U.S. patent application number 11/825285 was filed with the patent office on 2009-01-08 for insulated board having an integral drain.
Invention is credited to Todd A. Jordan, Gene S. Vallelonga.
Application Number | 20090007509 11/825285 |
Document ID | / |
Family ID | 40220357 |
Filed Date | 2009-01-08 |
United States Patent
Application |
20090007509 |
Kind Code |
A1 |
Jordan; Todd A. ; et
al. |
January 8, 2009 |
Insulated board having an integral drain
Abstract
A foundation protective layer for installation adjacent a
foundation wall of a building includes a thermally insulative layer
comprising a layer of foam and an upwardly extending drain passage
thereon to facilitate drainage of groundwater, typically into a
french drain. The drain passage may be formed within a conduit or a
strip of porous material mounted on the insulative layer. A channel
may be formed in the insulative layer in which the conduit or strip
of porous material is disposed. The conduit may have a corrugated
sidewall which may be perforated or split along its length. The
strip of porous material may be formed of a web of non-woven
fibers. An attachment mechanism may be used for attaching the
insulative layer to the foundation wall.
Inventors: |
Jordan; Todd A.; (Tallmadge,
OH) ; Vallelonga; Gene S.; (Diamond, OH) |
Correspondence
Address: |
SAND & SEBOLT
AEGIS TOWER, SUITE 1100, 4940 MUNSON STREET, NW
CANTON
OH
44718-3615
US
|
Family ID: |
40220357 |
Appl. No.: |
11/825285 |
Filed: |
July 5, 2007 |
Current U.S.
Class: |
52/302.1 |
Current CPC
Class: |
E02D 31/10 20130101;
E02D 31/02 20130101 |
Class at
Publication: |
52/302.1 |
International
Class: |
E04B 1/70 20060101
E04B001/70 |
Claims
1. A foundation protective layer comprising: a thermally insulative
layer comprising a layer of foam and adapted to be positioned
adjacent a foundation wall; a first upwardly extending channel
formed in the insulative layer; a first structure disposed in the
channel; and a first upwardly extending drain passage formed in the
first structure.
2. The protective layer of claim 1 wherein the foam is
substantially rigid.
3. The protective layer of claim 2 wherein the foam is a
closed-cell foam.
4. The protective layer of claim 1 wherein the insulative layer has
first and second sides defining therebetween a thickness of the
insulative layer; and wherein the channel extends inwardly from the
first side.
5. The protective layer of claim 4 further comprising a second
upwardly extending channel which is formed in the insulative layer
and extends inwardly from the second side; a second structure
disposed in the channel; and a second upwardly extending drain
passage formed in the second structure.
6. The protective layer of claim 1 wherein the first structure is
connected to the insulative layer without the use of a fastener
extending between the first structure and the insulative layer.
7. The protective layer of claim 1 wherein the insulative layer has
a top and a bottom; and the first drain passage extends from the
top to the bottom.
8. The protective layer of claim 1 wherein the first structure
comprises a conduit disposed in the first channel and defining the
first drain passage.
9. The protective layer of claim 8 wherein the conduit comprises a
corrugated sidewall.
10. The protective layer of claim 8 further comprising a plurality
of perforations formed in the sidewall in communication with the
first drain passage.
11. The protective layer of claim 8 wherein the conduit is press
fit into the first channel.
12. The protective layer of claim 1 wherein the first structure is
press fit into the first channel.
13. The protective layer of claim 1 wherein the first structure
comprises a strip of porous material disposed in the channel and
defining the first drain passage.
14. The protective layer of claim 13 wherein the strip of porous
material comprises a fibrous material.
15. The protective layer of claim 14 wherein the fibrous material
comprises a web of non-woven fibers.
16. The protective layer of claim 13 wherein the strip of porous
material is press fit into the first channel.
17. The protective layer of claim 1 further comprising an
attachment mechanism on the insulative layer whereby the insulative
layer is adapted to attach to the foundation wall.
18. The protective layer of claim 16 wherein the attachment
mechanism comprises an adhesive.
19. The protective layer of claim 1 further comprising a foundation
wall; and wherein the insulative layer abuts the foundation
wall.
20. The protective layer of claim 19 further comprising a french
drain adjacent the foundation wall; and wherein the first drain
passage is in fluid communication with the french drain.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates generally to insulative layers
used in residential or commercial buildings. More particularly, the
invention relates to such layers which include foam and are used on
the outside of underground or foundation walls of such buildings.
Specifically, the invention relates to such layers having an
integral drain to facilitate the drainage of ground water into the
drainage system associated with the building.
[0003] 2. Background Information
[0004] Insulative layers such as insulated planks or boards are
well known in the field of residential and commercial construction
and are used internally and externally along various walls, beneath
floors, atop roofs and the like. These insulative planks are
typically formed of a rigid closed-cell foam which provides
substantial thermal insulation. While the use of such insulative
planks against foundation walls is known, one of the problems that
arises relates to the drainage of ground water around these
foundation or basement walls. Thus, there is need in the art to
facilitate the drainage of this ground water into the drainage
system of residential or commercial buildings. The present
invention addresses this and other problems in the art.
BRIEF SUMMARY OF THE INVENTION
[0005] A foundation protective layer comprising a thermally
insulative layer comprising a layer of foam and adapted to be
positioned adjacent a foundation wall; and a first upwardly
extending drain passage on the insulative layer.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of a house having a foundation
wall with which the first embodiment of the insulative plank of the
present invention is used.
[0007] FIG. 2 is an enlarged exploded perspective of view of the
first embodiment with the conduits shown separate from the
plank.
[0008] FIG. 3 is similar to FIG. 2 and shows the plank and conduits
assembled.
[0009] FIG. 3A is an enlarged fragmentary top plan view of a
portion of the first embodiment of the plank showing a conduit in
one of the channels of the plank.
[0010] FIG. 4 is similar to FIG. 2 and shows a second embodiment of
the plank with the porous strips separate therefrom.
[0011] FIG. 5 is similar to FIG. 4 and shows the porous strips and
plank assembled.
[0012] FIG. 5A is an enlarged fragmentary top plan view showing a
portion of the second embodiment of the plank with a strip of
porous material within a channel thereof.
[0013] FIG. 6 is an enlarged top plan view showing the first
embodiment of the plank prior to attachment to the foundation
wall.
[0014] FIG. 7 is similar to FIG. 6 and shows the first embodiment
of the plank attached to the wall.
[0015] FIG. 8 is a fragmentary sectional view looking down on the
foundation wall and showing plurality of the planks of the first
embodiment attached thereto.
[0016] FIG. 9 is a sectional view taken on line 9-9 of FIG. 8.
[0017] FIG. 10 is a sectional view taken on line 10-10 of FIG.
8.
[0018] FIG. 11 is a fragmentary top plan view showing the plank of
first embodiment attached to the foundation wall in a reverse
orientation with the drain passage against the foundation wall.
[0019] FIG. 12 is similar to FIG. 8 and shows the reverse
orientation of the plank on the foundation wall.
[0020] FIG. 13 is a sectional view taken on line 13-13 of FIG.
12.
[0021] FIG. 14 is similar to FIG. 11 and shows a third embodiment
of the plank of the present invention attached to the foundation
wall.
[0022] Similar numbers refer to similar parts throughout the
drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The first embodiment of the thermally insulative layer or
plank of the present invention is shown generally at 10 in FIGS. 2
and 3; the second embodiment is shown generally at 100 in FIGS. 4
and 5; and a third embodiment is indicated generally at 200 in FIG.
14. Each of planks 10, 100 and 200 is configured to facilitate
drainage of groundwater adjacent a foundation wall.
[0024] Referring to FIG. 1, a plurality of planks 10 are attached
to the outside of a foundation wall 12 of a building such as a
house 14 and in abutment with and covered by ground 16 or soil
surrounding foundation wall 12. Wall 12 is commonly a basement wall
found in the basement of house 14. When in use with foundation wall
12, planks 10 are disposed in a substantially vertical orientation,
and the directional descriptions herein will be relative to the
plank in this vertical orientation. Plank 10 has a top 18 and a
bottom 20 (FIG. 9) defining therebetween a height of plank 10.
Plank 10 also has lateral ends 22 and 24 defining therebetween a
width of plank 10. Plank 10 has first and second substantially flat
sides 26 and 28 defining therebetween a thickness which is
substantially less than the width or height of plank 10. Although
plank 10 may be formed in any size desired, plank 10 is often
formed in relatively large sheets, for instance, wherein the width
is between two and four feet and the height is approximately six to
eight feet. These sheets or panels may be easily cut into any
desired size. The thickness of plank 10 typically ranges from about
one to four inches.
[0025] Plank 10 includes a layer of foam or may be formed entirely
of a layer of foam. Preferably, the foam is a closed-cell foam
which is substantially rigid. Most preferably, this foam is an
extruded polystyrene although other possibilities include expanded
polystyrene, polyurethane and polyisocyanurate. Extruded
polystyrene tends to have better moisture resistance than the
others partly due to the fact that it has a smooth continuous outer
skin. A suitable extruded polystyrene is sold by Owens-Corning.
These foam boards or planks may be formed with various strengths,
typically ranging from 20 to 100 psi. The foam density is typically
within the range of 1-2 pounds per cubic foot and typically about
1.5 pounds per cubic foot. Plank 10 has an R-value which typically
falls somewhere in the range of 4-8 per inch.
[0026] In accordance with the invention and with reference to FIGS.
2-3A, plank 10 is formed with a plurality of drain passages to
facilitate the drainage of ground water. A plurality of vertically
elongated channels 30 are formed in plank 10 which extend
continuously from top 18 to bottom 20 and inwardly from first side
26. Preferably, channels 30 have a dove-tailed configuration. More
particularly, each channel 30 is bounded by a rear surface 32 and
first and second side surfaces 34 and 36 which extend inwardly from
first side 26 and angle or taper away from one another to back
surface 32. Thus, each channel 30 widens as it extends inwardly
from first side 26 toward second side 28. Although the size of
channels 30 may vary, each channel 30 typically has a depth
measured between back surface 32 and first side 26 of roughly 0.5
to 1.0 inch with a width which is also typically within that
range.
[0027] A plurality of conduits 38 are disposed respectively within
channels 30 and likewise extend from top 18 to bottom 20 of plank
10. Each conduit 38 has a substantially cylindrical side wall 40
which is typically corrugated and perforated. Preferably, each
conduit 38 is press fit into a channel 30 with sidewall 40 abutting
surfaces 32, 34 and 36 so that no adhesive or other attachment
mechanism is needed to attach conduit 38 to plank 10. Conduit 38
may also be of a split type in which sidewall 40 is cut or has a
slit formed along its length. Conduits 38 are formed of a
non-corrosive material which is typically a plastic such as nylon,
polypropylene, polytetrafluorlethylene (PTFE) or another suitable
plastic. Side wall 40 defines a drain passage 42 extending from top
18 to bottom 20 of plank 10. While passage 42 may form the primary
drain passage, other spaces within each channel 30 may also serve
as drain passages. For instance, another drain passage 44 may be
formed between side wall 40 and portions of surfaces 32 and 34.
Likewise, an additional drain passage 46 may be formed between side
wall 40 and portions of surfaces 32 and 36. An attachment mechanism
typically in the form of glue or an adhesive 48 (FIG. 6) is
disposed on second side 28 of plank 10. Adhesive 48 may be attached
to plank 10 with a peel strip covering it to prevent it from
sticking prior to use or it may be applied immediately prior to
use.
[0028] Referring to FIGS. 4-5A, plank 100 is described. Plank 100
is similar to plank 10 except that it includes a plurality of
channels 50 which are slightly different than channels 30. A
plurality of strips 52 of porous material is disposed in channels
50. Similar to channels 30, channels 50 have a dove-tailed
configuration which widens from first side 26 toward second side
28. Each channel 50 is bounded by a back surface 54 and first and
second side surfaces 56 and 58 which angle away from one another as
they move away from side 26. The depth of each channel 50 between
back surface 50 and first side 26 is typically less than that of
each channel 30 although this may vary. Each strip 52 has a
generally rectangular cross section and is sufficiently flexible to
conform to surfaces 54, 56 and 58 when inserted in channel 50. Each
strip 52 is simply pressed into respective channel 50 and may be
held simply by frictional engagement between the strip 52 and side
surfaces 56 and 58 although the dove-tail configuration further
provides an interference to help prevent removal of the strip from
the channel.
[0029] In a preferred embodiment, strips 52 are formed of an
abrasive non-woven web material such as that sold by the Minnesota
Mining and Manufacturing Company (3M) under the name
Scotch-Brite.RTM.. Strips 52 are thus typically formed of a
flexible web of convoluted fibers or filaments which are
spot-bonded to one another. The fibers as typically formed of a
plastic material such as nylon and are impregnated with an abrasive
material which typically contains aluminum oxide. A drain passage
53 or a plurality of passages are formed within each strip 52
within the pores thereof, which in the preferred embodiment would
be between the various fibers thereof.
[0030] The operation of planks 10 and 100 is described with
reference to FIGS. 6-10. FIG. 6 shows plank 10 positioned adjacent
foundation wall 12 with second side 28 and adhesive 48 facing the
outer surface of wall 12. Plank 10 is then moved toward wall 12 as
indicated at arrows A in FIG. 6 in order to attach plank 10 to the
outer surface of wall 12 as shown in FIG. 7 with second side 28
abutting wall 12. This process may be repeated with multiple planks
10 to completely surround wall 12 as shown in FIG. 8. Once the soil
is replaced, ground 16 abuts first side 26 and conduits 38, or
strips 52 in the case of plank 100, and top 18 so that ground 16
completely covers plank 10 as shown in FIG. 9. When installed,
bottom 20 of plank 10 is seated atop a french drain 60 which is in
communication with underground drain pipes 62 some of which pass
below wall 12 and a basement floor 64. FIG. 9 also illustrates that
rainwater falls on and seeps into ground 16 as indicated at arrows
B to become ground water which moves generally downwardly and
toward planks 10 as indicated at arrow C. The groundwater then
enters the various drain passages on plank 10 or plank 100 and
moves downwardly therethrough as indicated at arrows D into french
drain 60 and subsequently into underground pipes 62. The water is
carried away from the building as indicated at arrows E.
[0031] FIG. 10 further shows that the rainwater indicated at arrows
B becomes groundwater within soil 16 which then may enter into
passage 42 of conduit 38 either via the upper entrance opening
thereof as indicated at arrows F or from the sides of conduit 38
via the perforations formed therein as indicated at arrows G. The
water then flows downwardly as indicated by the arrows within
passage 42 and into the french drain as indicated by arrows H and
into pipes 62 as indicated at arrow J. As previously noted with
reference to FIG. 3A, additional passages 44 and 46 can also carry
groundwater downwardly from above or from the side since the
groundwater may seep around the sides of conduits 38, which may be
facilitated by the use of corrugated conduits. In addition, the use
of a split conduit will also allow for the flow of water into
passage 42 via the split. With regard to plank 100, the water will
flow in a like manner through passages 53 of strips 52.
[0032] While it is preferred that the passages of planks 10 and 100
are positioned away from wall 12 and toward soil 16 so that the
groundwater therein may move into the drain passages laterally, it
may also be desired to utilize plank 10 or similar planks with the
channels and drain passages facing wall 12 (FIG. 11). In this case,
the adhesive would be applied to first side 26 for adhering plank
10 to wall 12. FIG. 13 shows that when the planks are positioned as
shown in FIGS. 11 and 12 that the groundwater would flow primarily
through the upper entrance of the passage as indicated at arrows K
and flow downwardly through passage 42 into french drain 60 and
pipes 62. This configuration thus facilitates the drainage of
groundwater which is closely adjacent to the outer surface of wall
12.
[0033] As shown in FIG. 14, plank 200 combines channels and
conduits on each side 26 and 28 to provide drainage as shown in
FIGS. 10 and 13 at the same time. While FIG. 14 shows opposed
channels and opposed conduits aligned with one another, they may be
offset to maintain better thermal insulation properties and
strength of the insulative plank.
[0034] Thus, planks 10, 100 and 200 provide an insulated plank or
board which includes an integral drain passage to facilitate the
drainage of groundwater into the drain system of the building in
order to help keep the foundation wall and other foundation
structures dry.
[0035] In the foregoing description, certain terms have been used
for brevity, clearness, and understanding. No unnecessary
limitations are to be implied therefrom beyond the requirement of
the prior art because such terms are used for descriptive purposes
and are intended to be broadly construed.
[0036] Moreover, the description and illustration of the invention
is an example and the invention is not limited to the exact details
shown or described.
* * * * *