrating a foam panel 16. The
connector 36 has holes 40 for connecting to interior studs and an
inner hole 38 containing a steel loop 39 which becomes embedded in
a mortar joint between bricks thereby locking a brick outer shell
to the frame.
[0030] The gauge shows a further form of elastic connector strip
used for connecting stucco lath mesh. This strip 42 has a sharp
point 44, connector holes 40 and a loop portion 43 which loops
around and holds the stucco lath mesh.
[0031] The connector of FIG. 9 can be used for a variety of
purposes having a perpendicular end flange 35. This is the flange
shown in use in FIG. 1.
[0032] It will be understood that the wall construction of this
invention can be used with any exterior building cladding,
including brick, stucco or siding, e.g. wood, metal or vinyl
siding. For the mounting of the siding vertical furring strip are
typically used which are attached, e.g. by screws, to horizontal
plastic splines 31 inserted between the rigid foam insulation
panels.
[0033] The present invention is not limited to the embodiment
disclosed and the right is reserved to make variations and
modifications in the invention that do not depart from the spirit
of scope thereof as herein defined by the appended claims.
* * * * *