U.S. patent number RE36,676 [Application Number 09/128,458] was granted by the patent office on 2000-05-02 for mortar and debris collection device and system.
Invention is credited to Tom Sourlis.
United States Patent |
RE36,676 |
Sourlis |
May 2, 2000 |
**Please see images for:
( Certificate of Correction ) ** |
Mortar and debris collection device and system
Abstract
A mortar and debris collection device for a cavity wall
construction has a non-water absorbent body formed with circuitous
paths therethrough making the body water-permeable. The collection
device has a porosity sufficient to permit water to pass
therethrough but insufficient to permit mortar and other debris to
pass therethrough to weep holes or other water channels covered by
the collection debris. The device may be freely placed on the wall
base within the cavity to cover the opening of a weep hole, or may
also be placed on existing wall ties within the cavity.
Inventors: |
Sourlis; Tom (Highland,
IN) |
Family
ID: |
25338217 |
Appl.
No.: |
09/128,458 |
Filed: |
August 4, 1998 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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Reissue of: |
862324 |
Apr 2, 1992 |
05230189 |
Jul 27, 1993 |
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Current U.S.
Class: |
52/169.5; 52/379;
52/562 |
Current CPC
Class: |
E04B
1/644 (20130101); E04B 1/7061 (20130101) |
Current International
Class: |
E04B
1/64 (20060101); E04B 1/70 (20060101); E02D
019/00 () |
Field of
Search: |
;52/421,169.5,302,303,310,379,380,381,382,383,513,562,565
;405/50 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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36580 |
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Oct 1935 |
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NL |
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1566196 |
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Apr 1980 |
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GB |
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Primary Examiner: Smith; Creighton
Attorney, Agent or Firm: Rockey, Milnamov & Kat
Claims
What is claimed is:
1. A mortar and debris collection device for use in a cavity wall
construction having an inner wall and an outer wall with channels
formed therein through which channels water can drain from a
channel opening communicating with a cavity defined between the
walls, comprising:
a water-permeable body positioned in alignment with at least some
of said channel openings, said body having circuitous non-linear
pathways therethrough which interrupt the downward movement of
free-falling material and extending from an upper surface upon
which water and debris can fall, and yielding a porosity for said
body sufficient to permit water to pass therethrough, but mortar
and other debris is .[.substantial.]. .Iadd.substantially
.Iaddend.prevented from passing therethrough, at least a portion of
said body having a thickness dimension substantially the same as
the cavity between said inner and outer walls.Iadd., said body
having a plurality of upwardly facing first surfaces formed thereon
that are separated by first horizontal spaces, and a plurality of
upwardly facing second surfaces formed thereon that are separated
by second horizontal spaces, said second surfaces elevated from
said first surfaces, at least some of said first surfaces being
disposed in vertical alignment with some of said second horizontal
spaces between said second surfaces, whereby mortar and other
debris falling under the influence of gravity within said cavity
contacts at least one of said first and second
surfaces.Iaddend..
2. .[.The collection device of claim 1.]. .Iadd.A mortar and debris
collection device for use in a cavity wall construction having an
inner wall and an outer wall with channels formed therein through
which channels water can drain from a channel opening communicating
with a cavity defined between the walls, comprising:
a water-permeable body positioned in alignment with at least some
of said channels openings, said body having circuitous non-linear
pathways therethrough which interrupt the downward movement of
free-falling material and extending from an upper surface upon
which water and debris can fall, and yielding a porosity for said
body sufficient to permit water to pass therethrough, but mortar
and other debris is substantially prevented from passing
therethrough, at least a portion of said body having a thickness
dimension substantially the same as the cavity between said inner
and outer wall, .Iaddend.wherein said body is elongated along a
long axis and has an upper surface with a non-planar contour of
peaks and valleys along said long axis adapted to break up
accumulations of mortar and debris falling thereon.
3. The collection device of claim 2 wherein said body has an upper
surface with a repeating dove-tailed contour along its long
axis.
4. .[.The collection device of claim 1 further including.]. .Iadd.A
mortar and debris collection device for use in a cavity wall
construction having an inner wall and an outer wall with channels
formed therein through which channels water can drain from a
channel opening communicating with a cavity defined between the
walls, comprising:
a water-permeable body positioned in alignment with at least some
of said channels openings, said body having circuitous non-linear
pathways therethrough which interrupt the downward movement of
free-falling material and extending from an upper surface upon
which water and debris can fall, and yielding a porosity for said
body sufficient to permit water to pass therethrough, but mortar
and other debris is substantial prevented from passing
therethrough, at least a portion of said body having a thickness
dimension substantially the same as the cavity between said inner
and outer wall, and .Iaddend.a wick for wicking water attached to
said body, said wick being adapted to fill a channel.
5. The collection device of claim 1 wherein said body is adapted to
be emplaced within the cavity resting on a wall base at the bottom
of the cavity, with the body covering at least one respective
channel opening and blocking the channel opening from mortar and
debris.
6. The collection device of claim 2 wherein said body has a
horizontal thickness defined perpendicular to said long axis, and
has a non-planar contour along said thickness on said upper
surface.
7. The collection device of claim 1 wherein the body portion having
a thickness dimension substantially the same as the space between
said inner and outer walls is located at the lower end of said
body.
8. The collection device of claim 1 wherein said body has
substantially the same thickness dimension throughout its length
and height.
9. The collection device of claim 1 wherein said body is positioned
in alignment with at least some of said channel openings by being
positioned directly outwardly of said openings.
10. A mortar and debris collection device for use in a cavity wall
construction having an inner wall and an outer wall with channels
formed therein through which channels water can drain from a
channel opening communicating with a cavity defined between the
walls, comprising:
a water-permeable body having circuitous non-linear pathways
therethrough extending from an upper surface upon which water and
debris can fall, and yielding a porosity for said body sufficient
to permit water to pass therethrough, but mortar and other debris
is substantially prevented from passing therethrough, said body
being formed of a water-resistant fibrous mass and emplaceable
within the cavity without any fixation device required.Iadd., said
body having first and second horizontal surface portions exposed
from above and located on at least two elevations.Iaddend..
11. .[.The collection device of claim 10.]. .Iadd.A mortar and
debris collection device for use in a cavity wall construction
having an inner wall and an outer wall with channels formed therein
through which channels water can drain from a channel opening
communicating with a cavity defined between the walls,
comprising:
a water-permeable body having circuitous non-linear pathways
therethrough extending from an upper surface upon which water and
debris can fall, and yielding a porosity for said body sufficient
to permit water to pass therethrough, but mortar and other debris
is substantially prevented from passing therethrough, said body
being formed of a water-resistant fibrous mass and emplaceable
within the cavity without and fixation device required,
.Iaddend.wherein said body is elongated along a long axis and
further includes at least one reinforcing rod affixed to said body
extending generally parallel to said long axis.
12. A mortar and debris collection device for use in a cavity wall
construction having an inner wall and an outer wall with weep holes
formed therein through which weep holes water can drain from a weep
hole opening communicating with a cavity defined between the walls,
comprising:
a water-permeable porous body of non-water absorbent randomly
oriented fibrous material positioned in alignment with at least
some of said weep hole openings, said body having a porosity
sufficient to permit water to pass therethrough but mortar and
debris is substantially prevented from passing therethrough,
said body having an upper surface including upwardly extending
protrusions yielding peaks and valleys adapted to break up
accumulations of mortar and debris falling thereon, at least a
portion of said body having a thickness dimension substantially the
same as the cavity between said inner and outer walls.
13. A mortar and debris collection device for use in a cavity wall
construction having an inner wall and an outer wall with weep holes
formed through a wall through which weep holes water can drain from
a weep hole opening communicating with a cavity defined between the
inner and outer walls, comprising:
a body of randomly oriented non-water absorbent fibrous material
formed into a water-permeable porous mass, said body being
positioned in alignment with at least some of weep hole openings
and having a porosity sufficient to permit water to pass
therethrough but substantially insufficient to permit mortar and
debris to pass therethrough, said body having a height and width
sized to cover at least one of the weep hole openings and
emplaceable within the cavity without any fixation device required,
at least a portion of said body having a thickness dimension
substantially the same as the cavity between said inner and outer
walls.Iadd., said body having a plurality of upwardly facing first
surfaces formed thereon that are separated by first horizontal
spaces, and a plurality of upwardly facing second surfaces formed
thereon that are separated by second horizontal spaces, said second
surfaces elevated from said first surfaces, at least some of said
first surfaces being disposed in vertical alignment with some of
said second horizontal spaces between said second surfaces, whereby
mortar and other debris falling under the influence of gravity
within said cavity contacts at least one of said first and second
surfaces.Iaddend..
14. The collection device of claim 13 wherein said body is emplaced
within the cavity and rests on a wall base at the bottom of the
cavity to cover at least one respective opening and block the
opening from mortar and debris.
15. The collection device of claim 13 further including a wick for
wicking water extending from said body at a body bottom, said wick
adapted to fit within the weep hole.
16. A drainage system for use in a cavity wall construction having
an inner wall and an outer wall with weep holes formed through one
of the walls adjacent a wall base at the bottom of the walls
through which weep holes water can drain from a weep hole opening
communicating with a cavity defined between the walls,
comprising:
a plurality of horizontally elongated drainage blocks, each of said
blocks being made of porous material formed with circuitous paths
through said blocks through which water can pass but through which
mortar and other debris cannot pass, each said block being sized to
fit within the cavity with a lateral face of said block being
positioned in alignment with and covering at least one respective
opening and blocking the opening from mortar and other debris with
said block resting on the wall base, each of said blocks having an
upper surface upon which mortar and other debris can collect, at
least a portion of said body having a thickness dimension
substantially the same as the cavity between said inner and outer
walls.Iadd., said upper surface having first and second horizontal
surface portions exposed from above and located on at least two
elevations.Iaddend..
17. .[.The drainage system of claim 16 wherein said drainage blocks
have an.]. .Iadd.A drainage system for use in a cavity wall
construction having an inner wall and an outer wall with weep holes
formed through one of the walls adjacent a wall base at the bottom
of the walls through which weep holes water can drain from a weep
hole opening communication with a cavity defined between the walls,
comprising:
a plurality of horizontally elongated drainage blocks, each of said
blocks being made of porous material formed with circuitous paths
through said blocks through which water can pass but through which
mortar and other debris cannot pass, each said block being sized to
fit within the cavity with a lateral face of said block being
positioned in alignment with and covering at least one respective
opening and blocking the opening from mortar and other debris with
said block resting on the wall base, each of said blocks having an
upper surface upon which mortar and other debris can collect, at
least a portion of said body having a thickness dimension
substantially the same as the cavity between said inner and outer
walls, said .Iaddend.upper surface including upwardly extending
protrusions formed thereon creating a non-planar surface contour of
peaks and valleys.
18. A drainage system for use in a cavity wall construction having
an inner wall and an outer wall with weep holes formed therein
adjacent a wall base at the bottom of the walls through which weep
holes water can drain from a weep hole opening communicating with a
cavity defined between the walls, comprising:
a plurality of horizontally elongated debris blocking bodies, each
of said bodies being made of non-water absorbent material formed
into a permeable mass having a porosity sufficient to permit water
to pass therethrough but insufficient to permit debris which is
greater than about 1/16 inch to pass therethrough, each of said
blocks having an upper surface upon which mortar and debris can
collect, said bodies being emplaced within the cavity and at least
some of said bodies resting on the wall base in alignment with and
covering at least one respective opening and blocking the opening
from debris, at least a portion of said body having a thickness
dimension substantially the same as the cavity between said inner
and outer walls.Iadd., said upper surface having first and second
horizontal surface portions exposed from above and located on at
least two elevations.Iaddend..
19. A drainage system for use in a cavity wall construction having
an inner wall, an outer wall, a wall base between the walls at the
bottom of the cavity wall construction, and ties extending between
and joining the walls above the base, with at least one channel
formed in a wall through which channel water can drain from a
channel opening communicating with a cavity defined between the
walls comprising:
a plurality of mortar and other debris blocking bodies, each of
said bodies being horizontally elongated along a major length with
a surface upon which mortar and debris can collect, made of
non-water absorbent material formed into a water-permeable porous
mass of randomly oriented passages which interrupt the downward
movement of free-falling material, said porous mass having a
porosity sufficient to permit water to pass therethrough but
insufficient to permit mortar and debris to pass therethrough, said
bodies being emplaced within the cavity on the wall base in
alignment with and covering at least one respective opening and
blocking the opening from such mortar and debris, at least a
portion of said bodies having a thickness dimension substantially
the same as the cavity between said inner and outer walls.Iadd.,
said surface having first and second horizontal surface portions
exposed from above and located on at least two
elevations.Iaddend..
20. A debris collection device for use in a cavity wall
construction having an inner wall and an outer wall with weep holes
formed therein adjacent a cavity wall base through which weep holes
water can drain from a weep hole opening communicating with a
cavity defined between the walls, comprising:
a plurality of screens, each said screen having a porosity
sufficient to permit water to pass therethrough but insufficient to
permit mortar and other debris having a size greater than about
1/16 inch to pass therethrough,
and means for organizing said screens in overlapping arrangement in
a plurality of generally parallel planes with screens in one or
more of said planes being spaced one from another, said screen so
organized giving the debris collection device a thickness at least
as great as the horizontal distance between the inner and outer
walls at the cavity wall base and defining a volume for the debris
collection device, said screens being overlapped such that a
vertical line perpendicular to said planes through said volume must
intersect at least one screen, whereby mortar and other debris
falling under the influence of gravity within the cavity and into
said volume must contact at least one such screen.
21. The collection device of claim 20 further including a wick for
wicking water extending through the weep hole into the cavity.
22. A mortar collecting device for use in a cavity wall
construction having an inner wall and an outer wall with channels
formed therein through which channels water can drain from a
channel opening communicating with a cavity defined between the
walls, comprising:
a supporting member having a lateral face, said supporting member
having a vertical height and longitudinal length adapted to yield
an area greater than that of at least one such channel opening,
a plurality of projections extending from said lateral face, said
projections being provided in staggered arrangement such that a
vertical line extending parallel to said lateral face will contact
at least one such projection, thereby forming a circuitous path for
debris passing along said lateral face,
whereby said collecting device when emplaced within the cavity with
said projections overlying at least one such channel opening serves
to prevent debris from plugging the channel opening.
23. The collecting device of claim 22 wherein said support member
is a backing board having a planar lateral face, and said
projections are adapted to extend across the cavity and contact one
wall with said backing board abutting the other wall.
24. The collecting device of claim 20 wherein said projections are
flexible.
25. The collecting device of claim 20 wherein said projections are
resilient.
26. A mortar collecting device for use in a cavity wall
construction having an inner wall and an outer wall with channels
formed therein through which channels water can drain from a
channel opening communicating with a cavity defined between the
walls, comprising:
a supporting member having two lateral side faces, said supporting
member having a vertical height and longitudinal length adapted to
yield an area greater than that of at least one such channel
opening,
a plurality of projections extending outwardly from each said side
lateral face, said projections being provided in staggered
arrangement such that a vertical line extending parallel to each
said side lateral face will contact at least one such projection,
thereby forming a circuitous path for debris passing along each
said side lateral face,
whereby said collecting device when emplaced within the cavity with
said projections overlying at least one such channel opening serves
to prevent debris from plugging the channel opening.
27. The collection device of claim 26 wherein said body is
elongated with a horizontal long axis, and further includes
reinforcing means affixed to said body and extending parallel to
said long axis for adding rigidity against bending along said long
axis.
28. A mortar collecting device for use in a cavity wall
construction having an inner wall and an outer wall with channels
formed therein through which channels water can drain from a
channel opening communicating with a cavity defined between the
walls, comprising:
a pair of opposed supporting members each having a lateral face,
each said supporting member having a vertical height and
longitudinal length adapted to yield an area greater than that of
at least one such channel opening,
a plurality of projections extending between said lateral faces,
said projections being provided in staggered arrangement such that
a vertical line extending parallel to each said side lateral face
will contact at least one such projection, thereby forming a
circuitous path for debris passing between said opposed supporting
members along a lateral face,
whereby said collecting device when emplaced within the cavity
overlying at least one such channel opening serves to prevent
debris from plugging the channel opening.
29. A mortar collecting device for use in a cavity wall
construction having an inner wall and an outer wall with weep holes
formed therein adjacent a cavity bottom through which weep holes
water can drain from a weep hole opening communicating with a
cavity defined between the walls, comprising:
a water permeable body positioned in alignment with at least some
of said weep hole openings, said body having non-linear water
pathways formed therein which interrupt the downward movement of
free-falling material and yielding a porosity sufficient to permit
water to pass therethrough, said body having a horizontal axis
relative to the cavity bottom, said body further including a layer
of material extending along said horizontal axis which material
passes water therethrough, at least a portion of said body having a
thickness dimension substantially the same as the cavity between
said inner and outer walls.Iadd., said body having a plurality of
upwardly facing first surfaces formed thereon that are separated by
first horizontal spaces, and a plurality of upwardly facing second
surfaces formed thereon that are separated by second horizontal
spaces, said second surfaces elevated from said first surfaces, at
least some of said first surfaces being disposed in vertical
alignment with some of said second horizontal spaces between said
second surfaces, whereby mortar and other debris falling under the
influence of gravity within said cavity contacts at least one of
said first and second surfaces.Iaddend..
30. .[.The collecting device of claim 29.]. .Iadd.A mortar
collecting device for use in a cavity wall construction having an
inner wall and an outer wall with weep holes formed therein
adjacent a cavity bottom through which weep holes water can drain
from a weep hole opening communicating with a cavity defined
between the walls, comprising:
a water permeable body positioned in alignment with at least some
of said weep hole openings, said body having non-linear water
pathways formed therein which interrupt the downward movement of
free falling material and yielding a porosity sufficient to permit
water to pass therethrough, said body having a horizontal axis
relative to the cavity bottom, said body further including a layer
of material extending along said horizontal axis which material
passes water therethrough, at least a portion of said body having a
thickness dimension substantially the same as the cavity between
said inner and outer walls, .Iaddend.wherein said body has an upper
surface including upwardly extending protrusions to prevent ponding
of material falling on said upper surface.
31. The collecting device of claim 30 wherein said body is
comprised of randomly oriented nonabsorbent fibrous material formed
into a water permeable porous mass, said body having a porosity
sufficient to permit water to pass therethrough but insufficient to
permit mortar and other debris having a size greater than about
1/16 inch to pass therethrough, said body having a height and width
sized to cover at least one of the weep hole openings.
32. A mortar and debris collection device for use in a cavity wall
construction having an inner wall and an outer wall with channels
formed therein through which channels water can drain from a
channel opening communicating with a cavity defined between the
walls, comprising:
a water-permeable body having circuitous non-linear pathways
therethrough extending from an upper surface upon which water and
debris can fall, and yielding a porosity for said body sufficient
to permit water to pass therethrough, but mortar and other debris
is substantially prevented from passing therethrough, said body
being elongated along a long axis and having an upper surface with
a non-planar contour along said long axis, and flashing affixed to
said body along a body bottom which is opposite to said upper
surface and generally parallel to said long axis.
33. A mortar and debris collection device for use in a cavity wall
construction having an inner wall and an outer wall with channels
formed therein through which channels water can drain from a
channel opening communicating with a cavity defined between the
walls, comprising:
a water-permeable body having circuitous non-linear pathways
therethrough extending from an upper surface upon which water and
debris can fall, and yielding a porosity for said body sufficient
to permit water to pas therethrough, but mortar and other debris is
substantially prevented from passing therethrough, said body being
elongated along a long axis and having a horizontal thickness
defined perpendicular to said long axis, said body also having an
upper surface with a non-planar contour of stepped configuration
along said upper surface.
34. A mortar and debris collection device for use in a cavity wall
construction having an inner wall and an outer wall with weep holes
formed therein through which weep holes water can drain from a weep
hole opening communicating with a cavity defined between the walls,
comprising:
a water-permeable porous body of non-water absorbent randomly
oriented fibrous material having a porosity sufficient to permit
water to pass therethrough,
said body having an upper surface including upwardly extending
protrusions which define overhangs along said upper surface to
provide gaps in material collected on said upper surface.
35. A mortar and debris collection device for use in a cavity wall
construction having an inner wall and an outer wall with weep holes
formed through a wall through which weep holes water can drain from
a weep hole opening communicating along with a cavity defined
between the inner and outer walls, comprising:
a body of randomly oriented non-water absorbent fibrous material
formed into a water-permeable porous mass, said body having a
porosity sufficient to permit water to pass therethrough but
substantially insufficient to permit mortar and debris to pass
therethrough, said body having a height, and width sized to cover
at least one of the weep hole openings, a wick for wicking water
extending from said body at a body bottom, said wick adapted to fit
within the weep hole, and flashing attached to said body
bottom.
36. A drainage system for use in a cavity wall construction having
an inner wall, an outer wall, a wall base between the walls at the
bottom of the cavity wall construction, and ties extending between
and joining the walls above the base, with at least one channel
formed in a wall through which channel water can drain from a
channel opening communicating with a cavity defined between the
walls comprising:
a plurality of mortar and other debris blocking bodies, each of
said bodies being made of non-water absorbent material formed into
a water-permeable porous mass of randomly oriented passages, said
porous mass having porosity sufficient to permit water to pass
therethrough but insufficient to permit mortar and debris to pass
therethrough, said bodies being emplaced within the cavity on the
wall base covering at least one respectively opening and blocking
the opening from such mortar and debris, said bodies having a
thickness at least as great as the distance between the inner and
outer walls at the wall base, with each said bodies freely resting
on one or more of the wall base and ties.
37. A drainage system for use in a cavity wall construction having
an inner wall, an outer wall, a wall base between the walls at the
bottom of the cavity wall construction, and ties extending between
and joining the walls above the base, with at least one channel
formed in a wall through which channel water can drain from a
channel opening communicating with a cavity defined between the
walls comprising:
a plurality of mortar and other debris blocking bodies, each of
said bodies being made of non-water absorbent material formed into
a water-permeable porous mass of randomly oriented passages, said
porous mass having a porosity sufficient to permit water to pass
therethrough but insufficient
to permit mortar and debris to pass therethrough, said bodies being
emplaced within the cavity on the wall base covering at least one
respective opening and blocking the opening from such mortar and
debris, at least some of said bodies being elongated along a major
length and include a reinforcing rod extending along said major
length to provide further rigidity to said body, as for supporting
said body between ties in the cavity. .Iadd.
38. The collection device of claim 1 wherein said upwardly facing
first and second surfaces are oriented in vertically and
horizontally spaced apart rows..Iaddend..Iadd.39. The collection
device of claim 1 wherein said body includes first and second
screen portions, and wherein said first surfaces are formed on said
first screen portions, said first surfaces disposed generally along
a first substantially horizontal plane; and
said second surfaces are formed on said second screen portions,
said second screen portions having a bottom surface facing
downwardly and disposed generally along a second substantially
horizontal plane, said first and second substantially horizontal
planes being separated by a vertical space..Iaddend..Iadd.40. The
collection device of claim 39 wherein said first and second screen
portions have a horizontal thickness dimension substantially the
same as the cavity between said inner and outer
walls..Iaddend..Iadd.41. The collection device of claim 39 wherein
said first and second surfaces are substantially horizontally
oriented..Iaddend..Iadd.42. The collection device of claim 39
wherein said first screen portions are arranged spaced apart along
the horizontal direction, and said second screen portions are
arranged spaced apart along the horizontal direction, said first
screen portions are each arranged to have at least a portion of a
respective first surface located along the horizontal direction
between two adjacent ones of said second screen
portions..Iaddend..Iadd.43. The collection device of claim 42
further comprising a plurality of third screen portions spaced
apart along the horizontal direction and located at a lower
elevation than said first screen portions, said third screen
portions include a third upwardly facing surface, said third screen
portions are arranged to have at least a portion of a respective
third surface located along the horizontal direction between two
adjacent ones of said first screen portions..Iaddend..Iadd.44. The
collection device of claim 43 wherein said first screen portions
include a bottom surface arranged generally along a third
horizontal plane, and said third upwardly facing surfaces of said
third screen portions are arranged generally along a fourth
horizontal plane, said third horizontal plane and said fourth
horizontal plane being
separated by a further vertical space..Iaddend..Iadd.45. The
collection device of claim 44 wherein said first, second and third
screen portions are formed by random-fiber, fibrous
material..Iaddend..Iadd.46. The collection device of claim 1
wherein said body includes first and second screen portions, and
wherein said first surfaces are formed on said first screen
portions, said first surfaces disposed generally along a first
substantially horizontal plane; and
said second surfaces are formed on said second screen portions,
said second screen portions having a bottom surface facing
downwardly and disposed generally along a second substantially
horizontal plane, said first and second substantially horizontal
planes being separated by a vertical space;
wherein said first and second screen portions have a horizontal
thickness dimension substantially the same as the cavity between
said inner and outer walls;
wherein said first and second surfaces are substantially
horizontally oriented;
wherein said first screen portions are arranged spaced apart along
the horizontal direction, and said second screen portions are
arranged spaced apart along the horizontal direction, said first
screen portions are each arranged to have at least a portion of a
respective first surface located along the horizontal direction
between two adjacent ones of said second screen portions;
and comprising a plurality of third screen portions spaced apart
along the horizontal direction and located at a lower elevation
than said first screen portions, said third screen portions include
a third upwardly facing surface, said third screen portions are
arranged to have at least a portion of a respective third surface
located along the horizontal direction between two adjacent ones of
said first screen portions;
wherein said first screen portions include a bottom surface
arranged generally along a third horizontal plane, an said third
upwardly facing surfaces of said third screen portions are arranged
generally along a fourth horizontal plane, said third horizontal
plane and said fourth horizontal plane being separated by a further
vertical space; and
wherein said first, second and third screen portions are formed
by
random-fiber, fibrous material..Iaddend..Iadd.47. The collection
device of claim 1 wherein said body includes first and second
screen portions, and wherein said first surfaces are formed on said
first screen portions, said first surfaces disposed generally along
a first substantially horizontal plane; and
said second surfaces are formed on said second screen portions,
said second screen portions having a bottom surface facing
downwardly and disposed generally along a second substantially
horizontal plane, said first and second substantially horizontal
planes being separated by a vertical space; and
said first and second screen portions are formed by random-fiber,
fibrous material..Iaddend..Iadd.48. The collection device of claim
1 wherein said body includes a plurality of third upwardly facing
surfaces, said third upwardly facing surfaces located on an
elevation below said first and second upwardly facing
surfaces..Iaddend..Iadd.49. The collection device of claim 1
wherein said body includes first and second screen portions, and
wherein said first surfaces are formed on said first screen
portions; and
said second surfaces are formed on said second screen portions,
wherein said first screen portions are arranged spaced apart along
the horizontal direction, and said second screen portions are
arranged spaced apart along the horizontal direction, said first
screen portions are each arranged to have at least a portion of a
respective first surface located along the horizontal direction
between two adjacent ones of said second screen portions;
and a plurality of third screen portions spaced apart along the
horizontal direction and located at a lower elevation than said
first screen portions, said third screen portions include a third
upwardly facing surface, said third screen portions are arranged to
have at least a portion of a respective third surface located along
the horizontal direction between two adjacent ones of said first
screen
portions..Iaddend..Iadd.50. A mortar and debris collection device
for use in a cavity wall construction having an inner wall and an
outer wall with channels formed therein through which channels
water can drain from a channel opening communicating with a cavity
defined between the walls, comprising:
a water-permeable body positioned in alignment with at least some
of said channels openings, said body having circuitous non-linear
pathways therethrough which interrupt the downward movement of
free-falling material and extending from an upper surface upon
which water and debris can fall, and yielding a porosity for said
body sufficient to permit water to pass therethrough, but mortar
and other debris is substantially prevented from passing
therethrough, at least a portion of said body having a thickness
dimension substantially the same as the cavity between said inner
and outer walls, said body having a plurality of upwardly facing
surfaces formed thereon that are separated by horizontal spaces,
whereby mortar and other debris falling under the influence of
gravity within said cavity can contact one of said upwardly facing
surfaces or fall through one of said horizontal spaces..Iaddend.
Description
FIELD OF THE INVENTION
This invention generally relates to mortar and debris collection
devices, such as are used in association with cavity wall
constructions. More particularly, in the course of construction of
a masonry cavity wall, mortar and other debris falls into the
cavity, and may then block weep holes or other water outlets
necessary to prevent moisture build-up within the wall cavity. This
invention more specifically relates to a device and system for
collecting loose mortar and other debris in order to prevent the
same from blocking the weep holes that ventilate such a cavity wall
construction.
BACKGROUND OF THE INVENTION
The present invention found its origin in so-called masonry cavity
wall constructions. Masonry cavity walls have inner and outer
vertical walls. The inner wall is typically constructed from wood
with an inner surface of drywall, structural clay tile, vertical
stacks of mortared bricks, or a shear concrete surface. The stacks
of bricks that are held together by mortar. A space, or cavity,
exists between the two walls, which may be partially filled with
insulation. It is applicant's understanding that the Brick
Institute defines a "cavity wall" as having a space greater than
about 2 inches but not more than 4 inches between the masonry
wythes.
A crack in the wall can allow water to enter the cavity. More
often, however, moisture can condense on the inside of the wall
under changing temperatures. Either way, water may collect in the
cavity between the inner and outer wall.
The presence of moisture in the space between the inner wall and
outer wall is undesirable for a number of reasons. First, the
trapped moisture can degrade the inner and outer wall, causing a
weakening of the structure. Second, the presence of water under
freezing temperatures may also cause cracks in the walls when the
water expands as it freezes. Trapped water in the cavity between
the inner and outer walls may cause the walls to become discolored,
and may even leak into the dwelling.
To overcome the problems associated with water trapped within a
masonry cavity wall, weep holes are commonly placed along the base
of the outer wall. The weep holes allow water to pass from the
cavity to drain outside the wall structure.
During construction of a masonry cavity wall, excess mortar and
other debris can and does fall between the inner and outer wall.
When the bricks are stacked during the erection of the outer wall,
for example, mortar droppings are squeezed into the space between
the walls. The excess mortar, as well as other debris, drops to the
base of the cavity, and can block the weep holes.
Wicks have been used in weep holes. For instance a cotton wick,
such as a segment of cotton rope, has been used in weep holes. Such
wicks can be extended from the weep hole up within the cavity to a
height considered sufficient to exceed any build-up of mortar
droppings. Moisture within the cavity is absorbed by the wick, and
passed to the outside face of the wall. Wicks are preferably made
from cotton, because nylon or hemp are considered less efficient in
transferring water. The cotton wick, however, may become broken or
squashed, and will rot with time. Accordingly, the weep hole may
still become blocked during and after construction, thereby
preventing moisture in the cavity from passing to the outside of
the wall.
Another attempt to overcome the problems associated with obstructed
weep holes is described in U.S. Pat. No. 4,852,320. The '320 patent
describes embodiments of a mortar collection device located in the
wall cavity. One embodiment is adapted to collect mortar but
deflect water. This mortar collection device has an upper surface
with sufficient inclination to cause moisture to slide off, but is
purportedly insufficiently inclined to prevent mortar from falling
off. A second embodiment has a plurality of vertically aligned
passageways of dimension sufficient to allow moisture to pass
therethrough, but of insufficient dimension to allow mortar to pass
therethrough. This honeycomb-like mortar collection device of the
'320 patent is made from a non-water absorbent material, such as
plastic.
It can be seen, nonetheless, that mortar or other debris may still
roll down the surface of one or more of the collection devices of
the '320 patent and plug a weep hole. Also, the '320 patent mortar
collection devices are specially adapted to be carried on
reinforcement rods extending between the inner and outer wall. They
are not shown adapted to simply rest on the base of the wall, so as
to completely cover the weep holes. Furthermore, in the second
embodiment of the '320 patent described above having the vertical
passageways, small pieces of mortar on other debris may still pass
through the holes extending through the unit, thereby allowing the
debris to reach the base of the wall and plug the weep holes.
It would be desirable to have a mortar and debris collection device
capable of resting on the base of the wall in the space between the
inner and outer walls to cover and protect the weep holes, as well
as being supportable at different heights on the wall without the
use of any additional fixation device or special attachment design
feature. Furthermore, a collection device should prevent mortar
droppings and other debris of any appreciable size from reaching
the weep holes.
SUMMARY OF THE INVENTION
Accordingly, it is a principal objective of this invention to
provide a mortar and debris collection device that can rest on the
base of the wall cavity to cover and protect one or more weep holes
preventing mortar or debris of any significant size from reaching a
weep hole and thereby blocking the holes. In addition, a related
objective is to provide such a collection device which can be
placed at different heights within the cavity without the use of
any fixation device or special adaptation of the collection
device.
Another objective is to provide a surface configuration for such a
collection device which facilitates adequate dispersal of debris
thereon to assure a water path remains to the collection
device.
To the foregoing and other ends, the improved mortar and debris
collection device of this invention comprises, in one aspect of the
invention, a water-permeable body formed with circuitous
(non-linear) pathways therethrough, which body can be readily
placed within a cavity wall construction. The inventive collection
device can preferably be a non-absorbent water-permeable fibrous
block having a porosity sufficient to permit water to pass
therethrough, but insufficient to permit mortar or other debris of
appreciable size to pass therethrough. Another embodiment
contemplates laterally extending projections formed on a supporting
board which form the circuitous path.
The collection device is intended to be placed on the wall base
within the cavity to cover up and block one or more weep hole
openings from mortar and debris. Water can migrate through the
porous mass to a drain outlet, such as the weep holes, but mortar
and debris cannot. It is furthermore contemplated that the
collection device may also be placed on existing supports, such as
ties, along the walls. No special fixation means for emplacement of
the collection device is therefore required, and the collection
device need not be specifically adapted for the particular
application.
A preferred form of the collection device has upwardly extending
protrusions, such as protrusions defining overhangs as well as
steps, which serve to break up mortar and debris falling on top of
the collection device. This prevents ponding of the material on the
surface of the collection device.
In one embodiment of the invention, a plurality of screens having a
porosity sufficient to permit water to pass therethrough but
insufficient to permit mortar or other larger-size debris to pass
therethrough, are organized in an overlapping arrangement in a
collection device. The screens are overlapped such that a vertical
line perpendicular to the base of the wall must intersect at least
one screen in the device. Mortar and the like falling under the
influence of gravity within the cavity must thereby contact at
least one of the screens, and preferably two, preventing the mortar
and debris from reaching the wall base and blocking a weep
hole.
The objectives and advantages of the invention will be further
understood with reference to the following detailed description of
embodiments of the invention read in light of the accompanying
drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a prior art mortar collection device
located in a cavity between an inner and outer wall;
FIG. 2 is a sectional view similar to that of FIG. 1, but of a
first embodiment of a collection device made according to the
present invention;
FIG. 3 is a perspective view partly in section and partially broken
away of the embodiment of FIG. 2 located in a wall cavity;
FIG. 4 is an enlarged perspective view of a portion of the
embodiment of the collection device shown in FIG. 3;
FIG. 5 is a perspective view of another embodiment of the inventive
collection device;
FIG. 6 is a perspective view of yet another embodiment of the
inventive collection device;
FIG. 7 is a perspective view of still another embodiment of the
inventive collection device;
FIG. 8 is a perspective view of a further embodiment of the
invention;
FIG. 9 is a perspective view of an embodiment similar to FIG. 4
having a fine porous layer therein;
FIG. 10 is a perspective view of an embodiment having a stepped
configuration across its horizontal thickness;
FIG. 11 is yet another embodiment employing a cleated lateral
surface;
FIG. 12 is a cross-sectional view of an embodiment similar to that
of FIG. 11 having cleats on both sides; and
FIG. 13 is a cross-sectional view of an embodiment employing
opposed cleated lateral surfaces.
FIG. 14 is a front elevational view of a portion of the fibrous
mass.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
Brick masonry cavity walls 10, as shown in FIGS. 1, 2 and 3,
consist of two wythes of masonry separated by an air space. The
interior masonry wythe (the inner wall) 12 may be brick, hollow
brick, structural clay tile, wood or hollow or solid concrete
masonry units, for example. The exterior masonry wythe 14 (the
outer wall) is brick. The cavity 16 between the two wythes may be
either insulated or left open as air space. The cavity has a
typical width of about 2 to about 4 1/2 inches, but could be
smaller, although non-standard.
A common problem associated with a cavity wall construction is how
to allow moisture, as from seepage or condensation, to pass from
the cavity to outside the wall. Weep holes 18 creating an
unobstructed opening passing from the cavity to the outside of the
wall are provided to this end. Generally, the weep holes 18 will be
placed approximately two feet apart at the base of the outer wall
14. Moisture collecting in the cavity is intended to run down the
cavity wall and be directed by flashing 20 toward the weep holes
18. The flashing 20 is composed of materials such as sheet metals,
bituminous membranes, plastics or vinyls.
A cotton wick 22 may be placed within the weep hole extending into
the cavity. The moisture from inside the cavity will be absorbed
and passed to the other end of the wick. The end of the wick is
left outside the wall to let the moisture evaporate outside the
wall.
In the course of construction of a cavity wall 10 as shown in FIGS.
1-3, mortar 24 and other debris will commonly fall into the cavity
16 between the inner wall 12 and outer wall 14. FIG. 1 illustrates
a prior art system for passing water to the outside face of the
masonry wall 10. A cotton wick 22 is inserted within a weep hole 18
and extends through the veneer face and into the cavity 16.
Moisture within the cavity is absorbed by the wick 22 and passed to
the outside face of the wall. The wick 22 is preferably made from
cotton, with nylon or hemp being considered less efficient than
cotton in transferring moisture to the outside surface of the
wall.
In the prior art structure depicted in FIG. 1, mortar and debris
may fall all the way to the base of the wall 26, where the weep
holes 18 are located. Because there is no easy access to the
interior of the cavity 16, mortar and debris falling within the
cavity 16 is not readily removable. If enough mortar 24 builds up
around the weep holes 18, or if it simply lodges in the weep holes
18, the weep holes 18 will become plugged, causing water to pond
between the walls 12, 14. The water can then leak into the
structure, or cause cracking, deterioration and/or discoloration of
the walls. Wicks have been found insufficient by themselves to
assure that water can always pass through the weep holes.
FIG. 2 shows one embodiment of an improved mortar and debris
collection device of the present invention. A fibroid body 28
according to the present invention rests on the base 26 of the
cavity between the inner wall 12 and the outer wall 14, covering at
least one weep hole 18. In this embodiment, the body has a
generally rectangular shape with a flat bottom edge that will rest
flush against the wall 14. The width of the body is roughly
determined by the width of the cavity 16.
The body is preferably composed of non-absorbent plastic, such as,
for example, the filament-type plastic used to surface walk-off
mats. These materials are preferred because they are
water-impervious, relatively inexpensive and can be formed into
cutable blocks or sheets. A quantity of one or more of these
materials is formed in a mass of random fibers with a density which
is sufficient to catch and support mortar and other debris thereon
without significant collapse, but allow water to pass freely
therethrough.
A cotton wick 22 may be attached to, or formed with, the body 28 to
aid in the passage of water from the wall. The wick 22 can serve to
hold the body 28 in place. When used with such an integral wick 22,
the body 28 would be emplaced when the wick holes were formed.
Otherwise, it is contemplated that the mortar collection device of
this invention will simply be set at the base 26 of the wall
foundation covering respective weep holes 18, without the need of
any fixation device. Flashing 20 can furthermore be directly
attached to the bottom and/or back of the body 28.
The porosity of the body 28 made from the fibrous material can be
quite varied, so long as it effectively serves to strain out the
mortar and debris before it reaches the weep hoes. Most mortar and
debris will be quite large, i.e., greater than 1/8 or 1/16 of an
inch or clearly visible to the naked eye, so a porosity sufficient
to catch such relatively large particulate matter will suffice to
prevent plugging of the weep holes.
Besides being emplacable on the base of the cavity 16, fibrous
bodies 28 may be placed on wall tie rods 32 above the base 26 of
the cavity. The tie rods 32 are often part of the cavity wall
structure, tying the inner wall 12 and the outer wall 14 together.
As particularly shown in FIGS. 3 and 4, the body 28 would
advantageously include reinforcing rods 30 extending along the
bottom of the body to support and better distribute weight on the
body 28 when not simply resting on the base 26 of the cavity 16.
The reinforcing rods 30 will better enable a collection device to
span adjacent tie rods 32 and still work effectively.
A system using the collection device of FIGS. 2-4 would, for
example, include bodies 28 placed on the base 26 in sufficient
number to cover and block some or all of the weep holes 18 in the
cavity 16. It could further include bodies 28, having the
reinforcing rods 30, placed on tie rods 32.
The body 28 of the embodiment of FIGS. 2-4 has trapezoidal-like
cutouts 36. Two slanted edges 38 of the body and a bottom edge 40
of the body (the latter running roughly parallel to the
longitudinal axis of the body) define the cutout 36. The
dove-tailed cutouts 36 thereby formed in the body 28 yield
protrusions which help break up the mortar and other debris falling
thereon to prevent ponding of moisture in the mortar and debris
that collect on the collection device surface. The overhangs formed
by the slanted sides 38 are intended to assure that gaps remain in
fallen mortar and debris for water to progress to the body 28.
FIG. 5 illustrates another embodiment of this invention having a
fibrous mass 41 with a stepped configuration along its length
created by a series of slanted edges 44. The top step 48 may have a
length of approximately 6 to 8 inches, for example. The height of
each step may be approximately 4 inches. Again, the stepped cutout
42 is intended to break up mortar and debris falling thereon to
thereby prevent the ponding of moisture.
FIG. 6 illustrates another embodiment of this invention with the
fibrous mass 50 having rectangular cutouts formed by a series of
perpendicular edges 54. In a presently contemplated embodiment, the
steps would have a height of approximately 4 inches and a length of
approximately 8 inches.
FIG. 7 illustrates yet a further embodiment of this invention. The
debris collecting fibrous body 58 has dove-tailed cutouts formed
from non-planar curved steps 60. This is another shape for the
upper surface of the collection device designed to break up the
mortar and other debris falling thereon, to thereby prevent the
ponding of moisture on the surface of the body 58.
FIG. 8 illustrates another embodiment of this invention. Three
series of planar screens 62, 64 and 66 having a porosity sufficient
to permit water to pass therethrough but at least collectively
insufficient to permit mortar and other debris to pass therethrough
are arranged to form the collection device. A first plurality of
screens 62 extend on one
horizontal plane. On a second and lower horizontal plane, a
plurality of screens 64 are arranged in spaced apart relation. On a
third and still lower horizontal plane, a plurality of screens 66
are arranged in spaced apart relation, but with portions
overlapping with screens 64 of the second horizontal plane. A
vertical line extending substantially perpendicular through the
collection device of FIG. 8 must therefore pass through at least
one and move often two screens in this embodiment.
Generally, the screens should have a width determined by the width
of the cavity 16. The screens can be formed of a sufficiently rigid
screen material to maintain their shape when attached to vertical
rods 68 or like supporting structure, or may each be provided with
a rigid frame. Screen 62 may have a large mesh size to catch only
the larger particles, with screens 64 and 66 having a smaller mesh.
Wicks 22 may be attached to the base of the rods 68. Screen 62
might also be omitted entirely, if desired. Whether present or not,
however, mortar droppings and other debris falling into the cavity
16 above the screen collection device of FIG. 8 must contact at
least one screen to thereby become trapped and isolated from the
weep holes.
FIG. 9 illustrates a modified embodiment similar to that of FIG. 4,
except that a thin layer of material 70 is provided above the
bottom of the fibrous body, which material has the ability to pass
water but substantially no visible solids. Such a material could be
the type of landscaping material used to control weeds. The layer
could be located 1 to 2 inches above the bottom, for example.
FIG. 10 illustrates an embodiment having a stepped upper surface
extending across its horizontal thickness, i.e., perpendicular to
its long axis. Steps 72a, 72b and 73a, 73b of the fibrous mass
serve to prevent "bridging" of material across the space of the
wall cavity (i.e., extending between the inner wall 12 and outer
wall 14).
FIG. 11 is another variation on the basic inventive concept which
utilizes a supporting base, such as a backing board 80, having a
plurality of cleat-like projections 82 extending from one or both
(see FIG. 12) of its lateral surfaces. The cleats 82 would
preferably be staggered so as to provide a tortuous path for water
and debris, and also preferably made of a flexible material so a to
permit the FIG. 11 embodiment to fit within most common cavity wall
spaces The FIG. 11 embodiment is intended to be placed in the
cavity 16 (e.g., FIG. 3) with the backing board 80 against one wall
and the cleats 82 extending across the gap and engaging the
opposite wall.
FIGS. 12 and 13 are modified embodiments similar in concept to FIG.
11. The FIG. 12 embodiment, shown here only in cross-section, has
projections 82 extending from both lateral sides of the backing
board 80. It would be placed in the middle of the cavity 16, with
projections 82 engaging respective walls.
The FIG. 13 embodiment, again shown here only in cross-section,
uses relatively thin backing boards 80' which are arranged in
opposed relationship so that the projections 82 extending from
respective lateral sides intermesh. The FIG. 13 embodiment would be
placed in cavity 16 with the backing boards 80' abutting the walls
defining the cavity.
Thus, while the collection device and system of this invention have
been described with respect to a number of different embodiments,
those of skill in this art will recognize changes and modifications
in material, structure and form and the like which will still fall
within the scope of the claims of this invention.
* * * * *