U.S. patent application number 10/660156 was filed with the patent office on 2005-03-17 for wall cavity drain panel.
This patent application is currently assigned to Clear Family Limited Partnership of c/o Dale Lierman, Esq.. Invention is credited to Tomes, Paul Allen.
Application Number | 20050055983 10/660156 |
Document ID | / |
Family ID | 34273608 |
Filed Date | 2005-03-17 |
United States Patent
Application |
20050055983 |
Kind Code |
A1 |
Tomes, Paul Allen |
March 17, 2005 |
Wall cavity drain panel
Abstract
An improved wall cavity drain panel and wall cavity structure
includes a grooved insulating panel with a water-permeable fabric
over the grooved face and a water permeable matrix on the fabric at
its lower edge and defining a mortar cath trough to prevent weep
hole clogging.
Inventors: |
Tomes, Paul Allen;
(Fairfield, OH) |
Correspondence
Address: |
WOOD, HERRON & EVANS, LLP
2700 CAREW TOWER
441 VINE STREET
CINCINNATI
OH
45202
US
|
Assignee: |
Clear Family Limited Partnership of
c/o Dale Lierman, Esq.
Suite 203, 6120 S. Gilmore Road
Fairfield
OH
45014
|
Family ID: |
34273608 |
Appl. No.: |
10/660156 |
Filed: |
September 11, 2003 |
Current U.S.
Class: |
52/782.1 |
Current CPC
Class: |
E04B 1/70 20130101; E04B
1/7061 20130101; E04B 1/7616 20130101; E04B 1/7046 20130101 |
Class at
Publication: |
052/782.1 |
International
Class: |
E04C 002/00 |
Claims
What is claimed is:
1. An insulating panel comprising: a member of insulating material
having at least a lower edge; a water-permeable fabric disposed on
one side of said member and extensible beyond said lower edge; and
a matrix attached to said fabric extensible beyond said edge of
said panel member.
2. A panel as in claim 1 wherein said matrix is flexible.
3. A panel as in claim 1 wherein said matrix and the fabric to
which it is attached comprises a flexible laminate.
4. A panel as in claim 1 wherein said member has a face defined by
a plurality of grooves and said fabric and said matrix is fixed to
said member at said grooved face.
5. A panel as in claim 1 wherein said fabric is a spun bond
non-woven fabric.
6. A panel as in claim 5 wherein said matrix is a filamentatious
fabric thicker than said water-permeable fabric.
7. A panel as in claim 6 wherein said matrix is
water-permeable.
8. A panel as in claim 7 wherein said matrix is heat bonded to said
water-permeable fabric.
9. A panel as in claim 1 wherein said fabric has one side attached
to said member and said matrix is attached to said one side of said
fabric.
10. An insulated water control panel for use between a brick wall
structure formed from brick and mortar and a subwall interior of
said brick wall structure, said panel comprising: a foam member
having a lower edge; a water-permeable fabric disposed on one face
of said member and extensible outwardly therefrom beyond said edge;
a water-permeable matrix attached to said fabric extensible beyond
said edge of said member; wherein said matrix has a length
extendible from said member toward a brick wall when said panel is
disposed adjacent thereto and thence extensible along a backside of
a lower cource of bricks in said brick wall structure.
11. A panel as in claim 10 wherein said extensible fabric and said
matrix are flexible.
12. A panel as in claim 11 wherein said fabric is fixed to an outer
face of said member.
13. A panel as in claim 12 wherein said outer face of said member
has groove comprising water passages.
14. A panel as in claim 12 wherein said matrix extends away from
said outer face from a position inwardly of said lower edge.
15. A panel as in claim 14 wherein said matrix extensible along a
backside of a lower course of bricks is parallel to and spaced from
said member.
16. A panel as in claim 10 wherein said fabric has one face fixed
to an outer face of said member, and said matrix is fixed to said
one face of said fabric.
17. A brick wall structure comprising: a brick wall defined by a
plurality of brick courses; an interior wall defining with an
interior surface of said brick courses a cavity therebetween, said
cavity having a distance thereacross; a panel disposed in said
cavity and spaced from said brick courses; said panel having an
insulating member with an outer face and lower edge; a
water-permeable fabric disposed on said outer face of said
insulating member and extensible beyond said lower edge of said
panel, said fabric having one side attached to said panel; and a
flexible, water-permeable matrix attached to said fabric beyond
attachment of said fabric to said panel and having a width in
excess of the distance across said cavity from said interior wall
to said brick courses and of sufficient dimension to extend
parallel along said interior surface of at least one of said brick
courses.
18. A structure as in claim 17 wherein said matrix is extended
across said cavity to a brick course and then upwardly alongside an
interior surface of a brick course.
19. A structure as in claim 18 wherein said cavity is further
defined by a base and wherein said matrix extending across said
cavity is spaced from said base.
20. A structure as in claim 19 further including a flashing
disposed over said base, said matrix extending across said cavity
is spaced from said flashing.
21. A structure as in claim 17 further including weep holes within
a course of bricks, and wherein water passing through said fabric
and said matrix flows through said weep holes.
22. A structure as in claim 17 wherein said fabric has a surface, a
portion of which is attached to said insulating member, said matrix
being attached to said surface of said fabric and on the same side
of said fabric as is attached to said insulating member.
23. A structure as in claim 17 further including a brick tie
extending from said brick courses to said interior wall through
said insulating member.
24. A structure as in claim 23 wherein said brick tie extends
through said fabric disposed on said outer face of said insulating
member.
25. A structure as in claim 24 wherein said matrix is fixed to said
interior wall by said tie and said fabric.
26. A structure as in claim 17 wherein said fabric and said matrix
attached thereto define a mortar catch channel for catching mortar
droppings thereon from between bricks in brick courses, and wherein
water passes through said fabric and said matrix attached
thereto.
27. A method of controlling water flow through weep holes in a
course of bricks defining a brick wall and from a cavity behind
said wall defined by an interior wall, wherein a panel having a
water-permeable facing fabric thereon is disposed in said cavity
and a flexible matrix is attached to said fabric for extending
across said cavity from said panel to said brick wall, said method
comprising: orienting said panel in said cavity with said fabric
thereon facing an interior surface of said brick wall, a lower end
of said panel resting on a base within said cavity; extending said
fabric and matrix away from said panel and across said cavity
toward said interior surface of said brick wall; orienting said
matrix along said interior surface above said base, thereby forming
a mortar catching trough of said fabric and matrix proximate said
base, and catching mortar dropping from brick courses onto said
trough whereby mortar is prevented from clogging said weep holes
and water in said cavity can pass through said fabric and matrix
and outwardly of said brick wall through said weep holes.
28. A method as in claim 27 including the further method step of
orienting said matrix includes orienting said matrix above and
spaced from said base.
29. A method as in claim 27 including flexing said fabric into a
channel shape above said base, and flexing said matrix thereon
upwardly along an interior surface of a lower course of bricks and
over an inlet of said weep holes.
30. A method as in claim 27 including the step of fixing said panel
to said interior wall.
31. A method as in claim 27 wherein said panel comprises a grooved
face to which said fabric is attached, the method comprising
passing water through said fabric into grooves on said grooved
face, passing water along said grooves to said base, and passing
water through said weep holes under said matrix.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates to brick walls and insulating panels
and more particularly to maintaining water flow from a cavity
behind a brick wall through weep holes in brick courses defining a
brick wall.
[0002] A brick wall structure typically includes a veneer or facing
of bricks laid in elongated courses outside of an interior or
subwall of concrete block, of framing with insulating sheathing, or
the like. Typically, the brick wall is set on a base, or on a
flashing on a base, with bricks held together by mortar between
adjacent bricks and between brick courses. A cavity is defined by
weep holes between side-by-side bricks in a lower course, for
example, and water finding its way into the cavity is anticipated
to drain outwardly through these weep holes.
[0003] The problem is that the weep holes can clog. Water can back
up in the cavity, causing mold, odor, damage or other nasty
results. The clogging of weep holes can be produced by a number of
agencies, can cause weep hole clogging, primarily among them is
mortar dropped from the setting process of laying one brick course
on top of another. Excess mortar falls down the rear or interior
surface of the brick wall and can clog the inlets of the lower weep
holes.
[0004] A variety of solutions have been proposed to prevent weep
hole clogging by mortar droppings. See, for example, only U.S. Pat.
Nos. 5,343,661; 5,230,189; Re. 36,676; 6,0234,892; 5,937,594;
6,112,476 and 5,598673. In several of these, open cell or
filamentatious bodies are inserted into the cavity between the
bricks and the subwall; the "bodies" may have particularly shaped
top surfaces and are placed without fixation devices, rest freely
on the wall base, or have a thickness the same as the cavity
width.
[0005] Such systems require the insertion then of a separate member
or "body" into the cavity and must be supplied as a separate
building element. Moreover, there is no uniform procedure by which
weep holes in upper floors, levels or courses can be protected.
[0006] Accordingly, it has been one objective of the invention to
improve the protection of weep holes in a brick wall from mortar
clogging.
[0007] A further objective of the invention has been to provide
improved brick wall structure to facilitate weep hole drainage.
[0008] A further objective has been to provide an improved
apparatus for reducing or preventing weep hole clogging in brick
walls.
[0009] A yet further object of the invention has been to provide
improved methods of controlling water flow through weep holes in a
course of bricks defining a brick wall and from a cavity defined
between a brick wall and an interior wall.
SUMMARY OF THE INVENTION
[0010] To these ends, a preferred embodiment of the invention
contemplates an improved dual-function panel for disposition in a
wall cavity wherein the panel is manufactured of an insulative
material such as foam. The panel has a grooved face over which is
disposed a water permeable fabric attached to the face. Insulating
panels having these features are available from T. Clear
Corporation of Hamilton, Ohio under their brands "Therma-Dry" and
"ThermaCav". In addition, however, the panels are improved from the
water control goals of this invention by having a lower edge of the
fabric not attached to the panel and being extensible therefrom. To
such an extensible portion is secured a preferably flexible, water
permeable matrix.
[0011] In use, such panels form an insulating sheathing or panel
exterior of a subwall of concrete block, for example, but interior
of and spaced from the interior side of the brick wall to define,
or reside in, a cavity. The lower edge of fabric is extended away
from the panel, across the cavity toward the brick wall, then
upwardly along a course of bricks above or over weep holes formed
in or under a brick course.
[0012] Thus, the fabric is flexed into a "U"-shaped channel above
any wall base and along the cavity at its lower end. The matrix is
attached to the fabric proximate the attachment of the fabric to
the insulating panel, extends across the cavity with the fabric,
and upwardly with it parallel to the rear surface of the brick
wall. The matrix thus extends across the cavity and is flexed about
ninety degrees upwardly in water-passing support of the fabric
channel. A mortar catching channel is thus formed, catching any
mortar falling off a brick course and stopping it before it can
clog the inlet of a weep hole covered or under the laminate of
fabric and matrix.
[0013] Water can then pass through the fabric and matrix onto the
cavity base or any flashing at the base, and out unclogged weep
holes under or in a brick course. In addition, water in the cavity
can flow through the fabric, down through grooves in the panel face
behind the fabric, or onto the base or flashing, with mortar
droppings retained by the above fabric and matrix laminate
extending across the cavity.
[0014] In addition to the benefits of maintaining the weep holes
free of mortar clogging, another significant benefit of this
invention is the provision of the water flow controlling structure
as described, together with an insulating panel used in a building
process so no additional inserts, mats or other special forms are
required. In particular, a contractor only needs to set the
insulating panels with extensible fabric and matrix as desired,
then fold the fabric and matrix laminate up along the rear surface
of one of the early brick courses. In this way, an insulated brick
wall structure is provided with the advantage of prevention of weep
hole clogging by mortar droppings and without the need for other
special inserts, mats or the like.
[0015] These and other objects and advantages will become readily
apparent from the following detailed written description and from
the drawings in which:
DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is an illustrative cross-sectional view of a brick
cavity wall showing the invention;
[0017] FIG. 1A is a perspective drawing of the rear surface of a
lower course of bricks in the wall of FIG. 1;
[0018] FIG. 2 is an enlarged view of the lower portion of FIG. 1;
and
[0019] FIG. 3 is a perspective view of a wall cavity drain panel
according to the invention as also shown in FIGS. 1 and 2 but with
a portion of the fabric and matrix peeled back for clarity.
[0020] Turning now to the drawings, there is shown in FIGS. 1 and 2
a brick cavity wall structure defined by a brick wall 11, a subwall
12 which, as shown in one embodiment, is a concrete block wall, and
a cavity 13 defined therebetween. As shown in FIG. 1, brick wall 11
is itself defined by a plurality of brick "courses", i.e. single
layers of end-to-end bricks, 15-23, set on top of one another from
the lower course 15 and so on as high as the wall 11 may be.
[0021] In a lower course of bricks 15, preferably a plurality of
weep holes 25 are formed, either in the bricks or defined by
lateral spaces between the bricks of course 15. These weep holes
have an inlet communicating with cavity 13, and extend outwardly so
water can flow (arrow A) from cavity 15 through the holes to the
exterior of the wall 10 at 25a as shown in FIG. 1A.
[0022] Concrete block wall 12 is defined by courses 26-28, and so
on, of concrete blocks.
[0023] Brick wall 11 and subwall 12 rest on a base 32 of concrete
or any other suitable material.
[0024] Bricks in the courses 15-23 are set in mortar, such as
mortar 34 between the courses, while the concrete blocks defining
subwall 12 can also be set in mortar such as at 35.
[0025] A brick wall tie 37 is extended outwardly into cavity 13
from mortar 35 between concrete block courses 27, 28, for example.
A wall tie 38 extends into cavity 13 from mortar 34 between brick
courses 20, 21, for example, and is operably connected to tie 37 in
any suitable fashion to facilitate stability of brick wall 11. As
many ties 37, 38 as are needed are used.
[0026] A bracket end39 extends downwardly from tie 37 as shown in
FIG. 1, and as will further be described.
[0027] An elongated flashing 41, shown in FIGS. 1 and 2 has a
vertical section 42 extending upwardly along block course 26, and a
horizontal section 43 extending from block course 26 outwardly on
base 32 under lower brick course 15. Flashing 41 helps to direct
water outwardly of any wall structure 10.
[0028] As illustrated in FIGS. 1, 1A and 2, mortar 34a, under brick
course 15, lies on flashing 41 and is somewhat mashed or compressed
by bricks thereon so it extends behind brick course 15 into cavity
13. When mortar 34b and 34c then is applied, as the courses are
set, such mortar (as at 36) tends to drop down behind lower brick
courses, into cavity 13 and toward or onto flashing 41 or onto base
32 in the absence of flashing. Without the use of the wall cavity
drain panel of this invention, and to be described, mortar 34a, 34b
and 34c, for example, can fill up or clot inlets from cavity 13
into weep holes 25.
[0029] Turning now to drain panel 50, according to the invention,
its overall features are perhaps best seen in FIG. 3. Panel 50
includes an insulating member 51, preferably of suitable insulating
foam such as extruded polystyrene having a plurality of vertical
grooves 52 and horizontal grooves 53 therein. FIG. 3 illustrates
only a small portion of a panel 50,it being understood that such
panels can be relatively larger, for example, two to four feet in
vertical dimension and six to eight feet in horizontal dimension,
or any other suitable size.
[0030] Grooves 52, 53 define blocks, such as at 55, 56, for
example, therebetween and these blocks have faces 57 defining an
outwardly directed face of insulating member 51.
[0031] Extending on member 51 and on some of the faces 57 is a
flexible, water-permeable fabric 60 preferably of non-woven
synthetic material of any suitable manufacture, although woven
material could be used.
[0032] Fabric 60 is preferably adhered to faces 57 of member 51 by
any suitable adhesive or bonding process, and excepting the last
two or three rows of blocks or faces 57 disposed at what will be
the lower margin or edge 58 of panel 50. In FIG. 3, the fabric 60
is curled backwards at 61 to illustrate the noted construction. It
will thus be appreciated that fabric 60 is extensible away from
member 51 and can be flexed into a U-shaped or channel-like
configuration as shown in the drawings.
[0033] A matrix 66 is attached to an inner face 62 of fabric 60.
Matrix 66 is open and water-permeable and can be of any suitable
material such as a randomly deposited or applied filamentary
synthetic. Matrix 66 is generally stiffer than fabric 60, but rains
flexible. It is adhered to fabric 60 in any suitable manner, such
as by adhesives, heat bonding or the like.
[0034] Returning to FIGS. 1 and 2, a panel 50 is shown oriented in
cavity 13 between brick wall 11 and concrete block subwall 12. In
this configuration, panel 50 rests on or close to flashing 41 at
the bottom of cavity 13. Nevertheless, neither the fabric 60 nor
matrix 66 touch or approach flashing 41 or base 32.
[0035] Instead, the fabric 41 is folded into a "U" or channel-like
shape as shown so to extend outwardly from member 51, across cavity
13 and then upwardly proximate a rear wall of the bricks in wall
11. Matrix 66 also extends across cavity 13, and upwardly against
the backside of bricks in wall 11 and more particularly in this
embodiment up along the back surface of bricks in lower course
15.
[0036] At the same time, the fabric and matrix define in part a
catch trough for any mortar droppings 36 which fall into cavity 13
from between the higher brick courses 16-23, etc.
[0037] Since the fabric 60 and matrix 66 extend across inlets into
weep holes 25 (such as at 31 in FIG. 2, for example), the inlets
are thus protected and the fabric 60 and matrix 66 serve to prevent
intrusion of clogging mortar into weep holes 25.
[0038] Thus, water W (FIG. 2) in cavity 13 filters through fabric
60 on member 51 into grooves 52, 53 and downwardly as indicated by
the arrows. At the bottom 58 of panel 50, water flows onto flashing
41, onto mortar 34a and into weep holes 25 from where it escapes
outwardly of brick walls 11, as shown by arrow A, through weep hole
outlet 25a.
[0039] The catch trough provided by fabric 60 and matrix 55
prevents mortar droppings 36 from falling to the cavity bottom and
blocking water flow. Yet water is free to flow through fabric 60
and matrix 66 to the bottom of cavity 13 and out weep holes 25.
[0040] A few other structural details are of interest. For example,
a number of panels 50 may be used end-to-end for long walls. Other
drain panels such as at 70 could be used on top of lower panels 50,
but the extended fabric 60 and matrix 66 is not necessary for
these.
[0041] In this regard, note that bracket leg 39 holds the top of
panel 50 in position in cavity 13, preventing its forward tilt.
Likewise, bend 40 in tie 38 keeps the bottom edge 71 of upper
panels 70 from scooting outwardly in cavity 13, and so on.
[0042] Multiple floors can each have a flashing and a lower panel
50, if desired at those floor breaks.
[0043] While the drawings show fabric 60 extending away from panel
member 51 at the lower-most face 57, the blocks 55, 56 may extend
down to lower edge 58 of panel member 51, with fabric 60 not
adhered to the lower faces 57.
[0044] Moreover, even if cavity 13 is wholly filled with mortar,
water can still egress from cavity 13 via grooves 52, 53 and weep
holes 25.
[0045] While fabric 60 and matric 66 can be of any suitable
manufacture, one form of suitable fabric is made by Reemay Inc. of
Old Hickory, Tenn., under product designation Typar.RTM. and one
suitable matrix 66 is made by Keene Building Products of Mayfield
Heights, Ohio, under product designation DriWall Rainscreen.
[0046] In this way, there are no special inserts, bodies or other
structures required to maintain drainage from a cavity wall. The
wall is simply insulated, but with a particular form of lower panel
50, then a mortar catch trough formed easily by the extensible
fabric and matrix extensible across the cavity and upwards at least
on the lower brick course, or higher. Weep holes so protected do
not clog and drainage is secured.
[0047] These and other modifications and alternative embodiments
will be readily apparent to one of ordinary skill in the art
without departing from the scope of the invention and applicant
intends to be bound only by the claims appended hereto.
* * * * *