Sheathing generally comprises sheets of plywood, oriented strand board (OSB), extruded foam board or gypsum board or the like which are nailed or otherwise fastened to structural members defining a building frame. Weather/water resistant barriers are typically placed on or secured to the sheathing to prevent the infiltration of water and/or air (drafts) into the building. A barrier material with vapor permeability can also promote passage of moisture therefrom.
Installation of weather resistant barriers to wall or roofing structures can be labor intensive. Exposure to the elements, especially strong winds, before cladding construction often necessitates replacement of entire wall sections, at great cost to the builder in terms of both time and materials Flashing of penetrations (e.g., windows, doors, etc) in a wall or roof and flashing of the joints between sheets of weather resistant barrier can be confusing, difficult and is often done improperly. Faulty installation can cause damage to and degradation of underlying structural members, eventually resulting in costly rehabilitation (e.g., wall, window, etc. replacement) well short of expected building lifetime.
Responsive to such issues, several material systems have been developed. Representative of such efforts is a wall sheathing panel with a water-resistive barrier constructed directly on an underlying support material. Such a composite allows one-step installation of both materials over a building frame. However, a flashing tape is needed to cover seams between adjacent panels. For obvious reasons, such an approach is problematic for vertical panel seams. Regardless, each piece of tape, in turn, creates two more seams for potential water penetration. Accordingly, there remains an on-going search in the art for a sheathing composite and configuration better able to utilize the benefits and advantages associated with available weather resistant barrier materials.
In light of the foregoing, it is an object of the present invention to provide a weather/water-resistant sheathing and/or method(s) for use in the building or construction trades, thereby overcoming various deficiencies and shortcomings of the prior art, including those outlined above. It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can meet certain other objectives. Each objective may not apply equally, in all its respects, to every aspect of this invention. As such, the following objects can be viewed in the alternative with respect to any one aspect of this invention.
It can be an object of the invention to provide an improved material system for use as wall sheathing which has a weather resistant layer component with an extended flashing to avoid cumbersome taping procedures of the prior art and improve weather resistance.
It can be another object of the invention to improve the overall quality of buildings by minimizing water and air infiltration into the structure.
It can be another object of the invention to minimize the common occurrence of weather resistant barriers disconnected from the structure and damaged prior to the completion of exterior wall and roof claddings.
It can be another object of the invention to provide a sheathing or component thereof promoting increased breathability and ventilation of underlying structural cavities.
It can be another object of this invention, alone or in conjunction with one or more of the preceding objectives, to provide a method of using the present sheathing composites to promote proper installation and provide for quick, visual confirmation before completion of exterior wall and/or roofing claddings.
Other objects, features, benefits and advantages of the present invention will be apparent from this summary and the following descriptions of certain embodiments, and will be readily apparent to those skilled in the art having knowledge of various building construction materials and techniques. Such objects, features, benefits and advantages will be apparent from the above as taken into conjunction with the accompanying examples, figures, and all reasonable inferences to be drawn therefrom.
In part, the present invention can be directed to a sheathing composite, as can be used in the building trades. Such a sheathing composite can comprise a substrate component and a layer component on or coupled to the substrate component and comprising at least one peripheral edge extending therebeyond. Such a peripheral edge can comprise a flashing component of the sheathing composite, and the flashing component can comprise at least one directional indicator thereon.
In certain non-limiting embodiments, the composite can comprise a parallelogram, rectangular or square configuration, with a layer component comprising one or more peripheral edges. In certain such embodiments, such a composite can comprise a plurality of flashing components extending beyond the substrate component. Regardless of composite configuration, as illustrated below, one or more flashing components can comprise a plurality of directional indicators thereon and/or can comprise, on an upper or lower surface thereof, a sealingly engageable member, such a member including but not limited to a self-adhesive material.
As would be understood by those skilled in the art and/or familiar with the building trades, such a substrate component can comprise but is not limited to an orient strand board, a particle board, a chip board, a gypsum board, a foam board, or can be constructed from hardboard or plywood or can comprise combinations thereof. Regardless of substrate component(s) composition or construction, a layer component can comprise a material comprising a vapor permeable component and/or a water resistant component. Such materials are also well known to those skilled in the art and/or a layer component can be treated to provide such permeability and/or resistance properties. Without limitation, one or more such layer components can be on, coupled to, or connected with such a substrate component. In certain such embodiments, a layer component can be mechanically coupled to such a substrate component. In certain other embodiments, such a layer component can be bonded to a substrate component, such bonding as can be achieved using an adhesive material compatible (e.g., vapor permeable, water resistant, etc.) with the layer component. Regardless of layer component coupling, such a substrate component can comprise one or more apertures or pores through first and second sides thereof.
In part, the present invention can also be directed to a rectangular sheathing composite comprising a substrate component comprising first and second opposed sides and at least one pore or aperture therethrough; and a layer component coupled to such a substrate component, such a layer component comprising peripheral edges extending beyond the substrate component, with each peripheral edge comprising a flashing component of the composite and each flashing component comprising at least one directional indicator thereon. Such layer and flashing components can be constructed and/or configured as otherwise described herein. Regardless, such a substrate component can be selected from, but is not limited to, orient strand board, particle board, chip board, hardboard, gypsum board, foam board, plywood and of other materials known to those skilled in the art made aware of this invention. Likewise, as illustrated herein, sheathing composite(s) of this invention can be coupled to a building structure framing member, such members including but not limited to one or more wall studs, roofing rafters and combinations thereof.
In part, this invention can also be directed to a building structure. Such a structure can comprise a plurality of framing members; a plurality of adjacent, peripherally coupled sheathing composites coupled to the framing members, each such composite comprising a substrate component of the sort described above; and a layer component coupled to the substrate component, such a layer component as can comprise multiple peripheral edges extending beyond the substrate and as can comprise flashing components of the composite. Each such flashing component can comprise at least one directional indicator thereon and, in the context of such a structure, the flashing component of one sheathing composite can overlap the layer component of another sheathing composite adjacent thereto. Framing members of such a structure can be selected from those understood in the art and associated building trades. In certain embodiments, without limitation, framing members can be selected from a plurality of wall studs, roofing rafters, window frames/jambs and/or door frames/jambs.
In certain such structural embodiments, regardless of sheathing composite configuration or material construction, each such flashing component can comprise a member sealingly engageable with the layer component of an adjacent sheathing composite and/or, as illustrated below, can comprise a plurality of directional indicators. In certain such embodiments, such an engageable member can comprise an adhesive strip, as can be positioned on a flashing underside for sealing engagement with overlap of an adjacent sheathing layer component. Such engagement can be effective in conjunction with a layer component comprising a vapor permeable and/or a water resistant material, non-limiting representative examples of which are discussed elsewhere herein.
In the context of a building structure, the present invention can also be directed to a method of using a sheathing composite of this invention to indicate and/or visually affirm an overlapping relationship of one such composite to another. Such a method can comprise providing a first sheathing composite comprising a substrate component, and a layer component coupled thereto and comprising multiple peripheral edges, at least one of which extends beyond the substrate and comprises a flashing component of the composite, such a flashing component comprising at least one directional indicator; coupling such a first sheathing composite to a building structure; and coupling a second sheathing composite to the building structure, with at least a portion of one second composite flashing component, with a directional indicator thereon, overlapping the layer component of the first sheathing composite.
In certain embodiments, illustrative of one or more benefits associated with this invention, such a second composite can be positioned upwardly from or in relation to a first sheathing composite, such that a bottom peripheral edge thereof can comprise a flashing component overlapping at least a portion of a first sheathing layer component. In certain such embodiments, the bottom flashing component can comprise a plurality of downward directional indicators, to readily evidence flashing overlap and water protection, upon visual inspection. Without limitation, such a methodology can, as described elsewhere herein, sealingly engage such a flashing component with an adjacent composite layer component, to further enhance or promote water protection.
As illustrated in one or more of the accompanying figures, a plurality of additional sheathing composites can be upwardly and/or laterally positioned with respect to the aforementioned first and/or second sheathing composites. Each additional sheathing composite can comprise a side and a bottom flashing component overlapping the layer component(s) of a composite positioned laterally or therebelow. Each such flashing component(s) can comprise one or more downward and/or horizontal directional indicators—affirming overlap, promoting water protection in conjunction with an adjacent layer component and/or visibly indicating a degree or condition of positive drainage of water away from a structure interior. Such positive drainage indication can be in or confirm compliance with a building or construction code, whether existing now or enacted later.
As also illustrated herein, such a building structure can provide one or more framing members of the sort discussed elsewhere herein. Without limitation, a plurality of wall studs can define a wall opening (e.g., door, window, etc.), and at least one of the first, second and/or additional sheathing composite flashing components and directional indicator(s) thereon can overlap such a defined opening, as discussed below, to promote and visually affirm an overlap relationship.
Representative of various non-limiting embodiments, this invention can comprise a weather resistant layer component laminated on a commonly-used wall sheathing material substrate component, with an extended layer component providing a flashing over or between adjacent composite sheath. Such sheathing composites are secured to structure framing members, with the weather resistant layer component facing outward. Once installed, such composites provide weather protection to exterior wall (or roof) structures, contribute to improve performance and provide for attachment of exterior claddings (e.g., clapboard, vinyl, siding, etc.) thereafter.
With reference to the partial sectional view of
Regardless of material construction,
Certain embodiments are illustrated by the side elevation view of
As discussed above, directional indicators 20 on one or more flashing components 18 promote proper installation and can facilitate visual inspection with respect to code compliance and the like.
With further reference to
In the context of building construction, the methods of this invention can be implemented with sheathing composites dimensioned according to such practical considerations. For example, regardless of material construction, a 52″×100″ layer component can be bonded to a 48″×96″ substrate to provide a 2″ layer component peripheral edge and flashing component extending beyond the underlying substrate component. As mentioned above, in conjunction with
While the principles of this invention have been described in connection with specific embodiments, it should be understood clearly that these descriptions are added only by way of example and are not intended to limit, in any way, the scope of this invention. For instance, the present invention can be applied more specifically to the construction of a roof/deck structure, in a manner as described above—substituting rafters and related structural supports for wall studs and the like. Likewise, while this invention has been described above in conjunction with certain exterior building structures, it will be understood by those skilled in the art that the composites of this invention can be used in conjunction with various internal wall and/or ceiling structures, such use as can depend upon choice of a suitable substrate component. Alternatively, as can be used with various other embodiments, a sheathing composite of this invention can comprise layer components coupled to both first and second sides thereof, as may be employed and depending on a particular construction or end-use application. Other advantages and features will become apparent from the claims to be filed hereafter, with the scope of such claims determined by the reasonable equivalence, as would be understood by those skilled in the art.
This application is a continuation of and claims priority benefit of application Ser. No. 12/005,876 filed Dec. 28, 2007—the entirety of which is incorporated herein by reference.
Number | Date | Country | |
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Parent | 12005876 | Dec 2007 | US |
Child | 14294882 | US |