U.S. patent application number 12/258837 was filed with the patent office on 2010-04-29 for molded polymeric drip edge.
This patent application is currently assigned to MITEK HOLDINGS, INC.. Invention is credited to Ronald P. Hohmann, JR..
Application Number | 20100101168 12/258837 |
Document ID | / |
Family ID | 42116140 |
Filed Date | 2010-04-29 |
United States Patent
Application |
20100101168 |
Kind Code |
A1 |
Hohmann, JR.; Ronald P. |
April 29, 2010 |
MOLDED POLYMERIC DRIP EDGE
Abstract
A drip edge device is disclosed for use with the drainage system
of a cavity wall structure. The drip edge device is disposed in the
outer wythe, above the shelf angle or lintel, of a cavity wall
structure extending the flashing and directing water and water
vapor collected within the cavity wall to the weep holes and beyond
the exterior surface of the outer wythe. The drip edge further
allows for cavity wall ventilation. Removal of the water and the
water vapor inhibits staining and material degradation. The drip
edge device is a molded polymeric which withstands adverse
environmental elements, including ultraviolet radiation. The drip
edge device includes a peel-and-stick hot melt adhesive which, upon
pressure activation, creates a durable bond with the rough surface
of the masonry block or the flashing material. Optionally, a foam
layer is placed on the lower surface of the drip edge.
Inventors: |
Hohmann, JR.; Ronald P.;
(Hauppauge, NY) |
Correspondence
Address: |
SENNIGER POWERS LLP
100 NORTH BROADWAY, 17TH FLOOR
ST LOUIS
MO
63102
US
|
Assignee: |
MITEK HOLDINGS, INC.
Wilmington
DE
|
Family ID: |
42116140 |
Appl. No.: |
12/258837 |
Filed: |
October 27, 2008 |
Current U.S.
Class: |
52/513 |
Current CPC
Class: |
E04B 1/7046
20130101 |
Class at
Publication: |
52/513 |
International
Class: |
E04B 1/70 20060101
E04B001/70; E04C 1/40 20060101 E04C001/40 |
Claims
1. A drip edge device for use in a cavity wall with an inner wythe
and an outer wythe with said outer wythe having an exterior surface
flashing therewithin, and said cavity wall having a drainage system
therethrough, said drip edge device comprising, in combination: a
molded base formed from an elastomeric compound having two major
surfaces, said base in turn comprising: an upper portion adapted
for disposition between said inner wythe and said flashing
material; and, a lower portion arcuately molded and adapted, upon
mounting on said outer wythe, to extend beyond said exterior
surface of said outer wythe and to direct water away from said
exterior surface of said outer wythe; whereby, upon mounting said
drip edge device on said outer wythe, said drip edge device
conducts water collected within said cavity wall to said drainage
system inhibiting staining and material degradation.
2. A drip edge device for use in a cavity wall with an inner wythe
and an outer wythe with said outer wythe having an exterior surface
flashing therewithin, and said cavity wall having a drainage system
therethrough, said drip edge device comprising, in combination: a
molded base formed from an elastomeric composite having two major
surfaces, said base in turn comprising: an upper portion adapted
for disposition between said inner wythe and said flashing
material; a lower portion arcuately molded and adapted, upon
mounting on said outer wythe, to extend beyond said exterior
surface of said outer wythe and to direct water away from said
exterior surface of said outer wythe; and, a middle portion having
a first end affixed to said upper portion and a second end affixed
to said lower portion adapted, upon installation into said cavity
wall, to have said first end lie in a higher longitudinal plane
than said second end; whereby, upon mounting said drip edge device
on said outer wythe, said drip edge device conducts water collected
within said cavity wall to said drainage system, inhibiting
staining and material degradation.
3. A drip edge device as described in claim 2 wherein said molded
base further comprises, in combination: a hot melt adhesive layer
mounted on said upper portion, said hot melt adhesive, upon
pressure activation, adapted by having sufficient tack to durably
adhere to the surface of said inner wythe upon pressure activation;
and, a release sheet adhered to said hot melt adhesive layer, said
release sheet being removable prior to mounting said drip edge
device in said inner wythe, whereby, upon mounting said drip edge
device on said outer wythe, said drip edge device conducts water
collected within said cavity wall to said drainage system.
4. A drip edge device as described in claim 2 wherein said lower
portion has a bottom portion adapted for placement on the outer
wythe, said molded base further comprising, in combination: a
resilient wedge of foam polymeric material mounted on said bottom
portion of said lower portion; whereby, upon mounting said drip
edge device on said outer wythe, said drip edge device conducts
water collected within said cavity wall to said drainage
system.
5. A masonry flashing system as described in claim 4 wherein said
foam polymeric material is selected from a group consisting of
cross-linked polyethylene, non-cross-linked polyethylene, and
closed-cell neoprene sponge.
6. A drip edge device as described in claim 2 wherein said drip
edge device is composed of at least one material selected from a
group consisting of ethylenepropylene diene monomer,
polyisobutylene, chlorinated polyethylene, natural rubber,
polyvinyl chloride, ethylene vinyl acetate, and chlorosulfonated
polyethylene.
7. A drip edge device as described in claim 6 wherein said drip
edge device includes 10 to 40 percent by weight of unplasticized
polyvinyl chloride, having a suspension or emulsion grade polyvinyl
chloride in the range of 20 to 30 percent by weight, and 10 to 40
percent by weight of an ethylene vinyl acetate carbon monoxide
terpolymer.
8. A drip edge device as described in claim 6 wherein said drip
edge device contains up to 15 percent of primary or secondary
plasticizer and up to 10 percent of processing aids or
stabilizers.
9. A drip edge device as described in claim 7 wherein said ethylene
vinyl acetate carbon monoxide terpolymer contains 15 to 85 percent
ethylene, 5 to 60 percent vinyl acetate, and 0.5 to 30 percent
carbon monoxide, all on a weight basis.
10. A drip edge device as described in claim 6 wherein said
material contains a color additive to match to associated mortar or
brick.
11. A drip edge device as described in claim 6 wherein said
material endures exposure to ultraviolet light without significant
deterioration.
12. A drip edge device for use in a cavity wall with an inner wythe
and an outer wythe with said outer wythe having an exterior surface
flashing therewithin, and said cavity wall having a drainage system
therethrough, said drip edge device comprising, in combination: a
molded base formed from an elastomeric composite having two major
surfaces, said base in turn comprising: an upper portion adapted
for disposition between said outer wythe and said flashing
material; and, a lower portion arcuately molded and adapted, upon
mounting on said outer wythe, to extend beyond said exterior
surface of said outer wythe and to direct water away from said
exterior surface of said outer wythe; whereby, upon mounting said
drip edge device on said outer wythe, said drip edge device
conducts water collected within said cavity wall to said drainage
system, inhibiting staining and material degradation.
13. A drip edge device as described in claim 12 wherein said molded
base further comprises, in combination: a hot melt adhesive layer
mounted on said upper portion, said hot melt adhesive, upon
pressure activation, adapted by having sufficient tack to durable
adhere to the surface of said inner wythe upon pressure activation;
and, a release sheet adhered to said hot melt adhesive layer, said
release sheet being removable prior to mounting said drip edge
device in said inner wythe, whereby, upon mounting said drip edge
device on said outer wythe, said drip edge device conducts water
collected within said cavity wall to said drainage system.
14. A drip edge device as described in claim 13 wherein said hot
melt adhesive is compatible with flashing membranes containing
ketone ethylene ester and meets industry flammability
standards.
15. A drip edge device as described in claim 12 wherein said lower
portion has a bottom portion adapted for placement on outer wythe,
said molded base further comprising, in combination: a resilient
wedge of foam polymeric material mounted on said bottom portion of
said lower portion; whereby, upon mounting said drip edge device on
said outer wythe, said drip edge device conducts water collected
within said cavity wall to said drainage system.
16. A masonry flashing system as described in claim 15 wherein said
foam polymeric material is selected from a group consisting of
cross-linked polyethylene, non-cross-linked polyethylene, and
closed-cell neoprene sponge.
17. A drip edge device as described in claim 12 wherein said drip
edge device is composed of at least one material selected from a
group consisting of ethylenepropylene diene monomer,
polyisobutylene, chlorinated polyethylene, natural rubber,
polyvinyl chloride, ethylene vinyl acetate, and chlorosulfonated
polyethylene.
18. A drip edge device as described in claim 17 wherein said drip
edge device includes 10 to 40 percent by weight of unplasticized
polyvinyl chloride, having a suspension or emulsion grade polyvinyl
chloride in the range of 20 to 30 percent by weight, and 10 to 40
percent by weight of an ethylene vinyl acetate carbon monoxide
terpolymer.
19. A drip edge device as described in claim 12 wherein said drip
edge device contains up to 15 percent of primary or secondary
plasticizer and up to 10 percent of processing aids or
stabilizers.
20. A drip edge device as described in claim 19 wherein said
ethylene vinyl acetate carbon monoxide terpolymer contains 15 to 85
percent ethylene, 5 to 60 percent vinyl acetate, and 0.5 to 30
percent carbon monoxide, all on a weight basis.
21. A drip edge device as described in claim 17 wherein said
material contains a color additive to match the associated mortar
or brick.
22. A drip edge device as described in claim 17 wherein said
material endures exposure to ultraviolet light without significant
deterioration.
Description
FIELD OF THE INVENTION
[0001] This invention relates to a drip edge for use with a
flashing system for a cavity wall structure, and more specifically
to an improved molded polymeric drip edge that is an integral part
of the flashing system.
DESCRIPTION OF THE PRIOR ART
[0002] In the past, investigations relating to cavity wall flashing
systems for brick veneer masonry construction have been conducted.
Flashing systems for cavity wall structures generally include
flashing, weep holes and drip edges. While strides have been made
in flashing-related technologies, including elastomeric materials
and hot melt adhesives, there still remain several areas where
continued development is ongoing.
[0003] The inventor's patents and their assignee's product line are
all related to accessories for cavity wall structures and include
insulation, anchoring and seismic devices, and flashing and are
sold under the trademarks of Seismiclip , Byna-Tie.RTM.,
DW-10-X.RTM., and FLEX-FLASH.TM.. These products, which are
manufactured by Hohmann & Barnard, Inc., Hauppauge, N.Y. 11788,
have become widely accepted in the industry and have provided the
inventors with particular insight into the technological needs of
this marketplace.
[0004] Masonry walls with brick veneer are designed with an inner
and an outer wythe and a cavity therebetween. The masonry block
inner wythe and insulation thereon isolates the interior of the
building from the environment, while the brick veneer outer wythe
provides an aesthetic finish to the building. The walls of a
building are constructed to exclude water and water vapor from the
interior. Since the presence of excessive levels of water or water
vapor in the cavity hastens the deterioration of building
materials, various masonry drainage systems have been proposed.
[0005] Because of widespread usage and familiarity with bituminous
and asphaltic products in roofing applications, when masonry
flashing systems were first designed, the building construction
industry adopted the familiar copper and asphalt products. At that
time the technology of pressure-sensitive hot melt adhesives needed
for peel-and-stick applications was insufficiently developed. Some
critics indicated that the adhesive quality was insufficient for
the rough masonry block surfaces. Because of the presence of
plasticizers, others were apprehensive about the available hot melt
adhesives meeting the requisite fire retardancy standards. Also, to
provide fire retardancy, some pressure-sensitive products were
marketed for building construction use with inorganic fillers, such
as alumina trihydrate, antimony oxide or calcium carbonate.
However, these filled pressure-sensitive products had
disadvantages, such as application problems, phase separation,
toxicity, and reduced adhesion upon activation.
[0006] Prefabricated peel-and-stick flashing materials have been
proposed, such as those shown in Harkness, U.S. Pat. No. 4,775,567
(see infra). These materials have included layers of bitumen and of
compound bitumen for adhering the materials to the exteriors of
masonry walls. While, under ideal circumstances, these
peel-and-stick materials were easy to apply, the patent literature
indicates that these materials did not conform well to irregular
surfaces. Thus, the prior art bitumens used to secure these
flashing materials to masonry walls often lacked the tackiness to
bond tightly and durably to the wall surfaces. On occasion, when
circumstances were not ideal, the bituminous materials drooled
marring the aesthetics of the brick veneer.
[0007] Despite these early efforts, developing the right
combination of materials and methods for flashing cavity walls in a
fast and efficient manner has proved elusive. In addition to the
above described technical problems, because there is frequently a
delay in erecting the inner wythe and the outer wythe, the flashing
installed in the inner wythe is often exposed to substantial
ultraviolet radiation. Thus, standards similar to ASTM
Specification D4434-96 for polyvinylchloride sheet roofing need to
be met by masonry flashing systems.
[0008] As flashing for cavity walls involves numerous technological
considerations, including, but not limited to, tensile strength,
puncture- and tear-resistance, UV exposure, water absorption,
pliability, peel and lap adhesion, and flammability, various
industry standards under ASTM have arisen which serve as a guide to
flashing manufacturers, architectural engineers, and others
preparing and meeting construction specifications. Among the
relevant ASTM standards are ASTM D 624, Standard test method for
tear strength of . . . thermoplastic elastomers; ASTM D 412,
Standard test method for . . . thermoplastic elastomers--tension;
ASTM D 2240, Standard test method for rubber property--durometer
hardness (applies to thermoplastic elastomers); and, ASTM G 154,
Standard practice for operating fluorescent light apparatus for UV
exposure of nonmetallic materials.
[0009] When possible, flashing for cavity walls should extend
beyond the face of the outer wythe. This extension is accomplished
through the use of a drip edge, which is secured to either the
outer wythe under the flashing or to the flashing itself, and
extends through the inner wythe to allow for drainage. The drip
edge is premolded at an angle and disposed in the inner wythe to
drain any water in the cavity through the inner wythe and away from
the wall structure. Because the drip edge requires dimensional
stability and will be exposed to UV light, which can cause
significant deterioration of some materials, careful consideration
must be given to the type of material used.
[0010] A common choice of drip edge material is stainless steel.
Stainless steel has excellent chemical resistance and does not
stain masonry. However, stainless steel is difficult to accurately
shape and can be bent or otherwise misshapen at the construction
site. Further, stainless steel does not match brick, or other
masonry outer wythes, creating an aesthetically-displeasing effect.
Copper is another common choice because it is durable and easy to
form and solder, but exposed copper may stain adjacent masonry and
can be damaged if caustic alkalis are present in the mortar.
Plastic or rubber flashing is generally easy to form and join, but
because exposure to UV light causes degradation and dimensional
stability is also a concern it is not a good choice for drip edge
material. The shortcomings of the aforementioned materials show the
need for an improved drip edge
[0011] The present invention provides a polymeric based drip edge
that solves the problems associated with the prior art materials
and provides a simple and economical drip edge solution. The
polymeric drip edge is extremely tough, holds its shape after
extrusion and is not susceptible to UV degradation. Further, the
drip edge can be color matched to the individual mortar or brick
color to hide its presence. The present invention employs a
"peel-and-stick" pressure-sensitive, clear adhesive that provides a
firm bond and does not leach onto the exterior of the building. The
drip edge can be easily positioned in the outer wythe through
either an optional foam attachment or by simply propping it up on
rolled flashing.
[0012] In preparing for this application the following patents came
to the attention of the inventors and are believed to be relevant
to the further discussion of the prior art:
TABLE-US-00001 Patent Inventor Issue Date 6,964,136 Collins Nov.
15, 2005 6,945,000 Hohmann et al. Sep. 20, 2005 6,928,780 Hohmann
et al. Aug. 16, 2005 6,584,746 Hohmann et al. Jul. 1, 2003
6,224,700 Oakley May 1, 2001 6,035,582 Pacific Mar. 14, 2000
5,870,864 Snyder Feb. 16, 1999 5,860,259 Laska Jan. 19, 1999
4,910,931 Pardue Mar. 27, 1990 4,775,567 Harkness Oct. 4, 1988
4,755,409 Harkness Jul. 5, 1988 4,295,911 Haage et al. Oct. 20,
1981 4,239,795 Haage et al. Dec. 16, 1980
[0013] U.S. Pat. No. 6,964,136--Collins--issued Nov. 15, 2005
[0014] Collins describes a combination flashing and weep apparatus
to detail sills and lintels to avoid water accumulations and
provide drainage through the use of a two-panel extrusion. A second
embodiment secures the flashing and weep apparatus to the outer
face of the inner wall at the sill or lintel of the door, window or
other opening.
[0015] U.S. Pat. No. 6,945,000--Hohmann et al.--issued Sep. 20,
2005
[0016] A metal-foil flashing laminate for cavity walls with at
least one layer of an elastomeric composite under a hot melt
adhesive layer is taught. The laminate is used with release paper
to form a peel-and-stick product suitable for surface mounting. A
termination bar is used with the flashing.
[0017] U.S. Pat. No. 6,928,780--Hohmann et al.--issued Aug. 16,
2005
[0018] A metal foil/scrim flashing laminate for a cavity wall with
at least one layer of roll coated polymeric coating on the central
metal foil is disclosed. The metal foil lamina is either set
between layers of the polymeric coating or between a coating layer
and a hot melt adhesive layer. The laminates are used with release
paper to form a peel-and-stick product suitable for surface
mounting.
[0019] U.S. Pat. No. 6,584,746--Hohmann et al.--issued Jul. 1,
2003
[0020] A masonry flashing system for cavity walls which includes a
hot melt adhesive coated reinforced laminate is disclosed. The
system includes a stainless steel drip plate with a hot melt
adhesive coating that works in conjunction with the laminate to
redirect waterflow away from the cavity wall. A stainless steel
drip edge is used with the masonry flashing system because the
disclosed elvaloy flashing lacks the resilience needed to form a
drip edge.
[0021] U.S. Pat. No. 6,224,700--Oakley--issued May 1, 2001
[0022] Oakley in U.S. Pat. No. 6,224,700 (assigned to Mar-Flex
Systems, Inc., Middletown, Ohio) describes a method of applying a
composite material to an above-grade building component to form a
tacky non-swelling elastomeric membrane. Thereafter, a flexible,
non-porous polymeric sheet is pressed onto the tacky exterior of
the elastomeric membrane. The polymeric sheet is stronger than the
elastomeric membrane and protects the elastomeric membrane from
punctures or tears. Here, in situ construction is both labor
intensive and requires special equipment for installation.
[0023] U.S. Pat. No. 6,035,582--Pacific--issued Mar. 14, 2000
[0024] Pacific describes a flashing material which includes a sheet
layer of copper, aluminum or other metal or a thin sheet of
unreinforced plastic. Here it appears that in situ adhesives are
applied.
[0025] U.S. Pat. No. 5,870,864--Snyder--issued Feb. 16, 1999
[0026] Snyder describes a drainage system employing water
collection pans for insertion into the interior cavities of masonry
block units. The system extends over the length of a selected block
wall course; drains water collected from the interior cavities of
the upper courses; and, directs water to the exterior of the
wall.
[0027] U.S. Pat. No. 5,860,259--Laska--issued Jan. 19, 1999
[0028] Laska describes an insulated drainage panel for use in
cavity wall or veneer wall construction, which panel includes a
planar insulating board with a porous structure thereof.
[0029] U.S. Pat. No. 4,910,931--Pardue--issued Mar. 27, 1990
[0030] In the Pardue patent, a water collection and drainage system
is described for a masonry block wall having bond beam block
courses and intervening standard block courses. A system of upper
water collection pans is supported along each upper bond beam
course. Downspouts leading from drain openings in the upper
collection pans drain collected from the pans through the vertical
block cavities in lower block courses to the next lower series of
collection pans. Weeping spouts head laterally from the base
collection pans to the exterior of the wall to continuously drain
collected water from the interior wall cavities.
[0031] U.S. Pat. Nos. 4,775,567 and 4,755,409--Harkness--issued
Oct. 4, 1988 and Jul. 5, 1988, Respectively
[0032] A waterproofing laminate suitable for use in roofs, floors
or other surfaces where waterproofing is desired contains a
reinforcing sheet, first and second bitumen layers secured to
opposite surfaces of the reinforcing sheet, first and second
compound bitumen layers secured to the bitumen layers, an
elastomeric sheet secured to the first compound bitumen layer and a
release sheet secured to the second compound bitumen layer. Certain
preferred materials for use in the laminate are recited.
[0033] U.S. Pat. Nos. 4,295,911 and 4,239,795--Haage et al.--Oct.
20, 1981 and Dec. 16, 1980, Respectively
[0034] A protective covering for the protection of surface seals
against mechanical damage in building constructions and other civil
engineering constructions which comprises a composite of an
elastic, waterproof thermoplastic synthetic resin film sheet and/or
synthetic resin layer and a lattice-like fabric having knot
couplings or points of intersection of the threads that yield under
the effect of a load.
[0035] The use of the polymeric drip edge of this invention in a
cavity wall structure is an integral part of the flashing system.
The drip edge described herein holds its shape and provides a seal
with the flashing structure and together with the weep holes
directs water or water vapor outside the structure, protecting
against deterioration of the cavity wall structure.
SUMMARY
[0036] In general terms, the drip edge device disclosed hereby is
an integral part of the flashing system for cavity wall structures.
The drip edge device is disposed in the outer wythe, above the
shelf angle or lintel, of a cavity wall structure and directs water
and water vapor collected within the cavity wall to the weep holes
and beyond the exterior surface of the outer wythe. The drip edge
further allows cavity wall ventilation. Removal of the water and
water vapor inhibits staining and material degradation.
[0037] The drip edge device is a molded polymeric which withstands
adverse environmental elements, including ultraviolet radiation.
Further, the drip edge device can be color matched to the adjacent
mortar or brick to provide an aesthetically pleasing outer
wythe.
[0038] The drip edge device includes a hot melt adhesive which
coats a surface of the drip edge device. The adhesive is selected
for compatibility with a peel-and-stick installation, thus, upon
pressure activation, when, for instance, the drip edge device with
the hot melt adhesive thereon is pressed against the rough surface
of the masonry block or the flashing material, a durable bond is
created. The drip edge adhesive coating enables the installer to
accurately position the drip edge and, during construction,
maintain the alignment thereof. Optionally, a foam layer is placed
on the lower surface of the drip edge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] In the following drawings, the same parts in the various
views are afforded the same reference designators.
[0040] FIG. 1 is a perspective view of a first embodiment of a drip
edge device of this invention and shows a wall with an inner wythe
of masonry block and an exterior wythe of brick having a
through-wall drainage system installed therein;
[0041] FIG. 2 is a cross sectional view of FIG. 1 taken along a
plane bisecting the outer wythe showing the drip edge device
disposed within the outer wythe;
[0042] FIG. 3 is a perspective view of an uninstalled drip edge
device of the first embodiment;
[0043] FIG. 4 is a perspective view of a second embodiment of a
drip edge device of this invention and shows a wall with an inner
wythe of masonry block and an exterior wythe of brick having a
through-wall drainage system installed therein;
[0044] FIG. 5 is a perspective view of the uninstalled drip edge
device of the second embodiment.
DETAILED DESCRIPTION OF THE DRAWINGS
[0045] In the embodiments described hereinbelow, the drip edge
device of this invention employs an innovative design with novel
material that works in conjunction with the flashing system for a
cavity wall structure and can withstand adverse weather conditions.
The novel drip edge device is a molded polymeric that is disposed
in the outer wythe above a lintel or shelf angle. The drip edge
device works with the flashing system to protect the structure
against deterioration by removing water and ventilating the cavity
wall.
[0046] Proper design, detailing and construction of cavity wall
structures are necessary to minimize water penetration into or
through the cavity wall. Protecting a cavity wall from water is
desirable because if a cavity wall is saturated with water,
freezing and thawing may cause cracking, crazing, spalling and
disintegration over time. Further, water can cause dimensional
changes, corrosion, reduce insulation effectiveness, and cause mold
growth.
[0047] Construction of drainage wall systems such as cavity walls
are designed to combat water penetration. A cavity wall is designed
to allow water to flow inward to the cavity between the wythes,
where it is collected on the flashing and redirected out of the
cavity wall through weeps by a drip edge, which is disposed on the
inner wythe.
[0048] Referring now to FIGS. 1-3, views of the first embodiment of
this invention in which a drainage system within a cavity wall
structure, referred to generally by the reference designator 10,
are shown. In this embodiment, a cavity wall structure 12 is shown
having an inner wythe 14 of masonry blocks 16 and an outer wythe 18
of facing brick 20. Between the inner wythe 14 and the outer wythe
18, a cavity 22 is formed. Successive bed joints 24 and 26 are
formed between courses of blocks 16 and the joints are
substantially planar and horizontally disposed. Also, successive
bed joints 28 and 30 are formed between courses of bricks 20 and
the joints substantially planar and horizontally disposed. Selected
bed joint 24 and bed joint 30 are constructed to align, that is to
be substantially coplanar, the one with the other.
[0049] For purposes of this discussion, the exterior surface 32 of
the inner wythe 14 contains a horizontal line or x-axis 34 and an
intersecting vertical line or y-axis 36. A horizontal line or
z-axis 38 also passes through the coordinate origin formed by the
intersecting x-and y-axes. In the discussion which follows, it will
be seen that the drainage system 10 of this invention is
constructed to completely seal the cavity, to drain water therefrom
and to permit air and water vapor to exit using the drip edge
device 46 and weep hoes 40.
[0050] Affixed to the inner wythe 14, in this embodiment, a
through-the-wall installation of the masonry flashing 59 is shown.
The details of this embodiment can also be applied in the same
manner for surface mounted flashing. The masonry flashing 59 is
constructed for embedment in bed joint 26 in an x-z plane, for
adherence to surface 32 in an 3-y plane. In this mode, it is seen
that the flashing 59 is installed behind optional insulation 44.
Between the flashing 59 and the inner wythe 14, the upper portion
of the drip edge device is secured against the inner wythe 14
through the use of a peel-and-stick hot melt adhesive 50 to improve
the communication between the drainage system 10 and weep holes
40.
[0051] The lower portion 53 of the drip edge device 46 is disposed
in the bed joint 28 of the outer wythe 18 and connected to the
upper portion 48 by the middle portion 52 at an angle that
facilitates drainage of the water and water vapor beyond the
exterior surface 45 of the outer wythe 18. The drip edge device 46
can be installed flat in the bed joint 28 or propped up using
either a loop of flashing (not shown) or an affixed resilient layer
of foam polymeric material 54 mounted on the lower portion of the
drip edge device 46 to better direct the flow of water and water
vapor into the drainage system 10 and outside the exterior surface
45 of the outer wythe 18. The foam polymeric material 54 is
constructed from material selected from a group consisting of
cross-linked polyethylene, non-cross-linked polyethylene, and
closed-cell neoprene sponge.
[0052] The drip edge device 46 is constructed from a rigid extruded
polymeric molded to an optimal shape to direct water to the weep
holes 40 and away from the exterior surface 45 of the outer wythe
18. The lower portion 53 of the drip edge device 46 is optimally
offset at a 45 degree angle. To further seal and place the drip
edge device 46, optional sealant 58 and a backer rod 60 may be
disposed in the bed joint 28.
[0053] The molded polymeric is UV resistant and contains at least
one material selected from the group consisting of
ethylenepropylene diene monomer, polyisbotylene, chlorinated
polyethylene, natural rubber, polyvinyl chloride, ethylene vinyl
acetate, and chlorosulfonated polyethylene. A specifically
preferred formulation for the drip edge device includes about 10 to
40 percent by weight of unplasticized polyvinyl chloride, and about
10 to 40 percent by weight of an ethylene vinyl acetate carbon
monoxide terpolymer. The drip edge device 46 may also contain up to
about 15 percent of primary or secondary plasticizer with, or
without, up to about 10 percent of processing aids or
stabilizers.
[0054] The drip edge device 46 contains polyvinyl chloride is
preferable range of about 20 to 30 percent by weight of the entire
composition and may advantageously be provided as a suspension or
emulsion grade of polyvinyl chloride. The ethylene vinyl acetate
carbon monoxide terpolymer may contain about 15 to 85 percent
ethylene, about 5 to 60 percent vinyl acetate, and about 0.5 to 30
percent carbon monoxide, all on a weight basis. A suitable
terpolymer for use in this context is that marketed by E. I. du
Pont de Nemours & Company under the trademark Elvaloy, with the
preference being for Elvaloy 742.
[0055] A peel-and-stick polymeric membrane 50 is affixed to the
exterior surface of the upper portion 48 of the drip edge device 46
which surface faces the exterior surface 32 of the inner wythe 14.
When the release sheet 57 is removed, the drip edge device 46 is
affixed to the exterior surface 32 of the inner wythe 14 behind the
flashing 59 to inhibit water from reaching the inner wythe 14 and
to direct any water or water vapor into the drainage system 10.
[0056] The peel-and-stick polymeric membrane 50 includes a hot melt
adhesive layer which is formulated for pressure activation and
compatibility with a release sheet 57 adhered thereto. The
adhesives described herein are particularly useful for
peel-and-stick applications in building construction industry as
such adhesives are readily pressure activated after the release
paper is removed. The adhesive is formulated so that, in case of
fire, the coatings thereof will not contribute to smoke or
accelerate flame spreading and thus do not require inorganic
fillers which are known to interfere with the adhesive function.
Also, the adhesives are formulated to have sufficient tackiness so
that a durable bond between the membrane and the rough and porous
surface of the masonry block is experienced.
[0057] Incorporating by reference the D Rado et al. patent, U.S.
Pat. No. 5,106,447, the hot melt adhesive compositions of hot melt
layer may be prepared from 10 to 50 weight percent of an isotactic
thermoplastic polybutene-1/ethylene copolymer containing from about
5.5 to about 10% by weight ethylene (polybutylene); 20 to 50
percent of a tackifier; 15 to 50 percent of an amorphous diluent
having a softening point greater than 90 degrees C.; 0 to 2 percent
of the stabilizer; and, 0 to 5 percent wax.
[0058] The polybutylene copolymers employed herein are copolymers
of polybutene-1 and ethylene wherein the ethylene content varies
from about 5.5 to about 10% by weight of the copolymer. The
applicable isotactic polybutylenes are relatively rigid while in
their plastic form but flow readily upon being heated. Expressing
molecular weight in terms of melt index, the applicable isotactic
polybutylenes to be used in the present adhesive should exhibit a
melt index in the range of from about 5 to 2000 dg/min and
preferably from 400 to 700-dg/min. The latter melt flow values are
determined by the method described in ASTM D1238 and are inversely
related to molecular weight, i.e., the lower the melt index, the
higher the molecular weight. These copolymers are available from
Shell Chemical Company under the Duraflex trademark as Duraflex
8310, 8410, 8510 and 8910, with the 8910 having a melt index of
about 700, a grade preferred for use herein. Mixtures of these
copolymers may also be used.
[0059] The tackifying resins which may be used to extend the
adhesive properties of the isotactic polybutylene include: (1)
hydrogenated wood rosin or rosin ester; (2) polyterpene resins
having a softening point, as determined by an ASTM method E28-58T,
of from about 80 degrees C. to 150 degrees C., the latter
polyterpene resins generally resulting from the polymerization of
terpene hydrocarbons in the presence of Friedel-Crafts catalysts at
moderately low temperatures and including the latter resins which
are aromatically modified; examples of commercially available
resins of this type being the Nirez resins sold by Reichhold
Chemical, the Zonatac resins sold by Arizona, and the Piccolyte
S-10, S-25, S-40, S-85, S-100, S-115, S-125 and S-135 resins as
sold by Hercules Chemical; (3) aliphatic petroleum hydrocarbon
resins having a Ball and Ring softening point of from about 80
degrees C. to 160 degrees C., resulting from polymerization of
monomers consisting primarily of 5 carbon atom olefins and
diolefins, and including the latter resins which are aromatically
modified, examples of commercially available resins of this type
being Wingtack 95 and Wingtack Extra as sold by the Goodyear Tire
and Rubber Company and the Escorez 1000 series of resins sold by
the Exxon Chemical Corporation; and, (4) partially and fully
hydrogenated hydrocarbon resins such as Resin H-130 from Eastman,
Escorez 5000 series from Exxon, and Regalrez from Hercules. The
amorphous diluents which are needed and present in the adhesive
composition include (atactic) amorphous polypropylene or other
similar high softening point (i.e. greater than 90 degrees C.), low
crystalline diluent, (e.g. amorphous polyalphaolefins). These
diluents, are used at levels of 20 to 50% by weight, preferably
about 20 to 25% by weight.
[0060] To test the degree of tackiness of the above-described
flashing structure, a pull test is performed. An Elvaloy 742 (see
paragraph 040 above) 8-inch by 12-inch sample is coated with a hot
melt adhesive, which hot melt adhesive formulation includes one or
more of the aforementioned tackifying resins. A suitable release
paper is applied thereover. After a prescribed cure period, the
release paper is removed and the flashing of this invention is
applied to the surface of a concrete block. The application to the
concrete block is at room temperature utilizing a hand-operated
laminating roller to provide the pressure activation. A spring
scale is then attached to the masonry flashing and a 65 lb. force
is required to peel the flashing from the block. Repeating the test
for SBS-modified, peel-and-stick flashing, a force of 27 lb. (max.)
is required to peel the flashing from the block.
[0061] Among the applicable stabilizers or antioxidants utilized
herein are included high molecular weight hindered phenols and
multifunctional phenols such as sulfur and phosphorous-containing
phenols. Representative hindered phenols include: 1,3,5-trimethyl
2,4,6-tris(3,5-di tert-butyl-4-hydroxy-benzyl)benzene;
pentaerythrityl
tetrakis-3(3,5-di-tert-butyl-4-bydroxyphenyl)propionate;4,4'methylenbis(2-
,6-tert-butyl-phenol); 4,4'-thiobis(6-tert-butyl-o-cresol);
2,6-di-tertbutylphenol;
6-(4-hydroxyphenoxy)-2,4-bis(n-octyl-thio)-1,3,5-triazine;
di-n-octadecyl 3,5-di-tert-butyl-4-hydroxy-benzylphosphonate;
2-(n-octylthio)ethyl 3,5-di-tert-butyl-4-hydroxybenzoate; and,
sorbitol
hexa[3-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionate].
[0062] The performance of these antioxidants may be further
enhanced by utilizing, in conjunction therewith known synergists
such, for example, as thiodipropionate esters and phosphites.
Particularly useful is distearylthiodipropionate. These stabilizers
are generally present in amounts of about up to 2 weight percent,
preferably 0.25 to 1.0%. It is also possible to add minor amounts
(i.e. less than about 5% by weight of the formulation) of other
diluents such as (1) waxes including petroleum waxes such as a
paraffin wax having a melting point of from about 50 degrees C. to
75 degrees C. and microcrystalline wax having a melting point of
from about 50 degrees to 90 degrees C.; the latter melting points
being determined by ASTM method D127-60; (2) low molecular weight
(600 to 3000) liquid polybutene; (3) polyethylene greases having a
softening point of from about 80 degrees C. to 100 degrees C. and a
hardness value, as determined by ASTM method D-1321, of from about
60 degrees C. to 120 degrees C.; (4) hydrogenated animal, fish and
vegetable fats and oil such as hydrogenated tallow, lard, soya oil,
cottonseed oil, castor oil, menhaden oil and cod liver oil; and,
(5) synthetic waxes made by polymerizing carbon monoxide and
hydrogen, such as Fischer-Tropsch wax.
[0063] In addition, relatively small amounts (less than about 5%)
of isotactic polypropylene may be employed as a reinforcing agent.
Other additives such as flow modifiers, pigments, dyestuffs, etc.,
which are conventionally added to hot melt adhesives for various
end uses may also be incorporated in minor amounts into the
formulations of the present invention.
[0064] Referring now to FIGS. 4 and 5, a perspective view of the
second embodiment of this invention in which a surface-mounted
drainage system, referred to generally by the reference designator
110, is shown. In this embodiment, similar parts to those of the
first embodiment are referred to by reference designators 100 units
higher than a similar part in the first embodiment. Thus, for
example, the masonry block 16 in the first embodiment has an
analogous masonry block 116 in the second embodiment. Here a cavity
wall structure 112 is shown having an inner wythe 114 of masonry
blocks 116 and an outer wythe 118 of facing brick 120. Between the
inner wythe 114 and the outer wythe 118, a cavity 122 is formed and
optional insulation 144 is shown. Successive bed joints 124 and 126
are formed between courses of blocks 116 and the joints are
substantially planar and horizontally disposed. Also, successive
bed joints 128 and 130 are formed between courses of bricks 120 and
the joints are substantially planar and horizontally disposed.
Selected bed joint 124 and bed joint 130 are constructed to align,
that is to be substantially coplanar, the one with the other. For
purposes of this discussion, the exterior surface 132 of the inner
wythe 114 contains a horizontal line or x-axis 134 and an
intersecting vertical line or y-axis 136. A horizontal line or
z-axis 138 also passes through the coordinate origin formed by the
intersecting x- and y-axis. In the discussion which follows, it
will be seen that the drip edge device 146 is constructed to work
in combination with the drainage system 110 to completely seal the
cavity and to drain water and water vapor therefrom through weep
holes 140 thereof.
[0065] Across the cavity of 122, in this embodiment, through wall
flashing 159 is shown. However, the details of this embodiment can
be applied in the same manner for surface mounted flashing. The
drainage system 100 includes flashing 159 constructed for adherence
to surface 132 in an x-y plane, for extending across and into bed
joint 128 and sealing cavity 122, and for embedment in bed joint
128 in an x-y plane. The drip edge device 146 is disposed between
the flashing 159 and the brick 120 to facilitate drainage beyond
the exterior surface 145 of the outer wythe 118.
[0066] The lower portion 153 of the drip edge device 146 is
disposed in the bed joint 128 of the outer wythe 118 and connected
to the upper portion 148 at an angle that facilitates drainage of
the water vapor beyond the exterior surface 145 of the outer wythe
118. The drip edge device 146 can be installed flat in the bed
joint 128 or propped up using either a loop of flashing (not shown)
or an affixed resilient layer of foam polymeric material 154
mounted on the upper portion 148 of the drip edge device 146 to
better direct the flow of water and water vapor into the drainage
system 110 and outside the exterior surface 145 of the outer wythe
118. The foam polymeric material 154 is constructed from material
selected from a group consisting of cross-linked polyethylene,
non-cross-linked polyethylene, and closed-cell neoprene sponge.
[0067] The drip edge device 146 is constructed from a rigid
extruded polymeric molded to an optimal shape to direct water to
the weep holes 140 and away from the exterior surface 145 of the
outer wythe 118. The lower portion 153 of the drip edge device is
optimally offset at a 45 degree angle. To further seal and place
the drip edge device, optional sealant and a backer rod may be
disposed in the bed joint 128.
[0068] The molded polymeric is UV resistant and contains at least
one material selected from the group consisting of
ethylenepropylene diene monomer, polyisobutylene, chlorinated
polyethylene, natural rubber, polyvinyl chloride, ethylene vinyl
acetate, and chlorosulfonated polyethylene. A specifically
preferred formulation for the drip edge device includes about 10 to
40 percent by weight of unplasticized polyvinyl chloride, and about
10 to 40 percent by weight of an ethylene vinyl acetate carbon
monoxide terpolymer. The drip edge device 46 may also contain up to
about 15 percent of primary or secondary plasticizer with, or
without, up to about 10 percent of processing aids or
stabilizers.
[0069] The drip edge device 46 contains polyvinyl chloride is
preferable range of about 20 to 30 percent by weight of the entire
composition and may advantageously be provided as a suspension or
emulsion grade of polyvinyl chloride. The ethylene vinyl acetate
carbon monoxide terpolymer may contain about 15 to 85 percent
ethylene, about 5 to 60 percent vinyl acetate, and about 0.5 to 30
percent carbon monoxide, all on a weight basis. A suitable
terpolymer for use in this context is that marketed by E. I. du
Pont de Nemours & Company under the trademark Elvaloy, with the
preference being for Elvaloy 742.
[0070] A peel-and-stick polymeric membrane 150 is affixed to the
exterior surface of the upper portion 148 of the drip edge device
146 which surface faces the flashing 159 that seals the cavity.
When the release sheet 157 is removed, the drip edge device 146 is
affixed to the flashing 159 to inhibit water from reaching the
inner wythe 114 and to direct any water or water vapor into the
drainage system 110.
[0071] The peel-and-stick polymeric membrane 150 is formulated for
pressure activation and compatibility with a release sheet 157
adhered thereto. The adhesives described herein are particularly
useful for peel-and-stick applications in building construction
industry as such adhesives are readily pressure activated after the
release paper is removed. The adhesive is formulated so that, in
case of fire, the coatings thereof will not contribute to smoke or
accelerate flame spreading and thus do not require inorganic
fillers which are know to interfere with the adhesive function.
Also, the adhesives are formulated to have sufficient tackiness so
that a durable bond between the membrane and the rough and porous
surface of the masonry block is experienced.
[0072] Incorporating by reference the Di Rado et al. patent, U.S.
Pat. No. 5,106,447, the hot melt adhesive compositions of hot melt
layer may be prepared from 10 to 50 weight percent of an isotactic
thermoplastic polybutene-1/ethylene copolymer containing from about
5.5 to about 10% by weight ethylene (polybutylene); 20 to 50
percent of a tackifier; 15 to 50 percent of an amorphous diluent
having a softening point greater than 90 degrees C.; 0 to 2 percent
of a stabilizer; and, and 0 to 5 percent wax.
[0073] The polybutylene copolymers employed herein are copolymers
of polybutene-1 and ethylene wherein the ethylene content varies
from about 5.5 to about 10% by weight of the polymer. The
applicable isotactic polybutylenes are relatively rigid while in
the plastic form but flow readily upon being heated. Expressing
molecular weight in terms of melt index, the applicable isotatic
polybutylenes to be used in the present adhesives should exhibit a
melt index in the range of from about 5 to 2000 dg/min and
preferably from 400 to 700 dg/min. The latter melt flow values are
determined by the method described in ASTMD1238 and are inversely
related to molecular weight, i.e., the lower the melt index, the
higher the molecular weight. These copolymers are available from
Shell Chemical Company under the Duraflex trademark as Duraflex
8310, 8410, 8510, and 8910, with the 8910 having a melt index of
about 700, a grade preferred for use therein. Mixtures of these
polymers may also be used.
[0074] The tackifying resins which may be used to extend the
adhesive properties of the isotactic polybutylene include: (1)
hydrogenated wood rosin or rosin ester; (2) polyterpene resins
having a softening point, as determined by an ASTM method E28-58 T,
of from about 80 degrees C. to 150 degrees C., the latter
polyterpene resins generally resulting from the polymerization of
terpene hydrocarbons in the presence of Friedel-Crafts catalysts at
moderately low temperatures and including the latter resins which
are aromatically modified; examples of commercially available
resins of this type being the Nirez resins sold by Reichhold
Chemical, the Zonatac resins sold by Arizona, and the Piccolyte
S-10, S-25, S-40, S-85, S-100, S-115, S-125 and S-135 resins as
sold by Hercules Chemical; (3) aliphatic petroleum hydrocarbon
resins having a Ball and Ring softening point of from about 80
degrees C. to 160 degrees C., resulting from polymerization of
monomers consisting primarily of 5 carbon atom olefins and
diolefins, and including the latter resins which are aromatically
modified, examples of commercially available resins of this type
being Wingtack 95 and Wingtack Extra as sold by the Goodyear Tire
and Rubber Company and the Escorez 1000 series of resins sold by
the Exxon Chemical Corporation; and, (4) partially and fully
hydrogenated hydrocarbon resins such as Resin H-130 from Eastman,
Escorez 5000 series from Exxon, and Regalrez from Hercules. The
amorphous diluents which are needed and present in the adhesive
composition include (atactic) amorphous polypropylene or other
similar high softening point (i.e. greater than 90 degrees C.), low
crystalline diluent (e.g. amorphous polyalphaolefins). These
diluents are used at levels of 20 to 50% by weight, preferably
about 20 to 25% by weight.
[0075] To test the degree of tackiness of the above-described
flashing structure, a pull test is performed. An Elvaloy 742 (see
paragraph 040 above) 8-inch by 12-inch sample is coated with a hot
melt adhesive, which hot melt adhesive formulation includes one or
more of the aforementioned tackifying resins. A suitable release
paper is applied thereover. After a prescribed cure period, the
release paper is removed and the flashing of this invention is
applied to the surface of a concrete block. The application to the
concrete block is at room temperature utilizing a hand-operated
laminating roller to provide the pressure activation. A spring
scale is then attached to the masonry flashing and a 65 lb. force
is required to peel the flashing from the block. Repeating the test
for SBS-modified, peel-and-stick flashing, a force of 27 lb. (max.)
is required to peel the flashing from the block.
[0076] Among the applicable stabilizers or antioxidants utilized
herein are included high molecular weight hindered phenols and
multifunctional phenols such as sulfur and phosphorous-containing
phenols. Representative hindered phenols include: 1,3,5-trimethyl
2,4,6-tris(3,5-di tert-butyl-4-hydroxy-benzyl)benzene;
pentaerythrityl
tetrakis-3(3,5-di-tert-butyl-4-bydroxyphenyl)propionate;4,4'methylenbis(2-
,6-tert-butyl-phenol); 4,4'-thiobis(6-tert-butyl-o-cresol);
2,6-di-tertbutylphenol;
6-(4-hydroxyphenoxy)-2,4-bis(n-octyl-thio)-1,3,5-triazine;
di-n-octadecyl 3,5-di-tert-butyl-4-hydroxy-benzylphosphonate;
2-(n-octylthio)ethyl 3,5-di-tert-butyl-4-hydroxybenzoate; and,
sorbitol
hexa[3-(3,5-di-tert-butyl-4-hydroxyphenyl)-propionate].
[0077] The performance of these antioxidants may be further
enhanced by utilizing, in conjunction therewith known synergists
such, for example, as thiodipropionate esters and phosphites.
Particularly useful is distearylthiodipropionate. These stabilizers
are generally present in amounts of about up to 2 weight percent,
preferably 0.25 to 1.0%. It is also possible to add minor amounts
(i.e. less than about 5% by weight of the formulation) of other
diluents such as (1) waxes including petroleum waxes such as
paraffin wax having a melting point of from about 50 degrees C. to
75 degrees C. and microcrystalline wax having a melting point of
from about 60 degrees to 90 degrees C.; the latter melting points
being determined by ASTM method D127-60; (2) low molecular weight
(600 to 3000) liquid polybutene; (3) polyethylene greases having a
softening point of from about 80 degrees C. to 100 degrees C. and a
hardness value, as determined by ASTM method D-1321, of from about
60 degrees C. to 120 degrees C.; (4) hydrogenated animal, fish and
vegetable fats and oil such as hydrogenated tallow, lard, soya oil,
cottonseed oil, castor oil, menhaden oil and cod liver oil; and,
(5) synthetic waxes made by polymerizing carbon monoxide and
hydrogen, such as Fischer-Tropsch wax.
[0078] In addition, relatively small amounts (less than about 5%)
of isotactic polypropylene may be employed as a reinforcing agent.
Other additives such as flow modifiers, pigments, dyestuffs, etc.,
which are conventionally added to hot melt adhesives for various
end uses may also be incorporated in minor amounts into the
formulations of the present inventions.
[0079] Because many varying and different embodiments may be made
within the scope of the inventive concept herein taught and because
many modifications may be made in the embodiments herein detailed
in accordance with the descriptive requirement of the law, it is to
be understood that the details herein are to be interpreted as
illustrative and not in a limiting sense.
* * * * *