Patent Grant
8813443
Improvements in construction materials, construction methods, and more stringent local and state building codes have contributed to improved energy efficiency of new and remodeled insulated wall structures for homes and buildings.
The conventional approach to fabricating a highly energy-efficient wall is to erect a wall frame supporting multiple layers of insulation placed between interior and exterior layers of the wall. One or more breathable “house-wrap” styled layers is secured (e.g., stapled) to an exterior sheathing surface to prevent bulk water from wetting the insulation and thus reducing its insulative value (R-value), as well as wetting the sheathing and framing causing mold and rot. Typically, a low permeance (<0.1 perm polyethylene membrane) is attached to the warm-in-winter side of the framing members. Continuing experience shows that the combined effect of dry sheathing and a warm-side vapor retarder results in walls that have a tendency to retain moisture, which can undesirably lead to mold growth within the wall, degradation of the wall, insects, and/or other moisture-related problems. These conventional insulated wall structures also reduce heat loss through the wall by reducing drafts (infiltration) that remove heat from the home/building. However, since these conventional insulated wall structures are so tightly constructed/sealed, any water that is trapped in the wall (e.g., due to a breach or damage to the structure or to condensation build-up) tends to remain inside the wall. Moisture that is trapped inside a wall reduces the performance of the insulation and has the potential to feed the growth of mold and/or bacteria.
Moisture trapped inside of the walls includes moisture vapor and bulk water, such as condensation. Condensation can form inside a wall due to temperature differences across the insulated walls. For example, during typical northern cold winter months, the air outside of an insulated wall is cold and dry, and the air inside of the wall is relatively warm and humid. Thus, a natural humidity gradient is formed that drives moisture vapor in the air inside the wall toward the exterior of the wall. Large gradients between outside and inside air temperature and humidity can lead to a significant accumulation of moisture condensation within the insulated wall.
The opposite conditions occur during the summer months, when the air outside the structure is warm and humid, and the air inside the structure is conditioned to be cooler and dryer. Thus, during summer months a natural humidity gradient exists to drive warm humid air toward an interior of the insulated wall, which can analogously lead to a significant accumulation of moisture condensation within the insulated wall.
In some cases moisture accumulation in the insulated wall arises from wind driven water that enters the wall along a window or door seam. This form of moisture ingress can, for example, be the result of poor workmanship or from a deterioration of flashing or sealants around the window/door. In any regard, once the wall accumulates moisture it is difficult to dry the wall to a level that will not support the growth of mold and/or bacteria.
Owners, manufacturers, and remodelers of wall structures desire walls that are energy efficient, durable, and compatible with accepted construction practices.
One embodiment provides a building envelope assembly including a first structural wall frame, a flexible sheet, a drain assembly, and a seal. The flexible sheet is disposed along a surface of the first structural wall frame. The flexible sheet configured to transport moisture along two opposing surfaces. The flexible sheet includes an upper portion and a bottom portion having a moisture wicking sheet. The drain assembly is configured to receive moisture from the flexible sheet. The seal is attached to the bottom portion of the flexible sheet and is configured to prevent ingress of water, water vapor, and air toward the upper portion of the flexible sheet.
The accompanying drawings are included to provide a further understanding of embodiments and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments and together with the description serve to explain principles of embodiments. Other embodiments and many of the intended advantages of embodiments will be readily appreciated as they become better understood by reference to the following detailed description. The elements of the drawings are not necessarily to scale relative to each other. Like reference numerals designate corresponding similar parts.
In the following Detailed Description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the Figure(s) being described. Because components of embodiments of the present invention can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.
It is to be understood that the features of the various exemplary embodiments described herein may be combined with each other, unless specifically noted otherwise.
As used herein, moisture includes bulk liquid water, such as rain or rain droplets, and moisture vapor, such as humidity contained in the air.
As used herein, fluid is a broad term that includes both gases and liquids.
As used herein, barrier means to substantially prevent or deny the through-passage of air and to substantially prevent or deny the passage of moisture vapor. Thus, barrier as used herein means to substantially prevent the through-passage of moisture through the barrier, whether the moisture is in the form of moisture vapor or bulk liquid. As an example, conventional house wrap materials (e.g., nonwoven sheets of polyethylene or Tyvek™ sheets and the like) are not barriers since they do permit the passage of air (which can contain moisture vapor) through the sheet. A solid polyethylene film several milli-inches thick, in contrast, is a barrier to the through-passage of air, moisture vapor, and bulk liquid.
As defined herein, building envelope assembly is a broad term which includes any assemblies which separate interior and exterior environments of a building. A building envelope assembly serves to protect the indoor environment from the elements of nature (e.g., rain, snow, etc.) and facilitate its climate control. A building envelope assembly as defined herein includes vertical assemblies, such as walls, and non-vertical assemblies, such as roofs, for example.
Embodiments provide a sheet configured to remove moisture from a wall assembly, and particularly for sealed and insulated wall assemblies.
Embodiments provide a sheet that forms a barrier or a water separation plane configured for bulk transportation of moisture, which cooperates with permeable membranes in the sealed wall assembly to allow exterior sourced moisture to dry to the exterior by vapor diffusion and interior sourced moisture to dry to the interior by vapor diffusion. The bulk water that is collected by the barrier is delivered to and removed from a lower portion of the draining assembly. In this way, the water separation plane and the permeable membranes dry the sealed wall assembly by both bulk water transport and vapor diffusion without compromising the interior/exterior liquid and vapor sealing of the wall assembly.
Improvements in building construction have resulted in wall assemblies that are highly energy efficient. These wall assemblies are often highly insulated and include sealed joints around windows and doors to prevent drafts. While these walls have high thermal efficiency, it has been observed that moisture can potentially accumulate inside the wall over time due to naturally occurring temperature and/or humidity gradients. In addition, moisture can potentially accumulate inside sealed walls due to water running down a steeply pitched roof, for example in the case where the joint/seal between the wall and the roof deteriorates and provides an ingress location for water into the wall.
Insulated exterior walls in the northern climate are configured to maintain warmth on an interior side of the wall and protect against cold conditions on an exterior side of the wall. Heating the inside of the structure can result in moisture condensation forming on interior portions of the wall assembly because warm air has a greater capacity for holding moisture as compared to cold air. Since the wall assembly is insulated and sealed, any moisture that condenses on interior surfaces of the wall assembly can be undesirably trapped in the wall. Embodiments describe herein provide a passive mechanism for draining moisture out of a sealed wall assembly to an exterior location, regardless of the transport mechanism that delivers the water inside the wall. Other embodiments provide active (or dynamic) transportation of moisture out of a sealed wall assembly to a collection area that is ventilated to dynamically evaporate the moisture.
It has been surprisingly discovered that implementing the moisture transporting features of embodiment described herein enable maintaining the exterior sheathing of a tightly sealed and insulated wall assembly at a low moisture content of about 2%. This represents an improvement of between a factor of 2-4 times in the dryness of a state of the art wall assembly.
Embodiments provide mechanisms to remove moisture that accumulates within a sealed wall assembly, providing sealed walls with a moisture content of less than about 6% for a wide range of humidity gradients and even in the case where bulk water begins to undesirably accumulate inside the wall. In one embodiment, the moisture removal mechanisms described herein dry the interior portions of a sealed wall assembly down to a moisture content that will not support the growth of mold and/or bacteria.
Embodiments of the wall assemblies described herein apply to exterior wall assemblies, sealed and insulated exterior wall assemblies, interior wall assemblies, and/or subterranean wall assemblies. However, sealed exterior wall assemblies and subterranean wall assemblies are more susceptible to retaining moisture in the form of condensation and thus benefit directly from the embodiments described herein.
In one embodiment, wall assembly 102 includes one or more openings 120 formed to receive a window or a door, as examples, and first sheet 108 cooperates with a drain 122 to collect and transport moisture that enters into opening 120 away from wall frame 104. In one embodiment, wall assembly 102 includes a moisture transport spacer 124 (MTS 124, also termed a Dryspacer) configured to form a water separation plane and collect moisture that accumulates inside wall assembly 102 and direct bulk moisture to second sheet 118 for transportation of the moisture out of wall assembly 102. In one embodiment, MTS 124 forms a water separation plane that is configured to drain/direct moisture along both sides of MTS 124 to sheet 118. Condensation or bulk water entering wall assembly 102 from either the interior or the exterior is removed from wall assembly 102 by the combination of MTS 124 and sheet 118, which minimizes or eliminates the potential for mold and/or rot to be produced by moisture that is trapped within the wall.
In one embodiment, wall assembly 102 is provided as a sealed system and includes first seal 106 attached to first sheet 108 and second seal 116 attached to second sheet 118. Seals 106, 116 are provided as fluid seals that prevent the pressure driven flow of moist interior air and/or moist exterior air toward wall frame 104 and to prevent the diffusion of water vapor across sheets 108, 118 (thus preventing the unchecked movement of humid air into wall assembly 102). Seals 106, 116 limit the exchange of humid air through wall assembly 102 to enable sheets 108, 118 to efficiently collect and direct moisture away from wall frame 104. In one embodiment, seals 106, 116 are configured as vapor seals that enable capillary flow along a structure (for example fibers) coupled to one or both of sheets 108, 118.
In one embodiment, wall frame 104 is fabricated on a base 130 and extends through an insulated section 132 (illustrated in
Sheets 108, 118 are configured to wick moisture away from wall frame 104. In one embodiment, sheets 108, 118 are configured to wick moisture by capillary action and are formed of a hydrophilic fiber mat. In one embodiment, the hydrophilic fiber mat is a woven fiber mat of rayon fibers. In one embodiment, the hydrophilic fiber mat is a non-woven fiber mat formed of a random array of mutually-bonded rayon staple fibers. In other embodiments, the hydrophilic fiber web is formed on non-woven fiber forming equipment to have a preferential machine direction that configures the flow of moisture out of wall frame 104.
In one embodiment, MTS 124 is a polymer barrier sheet that forms a barrier to moisture transmission through MTS 124 by diffusion, capillary flow, hydrostatic flow or other penetration mechanisms. Moisture within wall assembly 102 will condense on MTS 124 barrier sheet, for at least the reason that the moisture is prevented from passing through MTS 124. The moisture that condenses on MTS 124 is transported down to sheet 118 and further transported along sheet 118 out of wall assembly 102, where the moisture is removed out of the wall and eventually evaporated. In one embodiment, MTS 124 is formed of a 10 mil polyethylene sheet.
Suitable cross-supports 140 include wooden beams such as a 2×4 or 2×6 wood beams attached to wall frame 104. Building paper 142 includes one or more layers of sixty minute grade D building paper or similar vapor permeable house wrap material stretched over and stapled to oriented-strand board 146. In one embodiment, pan flashing 144 is an appropriately formed sheet of thin metal or plastic or similar material that extends about six inches up the sides of studs formed around rough opening 120. Siding 148 includes any suitable cladding material, including vinyl siding, wood siding, aluminum siding, stucco, etc. In one embodiment, a bulk water seal 149 is disposed between drain 122 and siding 148 to minimize the potential for water undesirably entering between drain 122 and opening 120.
Drain 122 is placed into rough opening 120 and attached to cross-support 140 by any suitable attachment means, such as glue, nails, or screws. In one embodiment, EPC 134 is a window 134 is placed into opening 120 and set on drain 122. For ease of illustration, only a jamb portion of window 134 is illustrated resting on drain 122. Window 134 is subject to wind loading and could potentially shift within opening 120. In one embodiment, an interior bracket 150 is attached to cross-support 140 and window 134 to limit motion of window 134 after its installation.
Typically, wall assemblies are constructed in a manner that attempts to prevent moisture entrance. However, forming openings in the wall assembly for doors and windows unavoidably provides a pathway for moisture to enter the wall assembly. As described above, once moisture enters a wall assembly, it is difficult if not impossible to adequately dry the wall assembly. Drain 122 is configured to collect and direct moisture entering through opening 120 along first sheet 108 to a location outside of siding 148. In one embodiment, sheet 108 includes a capillary structure that is configured to wick moisture out of drain 122 to an outside surface of siding 148. Moisture that enters opening 120 is collected by drain 122, directed through drain holes 152 formed in drain 122 that communicate with flexible sheet 108, and subsequently directed along sheet 108 to an exterior of siding 148. In one embodiment, moisture that enters opening 120 that might bypass drain 122 is collected and directed along MTS 124 downward and out of a bottom portion of wall assembly 102.
In one embodiment, top plate 164 includes drain holes 152 and a first footing 168 spaced from a second footing 169. Holes 152 are formed in top plate 164 to enable water captured by the drain 122 to seep into flexible sheet 108 for transport out of drain 122. In one embodiment, a row of holes 152 is provided in top plate 164. In other embodiments, an array of holes or an open grid or screen-like pattern of holes 152 is formed in top plate 164 to enable water collected by drain 122 to flow down to flexible sheet 108. Footings 168, 169 extend from an exterior surface of top plate 164 and are configured to support a bottom jamb of window 134 or EPC 134 (
In one embodiment, drain 122 is extruded or molded as a single integral piece into which flexible sheet 108 and seal 106 are subsequently inserted. In one embodiment, bottom plate 162 and top plate 164 are extruded from plastic material such as polyethylene or polyvinyl chloride (PVC). Some window openings are formed to a standard size such as 36 inches wide or 48 inches wide or other standard width. In one embodiment, drain 122 is prefabricated in a molded form to fit in a standard width window and includes molded and sealed end caps formed on opposing lateral ends of drain 122. For example, for a standard width window opening of 36 inches, one embodiment of drain 122 includes integrally formed top and bottom plates 162, 164 extending about 36 inches between sealed end caps. In other embodiments, drain 122 is provided as an integral length of material several feet in length (on a roll, for example) and a desired length of drain 122 is selectively cut by a building contractor depending upon the window size/application.
Seal 106 is disposed between flexible sheet 108 and top plate 164 to prevent or limit ingress of bulk water into drain 122. With additional reference to
In one embodiment, an inside surface of top plate 164 includes pressure distribution bumps 170 that are configured to distribute the load applied to drain 122 by EPC 134 (
Embodiments of drain 122 enable and provide for the drainage of water from beneath the window jamb to the exterior of the cladding 148. In contrast, the known assemblies drain water from beneath the window jamb to a location between a permeable exterior sheath (house wrap) and the exterior cladding, which has the potential to rot the cladding or give rise to the growth of mold. Thus, the embodiments of drain 122 provide a significant and measurable advantage in moisture removal from sealed exterior wall assemblies over the art.
In one embodiment, interior wall layer 180 is a gypsum sheet configured to be nailed or screwed into wall frame 104. Siding 148 is typically a weather resistant board and includes any suitable form of exterior building siding including aluminum siding, vinyl siding, wood siding, stucco or the like. In one embodiment, an exterior vapor permeable barrier 142 is disposed between oriented-strand board 146 and siding 148, where the exterior vapor permeable barrier 142 allows moisture vapor on the exterior side of MTS 124 to dry to the exterior side of wall assembly 102.
In one embodiment, first insulation 188 is R-13 fiberglass insulation, although other suitable forms of insulation are also acceptable. In one embodiment, first membrane 190 is a vapor permeable polyamide membrane such as a 2 mil thick PA-6 membrane having humidity-dependent permeability or other suitable home construction membranes with similar vapor permeable characteristics. First membrane 190 is configured to allow moisture vapor on the interior side of MTS 124 to dry to the interior side of wall assembly 102. In one embodiment, second insulation 192 is an extruded polystyrene insulation having a thickness of about 1.5 inches. In one embodiment, oriented-strand board 146 is 0.5 inches thick as typically employed in the building construction industry.
In one embodiment, exterior vapor permeable barrier 142 is attached to an exterior of sheathing 146, first membrane 190 is a vapor permeable warm side vapor retarder attached to interior wall layer 180, and MTS 124 is disposed between vapor permeable barrier 142 and vapor permeable warm side vapor retarder 190.
In one embodiment, insulated section 132 is tightly constructed to prevent drafts or heat loss through wall assembly 102. Temperature gradients across insulated section 132 have the potential to create moisture condensation on one or more layers of wall assembly 102. In one embodiment, MTS 124 includes a film that forms a substantial barrier to the passage of air and moisture vapor through MTS 124. This film barrier to the passage of moisture also provides a surface onto which moisture condensate will naturally form. In one embodiment, MTS 124 includes one or more surfaces configured to transport the moisture condensate by capillary action vertically along (e.g., downward) wall frame 104 for eventual exit from wall frame assembly 102.
In contrast to conventional wall assemblies, wall assembly 102 includes a film within MTS 124 that is a barrier against both the passage of air and the passage of moisture vapor carried in the air, and thus provides a barrier for wall assembly 102. MTS 124 provides a surface that traps and collects moisture within wall assembly 102 and a wicking mechanism that directs the moisture away from wall frame 104 and out of wall assembly 102, which is contrary to the conventional approach to fabricating wall assemblies. It has been discovered that the R-value of insulation 192 and the ratio of the R-values between the insulation 188 and insulation 192 relates to the successful operation of system 102. The principle is to place MTS 124 where the sensible temperature on the interior surface of MTS 124 is less than the dew point temperature in the heating season so that condensation will form on the interior surface of MTS 124 where it is eventually removed from wall assembly 102 by sheet 118. Conversely, during the cooling season, the sensible temperature on the exterior surface of MTS 124 is less than the dew point temperature allowing exterior sourced vapor to condense on the exterior surface of MTS 124, where it is likewise removed from wall assembly 102 by sheet 118.
In one embodiment, the ratio of interior insulation R-value to exterior insulation R-value is 1.73 and is so selected to permit the favorable dew points in the heating and cooling seasons to occur on the interior and exterior surfaces of MTS 124, respectively.
In one embodiment, MTS 124 is positioned within the insulation such that the temperature on the interior condensing surface is less than the dew point temperature in the heating season, and the temperature on the exterior condensing surface is less than the dew point temperature in the cooling season.
Embodiments of MTS 124 and other embodiments of moisture transport spacers described herein are compatible with any internal sheathing, any external sheathing, and any external cladding suited for use in insulated external wall assemblies.
In one embodiment, MTS 124 includes mold preventing additives and/or a suitable flame retarding additive. In one embodiment, MTS 124 is fabricated from recyclable material(s).
In one embodiment, film 200 forms a substantial barrier to the passage of air and moisture vapor through MTS 124 and is a polymer film having a caliper of 0.010 inches (e.g., 10 mil film). Suitable polymer films include polyolefin, polyethylene, or polypropylene, as examples. In one exemplary embodiment, film 200 is a 10 mil polyethylene membrane configured to form a substantial barrier to the passage of air and moisture vapor through MTS 124. In one embodiment, film 200 is a substantially flat uniform-caliper film, although structured films as described below are also acceptable.
MWL 202 and 24 are configured to wick moisture away from film 200. In one embodiment, MWL 202 and 24 are configured to wick moisture away from film 200 by capillary action and are formed of a hydrophilic fiber mat. In one embodiment, the hydrophilic fiber mat is a woven fiber mat of rayon fibers. In one embodiment, the hydrophilic fiber mat is a non-woven fiber mat formed of a random array of mutually-bonded rayon staple fibers. In other embodiments, the hydrophilic fiber web is formed on non-woven fiber forming equipment to have a preferential machine direction that configures the flow of moisture along MWL 202, 204 to be uni-directional (for example, the moisture flows longitudinally along MWL 202, 204 which is vertical relative to wall assembly 202 as illustrated in
MTS 124 optionally includes a first mesh 206 attached to MWL 202 and a second mesh 208 attached to MWL 204. Meshes 206, 208 are configured to maintain a useful level of bending stiffness that assists in handling MTS 124 when placing it against wall frame 104 (
In one embodiment, MTS 124 is approximately 0.5 inches thick, including the 10 mil polymer film 200 and about ¼ inch thick sections for each of MWL 202 and MWL 204. Suitable meshes 206, 208 include nettings or other open materials that assist in keeping MWL 202, 204 in place for handling when attaching MTS 124 to wall frame 104.
In one embodiment, troughs 240 are provided as continuous longitudinal troughs extending along film 230 and are configured to capture and transport moisture down the troughs 240. In one embodiment, troughs 240 are at least partially filled with MWL 232, 234 that combine with troughs 240 to assist in transporting moisture along film 230.
In one embodiment, film 230 includes an array of cones 240 formed laterally across film 230 as illustrated in
MWL 232, 234 are similar to MWL 202, 204 as described in
In one embodiment, the three-part laminate formed by dimpled films 250, 253 attached to center film 251 is configured to form a substantial barrier to the through-passage of air and moisture vapor, and MWL 252, 254 are configured to transport/remove moisture captured by the three-part laminate.
In one embodiment, dimpled films 250, 253 include an ordered array of dimples 255 disposed along films 250, 253. In one embodiment, dimpled films 250, 253 include a staggered array of dimples 255 disposed along films 250, 253.
MWL 252, 254 are similar to MWL 202, 204 as described in
In one embodiment, a first open mesh 256 is attached to dimples 255 along film 250 and a second mesh 258 is attached to dimples 255 along film 253. Meshes 256, 258 are similar to meshes 206, 208 described above and are configured to assist in handling MTS 244.
In one embodiment, first section 244a of MTS 244 is sealed to the second section 244b of MTS 244 along a common edge 282 by bond 280. In one embodiment, bond 280 is suitably formed by a foam seal mat extending along common edge 282 or by an adhesive caulk deposited along common edge 282. In one embodiment, additional sealing support is provided across the union formed along common edge 282 by a first tape 284 attached and extending on either side of bond 280 and a second opposing tape 286 attached and extending on either side of bond 280.
Similar bonding methodologies are applied to achieve a bond for one or more of MTS 124, 224, or 264 as described above. Bond 280 is acceptably formed prior to inserting MTS 244 into wall assembly 102 (
In one embodiment, sheets 308, 310 are polymer films that are attached in a back-to-back arrangement such that opposing dimples 316 are oriented to project outward. In one embodiment, MTS 300 is provided as a flexible profiled sheet having an array of protrusions (e.g., dimples 316) formed to project away from at least one major surface of the sheet. The dimples 316 are provided as a profiled pattern of round protrusions projecting about ¼ inch outward to define a dimpled drainage plane, where the protrusions are formed in an ordered array on each exterior surface of films 308, 310. In one embodiment, scrim 302 is a nylon mesh that is attached to dimples 316 on one of the dimpled films 308, 310.
When MTS 300 is assembled into wall assembly 102 (
In one embodiment, adhesive 306 is provided as a soft, repositionable adhesive configured to removably attach first dimpled film 308 to second dimpled film 310. Adhesive 306 is suitable applied to interior surfaces of films 308, 310. In one embodiment, adhesive 306 is provided as a sheet of adhesive pressed between films 308, 310.
In one embodiment, films 308, 310 are formed from a polymer to have a caliper between about 4-14 mils thick and are structured to provide opposing dimples 316 that are formed in an ordered array on each exterior surface of films 308, 310. In one embodiment, dimples 316 are disposed in a staggered array across surfaces of films 308, 310, although aligned linear arrays of dimples 316 are also acceptable.
Wicking layers 312, 314 are similar to wicking layers 202, 204 (
The above-described mating of sections 304a, 304b does not require hand tools (apart from a scissors) and results in a durable seal between the sections 304a, 304b without the use of additional layers of tapes/adhesives. In addition, the resulting thickness of the combined two segments 304a, 304b is similar to the original thickness of MTS 304.
In one embodiment, edge seal 330 includes a first angled flange 332 and a second angled flange 334 that is adjustable relative to and attachable to first angled flange 332. Edge seal 330 is configured for use along the edges of wall frame 104 (
In one embodiment, angled flange 332 has a height of about 1.5 inches with a thickness of about 3/16 inches, and angled flange 334 has a height of about 1.25 inches with a thickness of about 3/16 inches. In one embodiment, angled flanges 332, 334 are formed from plastic. Suitable plastics for forming edge seal 330 include polyolefins, nylon, polyester, polyvinyl chloride or other plastics.
One advantage of rough opening edge seal 330 is that second angled flange 334 can be selectively pressed against MTS 304 to provide a desired amount of pressure sandwiching 304 between angled flanges 332, 334. In one embodiment, it is desirable to seal MTS 304 within wall assembly 102 (
In one embodiment, stud cap 352 is coupled to ends of vertical studs of wall frame 104 through pre-located slots from to provide a desired spacing between the studs and includes a stud plate 360 attached to a bottom of the vertical studs and a stud flange 362 extending from stud plate 360. In one embodiment, base cap 354 includes a base plate 370 attachable to base 130 and a base flange 372 extending from base plate 370. When assembled, MTS 124 is retained between stud flange 362 and base flange 372, and moisture wicking sheet 118 is placed on seal strip 342 in contact with MTS 124 and extends out from wall frame 104 between stud plate 360 and base plate 370. Thus, moisture wicking sheet 118 communicates with MTS 124 when wall assembly 102 is erected and forms a moisture conduit (a pathway for the flow of moisture to follow) extending from wall frame 104 to a dynamically ventilated trough 380.
Moisture vapor that accumulates within wall assembly 102 will condense on film 200 (
Trough 380 communicates with a dynamic ventilation system configured to remove moisture that is collected in trough 380. Trough 380 is attached to an interior side of wall assembly 102 in one embodiment. Trough 380 is attached to base 130 inside of wall assembly 102 in one embodiment.
In one embodiment, baseboard plate 382 forms a plenum and includes a fan 386 or an active drying mechanism 386 that is configured to blow air into/across trough 380 and evaporate moisture delivered into trough 380 by wicking sheet 118. Operating fan 386 will generally form a region or zone of lower vapor pressure within trough 380, which will encourage or dynamically drive the flow of moisture away from wall frame 104, down MTS 124, and along wicking sheet 118. Fan 386 is thus configured to dynamically draw moisture out of wall assembly 102 into trough 380 and to actively evaporate the moisture as it is collected in trough 380. It is acceptable to provide baseboard plate 382 with openings that enable air blown by fan 386 to exit the plenum formed by the baseboard plate 382. In one embodiment, active drying mechanism 386 includes a connection between the plenum and a central forced air system, where the central forced air system is configured to force warm, dry air through the trough 380 in winter and cool, dry air through the trough 380 in summer.
In one embodiment, trough 380 includes a heated rod disposed inside baseboard plate 382, where the heated rod (or other source of heat) is employed to drive moisture out of trough 380. Such an arrangement can also serve as a baseboard space heating device.
Seal 116 prevents pressure driven advection of moist air that could possibly be blown back into the space between stud cap 352 and base plate 354 as fan 386 operates. In addition, during humid months seal 116 prevents the diffusion of water vapor from humid exterior regions outside of wall assembly 102 from being drawn into regions of wall assembly 102 that have already been dried by MTS 124 and wicking sheet 118. Seal 116 and seal 342 combine to allow liquid to be drained from a lower portion of wall assembly 102 while sealing interior and exterior cavities of wall assembly 102 (relative to MTS 124) from interior sources of moisture. The interior sources of moisture include the diffusion of moisture caused by humidity gradients or moisture that arises from a pressure differential within wall assembly 102 in which the interior pressure of wall assembly 102 is greater than the exterior pressure. In addition, seal 116 and seal 342 combine to prevent leakage of moisture arising from a negative pressure differential (where the exterior pressure of wall assembly 102 is greater than the interior pressure), which prevents exterior air from infiltrating to the interior.
In one embodiment, fan 386 is an electric fan having a cross-sectional area between about 2-10 square inches and is electrically coupled to a moisture sensor 388 coupled to wicking sheet 118. Moisture sensor 388 includes a pair of spaced apart electrodes that are sensitive to the presence of moisture in the form of sensed capacitance or sensed change in resistance. For example, when wicking sheet 118 is transporting moisture, the moisture will generally increase capacitance across the electrodes. The change in the capacitance across the electrodes of moisture sensor 388 is configured to be sensed by fan 386, resulting for example in activating fan 386 at a predetermined sensed moisture level as recorded by moisture sensor 388. In one embodiment, moisture sensor 388 includes a voltage output that correlates to a level of moisture within wicking sheet 118. Fan 386 is selectively activated when moisture in sheet 118 exceeds the pre-set desired moisture level, thus dynamically drying moisture within trough 382 and sheet 118. When the moisture in sheet 118 drops below the pre-set desired moisture level fan 386 shuts off.
In the embodiment, moisture sensor 388 includes two wires of particular resistivity, and the wicking material forms a capacitor with the wicking material as the dielectric. The dielectric strength (capacitance) increases with moisture content in a direct and measurable way. This capacitance is detected by the electronics and converted into a voltage signal that is used in the embodiment to control the fan as well as provide a visual (e.g., via a light emitting diode) and digital indication (e.g., via a data logger) of the state of moisture of the wicking layer and thus by inference of the wall system.
In one embodiment, the moisture transport spacer (MTS 124 or Dryspacer) is positioned between interior and exterior vapor permeable membranes 142, 190 (
In one embodiment, stud cap 352 is generally a U-shaped cap including opposing flanges 362, 363 extending from base plate 360. Wall frame 104
(
Stud cap 352 is configured to carry and distribute the load of wall frame 104, and in one embodiment an exterior surface of base plate 360 is structured to have a load dissipating structure that distributes the weight of wall assembly 102 evenly over base 130 (
When stud cap 352 is assembled relative to base cap 354, foam seal 342 is disposed between flanges 362, 372, a portion of wicking sheet 118 is attached to foam seal 342 to communicate with MTS 124 (
Frame flange 390 is attachable to wall frame 104 to rigidly secure baseboard plate 382 against stud cap 352 and base cap 354 to form the plenum described in
In one embodiment, MTS 304 is coupled to edge seal 400 by a sealant 410 that seals an end of MTS 304 to one or both of base flange 402 and vertical flange 404. In one embodiment, sealant 410 is a moisture-curing sealant foam, although other forms of sealant are also acceptable. In one embodiment, sealant 410 is a foam adhesive delivered from a pressurized spray canister. Edge seal 400 is compatible with accepted practices for wall construction and is configured to enable a contractor to conveniently install MTS 304 along any rough opening within a wall assembly by simply securing edge seal 400 and bonding MTS 304 in place against edge seal 400.
Stud cap 452 and base cap 454 cooperate to retain any of the moisture transport sheets described above, such as MTS 124, against wall frame 104 and secure moisture wicking sheet 118 under wall frame 104 and in contact with MTS 124.
Trough 458 collects bulk moisture extracted from wall assembly 102 by MTS 124, and active drying mechanism 456 evaporates the moisture from trough 458. In one embodiment, active drying mechanism 456 is a fan that evaporates the moisture from trough 458 by forcing air along trough and out of vent 460. In one embodiment, active drying mechanism 456 is a heat source that evaporates the moisture from trough 458 into an interior room through vent 460.
In one embodiment, vent 460 and trough 458 are integrated into wall assembly so that vent 460 has the appearance of a baseboard.
Features of embodiments of exterior wall assemblies as illustrated in
The Reference Standard Test Panel and a Comparative MTS Test Panel similar to the structure illustrated in
The components of each of each of the test panels are listed in Table 1 below. The Reference Standard Test Panel includes components that are typically used in the construction industry to form a sealed wall assembly and include a breathable water resistive layer attached to a sheathing of oriented-strand board (OSB) which is covered by exterior cladding, insulation, and a warm-side vapor retarder (e.g., a 2 mil polyamide-6 membrane) placed inside an interior finish layer. The insulation is provided by an unfaced fiberglass batt (R-19 insulation value) placed between the wall studs.
The Comparative MTS Test Panel is constructed in a manner similar to the Reference Standard Test Panel but includes an MTS layer as described herein deposited between the sheathing and the warm-side vapor retarder. For example, the insulation is provided by an extruded polystyrene insulation, and unfaced fiberglass batt (R-13 insulation value) placed between the wall studs with the MTS layer placed between the studs and the extruded polystyrene insulation. Consequently, the comparative results between the two test panels represent the performance advantage provided by the MTS (or Dryspacer layer).
Each of the test panels were evaluated in a conditioned environment.
In one embodiment, the Comparative MTS Test Panel has a moisture content that is approximately a factor of 2.5 less than a moisture content of the Reference Standard Test Panel. The Comparative MTS Test Panel is drier than the conventional wall structure and can be dried to a level that precludes the growth of bacteria, mold, or the formation of rot.
It is noted that the Comparative MTS Test Panel was assembled in the configuration illustrated in
Mechanisms are provided that are configured to remove moisture from interior surfaces of a sealed wall assembly. It has been surprisingly discovered that providing a moisture barrier (in the form of a moisture transport spacer) that communicates with a moisture wicking sheet will remove high levels of moisture from the wall assembly, thus drying out the wall assembly.
The sealed wall assembly described above includes one or more moisture transporting sheets that are sealed within the wall assembly and provide a moisture wicking pathway for water to be directed out of the wall assembly. The wall assemblies described above comply with local and state building codes and are configured to be easily assembled without additional tools or approaches that would be new to the skilled contractor.
The sealed wall assemblies described above are believed to offer improved severe weather performance, for example in acting to stop of slow down flying debris; offer increased R-value insulation performance; and offer improved structural acoustics.
In one embodiment, existing wall assembly 601 includes existing sheathing 602, existing wall frame 604, insulation 606, and existing gypsum 608. Siding, stucco or other pre-existing exterior finishes of existing wall assembly 601 may have previously been removed and, thus, are not shown. In one embodiment, slots 610 and 612 are located between the studs of wall frame 604. In one embodiment, slots 610 and 612 are sawn or otherwise provided as rough openings in existing sheathing 602 and existing gypsum 608. In one embodiment, the bottom of slots 610 and 612 are flush with the top surface 614 of base 130. In one embodiment, slots 610 and 612 provide an initial means of assembly for exterior wall system 649 and bottom drain spacer assembly 616 with wall assembly 601, as further described below.
In one embodiment, exterior wall assembly 649 is a new wall assembly erected parallel with existing assembly 601. In one embodiment, exterior wall system 649 consists of plate 650, wall framing studs 652, insulation 654, sheathing 656, and vapor permeable water resistive barrier (WRB) 658. In one embodiment, plate 650 and wall framing 652 are assembled prior to erection and attachment of exterior wall system 649 with existing assembly 601. Exterior wall system 649 is secured to the existing assembly 601 using nails, screws, or other suitable fasteners. In one embodiment, the tops of base 130 and plate 650 are flush and provide a coplanar surface for drain spacer assembly 616. In one embodiment, prior to wall system 649 being secured to existing assembly 601, MTS 124 is assembled to existing sheathing 602 and drain spacer assembly 616 is installed.
In one embodiment, drain spacer assembly 616 is a predetermined size to be inserted into slots 610 and 612. In one embodiment, assembly 616 is of segments suitable to be inserted between the existing vertical wall framing studs 604. For example, assembly 616 may be 14 inches long when the stud framing 604 is spaced at 18 inch on center or less, while assembly 616 may be 20 inches long when the stud framing 604 is 24 inch on center studs. Drain spacer assembly 616, in one embodiment, includes top cap 618 assembled with, and spaced apart from, base cap 620. In one embodiment, top cap 618 is formed as a right angle including flat plate 630 and upright 632. Flat plate 630, in one embodiment, is a two-part assembly with a flat upper portion 626 and a variated lower portion 624. In another embodiment, flat plate 630 is constructed as a single piece. In one embodiment, base cap 620 is a formed at a right angle and includes upright 642 and plate 640. In one embodiment, top cap 618 and base cap 620 are constructed of a rigid material. In one embodiment, top cap 618 and base cap 620 are joined together by connectors 622 prior to insertion into slots 610 and 612.
In one embodiment, top cap 618 and base cap 620 cooperate to retain any of the moisture transport sheets described above, such as MTS 124, against existing sheathing 602 and secure moisture wicking sheet 118 to base 130 and in contact with MTS 124. In one embodiment, top cap 618 is placed on top of base cap 620 such that uprights 632, 642 are spaced apart to provide an opening to receive MTS 124. The width of the opening between uprights 632, 642 is varied by selectively positioning uprights 632, 642 a desired distance apart before fixing in place with connector 622. Connectors 622 may be an I-shaped fastener, rivet or other suitable fastening mechanism.
In one embodiment, moisture wicking sheet 118 and seal 666 are assembled between plates 630, 640 of drain spacer assembly 616. In one embodiment, drain spacer assembly 616 further includes seal 666 and moisture sensors 388, similar to those previous embodiments. In one embodiment, seal 666 is attached between moisture wicking sheet 118 and plate 630 and enables moisture to be wicked through sheet 118 to an exterior of the building envelope assembly 600. In one embodiment, spacer 644 is placed in the interior junction of the flat plate 640 and leg 642 in a horizontal fashion with the seal strip 646 and termination end 648 of moisture wicking sheet 118. Spacer 644, in one embodiment, is a material thickness equal to the thickness of the coupling channel 698 material. In one embodiment, seal strip 646 is attached between plate 640 and the wall space provided for MTS 124, acting as a bulk seal to prevent the transport of water vapor and infiltration air from the exterior assembly 649 to the interior assembly 601.
In one embodiment, drain spacer assembly 616 extends from within wall system 649, through existing wall assembly 601, to terminate a predetermined distance inside trough 680. In one embodiment, the top surface of plate 630 of drain spacer assembly 616 is sealed to slot 612 in existing gypsum 608 with a vapor/air seal 686. In one embodiment plate 640 mates with extension 682 of trough 680. In one embodiment, adhesive 684 bonds extension 682 with plate 640. Adhesive 684 may be PVC cement or other suitable adhesive, for example.
In one embodiment, vented trough 680 provides an outlet for moisture passively transported by the drain spacer assembly 616 and moisture wicking sheet 118. In one embodiment, vented trough 680 is attached to interior existing gypsum 608. In one embodiment, vented trough 680 is secured to existing gypsum 608 with tab 688. In one embodiment, vented trough 680 is a two-piece assembly and includes upper portion 690 and lower portion 692, although other configurations are also suitable. In one embodiment upper piece 690 is snap fit with lower piece 692. Trough 680 is assembled in sections to achieve a desired overall length suitable to accommodate moisture transportation for the building envelope assembly 600. In one embodiment, the vented trough 680 includes moisture sensors (not shown) similar to the moisture sensors used in previous embodiments. In one embodiment, mechanical device 694 (see
The building envelope assembly illustrated in
Studs 804, and similarly studs 824, are secured to base 813. In one embodiment, studs 804 and 824 are 2×4 wood members and base 813 is a 2×8 wood member, although other member types and sizes are also acceptable. In one embodiment, after passive dry spacer 840 is assembled between the stud framing assemblies, insulation is disposed between adjacent studs. This may be completed either prior to or after stud framing members 804, 824 are assembled to base 813.
Bottom drain spacer assembly 816 illustrated in
In another embodiment, the building envelope assembly is a structural insulated panel assembly 881 as illustrated in
One embodiment of a building envelope assembly 899 is illustrated in
In one embodiment, the profiled sheets 906 are central within the panel 899. In one embodiment, moisture wicking layers 922 are disposed between the unidirectional dimples 918 at the flat lengths 920. On either side of the flexible sheets 906, moisture wicking layers 922, and rigid insulation 902, 904 are attached. In one embodiment, rigid insulation 902, 904 is profiled with longitudinal grooves to fit dimples 918 of flexible sheets 906 while also allowing space for the moisture wicking layers 902. In one embodiment, rigid insulation 902, 904 is expanded or extruded polystyrene. In one embodiment, moisture wicking layer 922 is a non-woven rayon staple, similar to moisture wicking layer 312 described previously, for example. Structural sheathing 912, 916 are adhesively bonded, in one embodiment, to the exterior face of each of the rigid insulation layers 902, 904.
In one embodiment, the structural insulated panels are factory assembled for field assembly into a component of the building envelope. The structural insulated panels may be fabricated in any suitable length for further assembly on the construction site or out of the factory. The structural insulated panels may be assembled with the edges of the panels abutting one another. The structural insulated panels may also be cut to size to fit appropriate applications.
With further reference to
In one embodiment, a rigid insulation layer 956 is disposed over moisture transfer system 124. Additionally, rigid insulation layer 958 abuts rigid insulation 956 at opposing sides of moisture transport system 124. In one embodiment, rigid insulation 956 is two inch extruded polystyrene and rigid insulation 958 is three inch extruded polystyrene in order that the overall thickness is the same on each side of the moisture transport system 124. In one embodiment, rigid insulation 958 may be comprised of a single layer of rigid insulation or multiple layers of rigid insulation. Similarly, rigid insulation 956 may be a single layer or multiple layers of rigid insulation. In one embodiment, moisture transport system 124 extends to the moisture wicking plate assembly 960. In one embodiment, moisture wicking plate assembly 960 is installed at the juncture of the truss 952 and interior space 962 of the building. In one embodiment, plate assembly 960 extends from MTS 124 to trough 964 at interior space 962. In one embodiment, plate assembly 960 extends in a vertical fashion and moisture wicking transport sheet 966 extends into trough 964. In one embodiment, trough 964 includes an active moisture removal system such as a fan or other mechanical or electrical device or venting method (not shown). In one embodiment, plate assembly 960 is secured to blocking 968. In one embodiment, plate assembly 960 includes movable joint 970 and 972. In one embodiment, moveable joints 970, 972 are flexible in an otherwise rigid plate assembly 960. Joints 970, 972 enable plate assembly 960 to be installed at any angle relative to the moisture transport system 124. For example, a pitch range of 0:12 to 12:1 may be accommodated.
Additionally, fastener 980 secures the roof deck sheathing 982 in a roof application of this assembly. Fastener 980 is described in Provisional Utility Patent Application Ser. No. 61/249,497. In one embodiment, roofing felt 984 is provided over the sheathing 982. In one embodiment, vapor retarder 986 is installed at the interior face of the truss 952. Additionally, sheathing 988 may be installed on the interior face of the vapor barrier 986 with relative humidity dependent permeance (such as a 2-mil polyamide-6 membrane). In one embodiment, insulation 988 is installed between the rafters 952. Insulation 988 may be fiberglass backed insulation, fiberglass blown-in-blanket insulation, extruded/expanded polystyrene, open/closed cell spray polyurethane or other suitable insulation. In one embodiment the roof deck sheathing 982, bounding insulation layers 954 and 956 and drain spacer assembly 124 can be pre-assembled into panels at a manufacturing facility.
MTS 1124 includes wicking sheet 1008 attached along bottom portion 1125. Bottom portion 1125 is generally planar. Wicking sheet 1008 provides capillary wicking of moisture along MTS 1124. Similar to wicking layers described in previous embodiments, one suitable material for wicking sheet 1008 includes a non-woven sheet of rayon staple fiber. In one embodiment, wicking sheet 1008 is attached to bottom portion 1125 with an adhesive. In one embodiment, wicking sheet 1008 is adhered to both major faces of bottom portion 1125 and may extend around the bottom edge of MTS 1124. Wicking sheet 1008 may extend the same or different heights of the opposing faces of bottom portion 1125. In one embodiment, wicking sheet 1008 extends 3¼″ to 3½″ high. Alternatively, wicking sheet 1008 is disposed along only one face of bottom portion 1125. As assembled within building system assembly 1000, bottom portion 1125 is disposed between opposing seals 1010 and terminates within drain assembly 1020.
Drain assembly 1020 is disposed at the base of building envelope assembly 1000 and is configured to receive seals 1010 and bottom portion 1125 of MTS 1124. Seals 1010 are disposed on opposing faces of MTS 1124 within drain assembly 1020. In one embodiment, seal 1010 is a Q-LON material. In one embodiment, Q-LON, manufactured by Schlegel, is ½″ wide by ⅜″ thick. In one embodiment, seal 1010 is Q-LON compressed within the sealing cavity of drain assembly 1020 to 3/16″ on either side of MTS 1124.
Drain assembly 1020 is mechanically attached to at least one of either the exterior wall 1014 or the floor (not shown). In one embodiment, interior wall layer 1002, wall frame 1004, insulation 1006, and MTS 1124 extend fully between drain assembly 1020 and a top channel 1070. Drain assembly 1020 and top channel 1070 will be described in greater detail below with particular reference to
Top channel 1070 is configured to extend along a top edge of, and secure, interior wall layer 1002, wall frame 1004, insulation 1006, and MTS 1124. In one embodiment, top channel 1070 is configured to provide a transition from a below grade building envelope assembly to an above grade building envelope assembly. In one embodiment, fill 1014 is disposed in a recessed area 1078 of top channel 1070. In one embodiment, fill 1014 is CertainTeed ¾″ ProRoc shaftliner type X gypsum board, for example. Other suitable materials, particularly materials which have suitable fire rating to meet applicable building code requirements may also be disposed within recessed area 1078. For example, a wood stud may be used. In an alternative embodiment, a wood stud is installed along the top of building envelope assembly 1000 and top channel 1070 is not used.
Seal retainer clip 1028 includes a first leg 1032 joined with a second leg 1034 at a right angle. Second leg 1034 functions as a fastening leg onto base 1030. Seal retainer clip 1028 is attached to base 1030 with a fastening mechanism such as a screw, for example, inserted through a hole 1036 in second leg 1034. First leg 1032 includes seal stops 1038 which extend in a direction opposite to that of second leg 1034. First leg 1032 includes two seal stops 1038, a first seal stop 1038 positioned at a terminal end 1039 of first leg 1032 and a second seal stop 1038 positioned along first leg 1032 between the first seal stop 1038 and second leg 1034. Seal stops 1038 are positioned along first leg 1032 and extend a distance suitable to secure seals 1010 when assembled with base 1030. In one embodiment, seal stops 1038 each extend ⅛″ from first leg 1032 and are positioned with a distance of ¾″ between the seal stops 1038. In one embodiment, first leg 1032 has a length of 1¼″ and second leg 1034 has a length of ½″.
Base 1030 includes a bottom plate 1040 and a vertical leg 1042. Vertical leg 1042 is joined with bottom plate 1040 at a right angle. Vertical leg, or face plate 1042, forms one side of sealing cavity 1022, transfer cavity 1024, and drainage cavity 1026. Sealing cavity 1022, transfer cavity 1024, and drainage cavity 1026 are configured in a serial configuration along vertical leg 1042. Vertical leg 1042 includes two seal stops 1038 which correspond and align with the seal stops 1038 of seal retainer clip 1028 when assembled together. Sealing cavity 1022 is formed between seal stops 1038 of vertical leg 1042 in combination with seal retainer clip 1028. Likewise, transfer cavity 1024 is formed between seal retainer clip 1028 and vertical leg 1042. Base 1030 also includes a horizontal member 1046 having a series of openings 1048 adjacent to vertical leg 1042. In one embodiment, openings 1048 are positioned in a series along a center space between vertical leg 1042 of base 1030 and first leg 1032 of seal retainer clip 1028. Horizontal member 1046 forms a bottom surface of transfer cavity 1024 as well as a top surface of drainage cavity 1026. Openings 1048 provide fluid communication between transfer cavity 1024 and drainage cavity 1026.
A raised platform 1050 is configured on horizontal member 1046 and is, in one embodiment, channel shaped. Raised platform 1050 may support insulation 1006 when assembled within the building envelope assembly 1000, as illustrated in
While the dimensions of drain assembly 1020 may vary, in one embodiment, the length of bottom plate 1040 is approximately 5″ and the height of vertical leg 1042 is approximately 3″. In one embodiment, drain assembly 1020 is extruded from plastic material such as polyethylene or polyvinyl chloride (PVC). The material thickness of elements of drain assembly 1042 may vary depending on the structural requirements of the various elements.
In one embodiment, exterior wall system 1102 is a concrete wall. A water seal 1126 is disposed along exterior wall system 1102 above drain assembly 1120 and extends into drain assembly 1120. Water seal 1126 is secured to exterior wall system 1102 and is configured to direct moisture running along the interior surface of exterior wall system 1102 to within drain assembly 1120. Sealant 1016 adheres water seal 1126 to exterior wall system 1102. A waterproofing membrane 1128 is disposed between drain assembly 1120 and exterior wall system 1102 and a floor system (not shown) to seal the joint from moisture entering from the exterior between exterior wall system 1102 and the floor system. Water seal 1126 and waterproofing membrane 1128 are ethylene propylene diene monomer rubber (EPDM) or other suitable material.
Second member 1123 is configured to be assembled with first member 1122. In one embodiment, second member 1123 is formed as a U-shaped cap. Second member 1123 includes opposing first and second legs 1170, 1172 extending from opposing ends of a top plate 1174. Second leg 1172 includes a ridge 1176 which correspondingly mates with notch 1150 of first member 1122. First leg 1170 includes two seal stops 1162 which, when assembled with first member 1122, align with the seal stops 1162 of vertical member 1142 and end of leg 1170 is positioned against upright portion 1156. Leg 1172 is coupled between the retaining flanges 1146 and 1148. In this manner, first member 1122 and second member 1123 form drainage cavity 1136 with top plate 1174 forming the upper portion of drainage cavity 1136. Also in this manner, sealing cavity 1122 and transfer cavity 1134 are formed with first leg 1170 of second member 1123 in conjunction with first member 1122, as illustrated in
MTS 1124a includes wicking sheet 1008 disposed on bottom portion 1125 of MTS 1124a which extends from the transfer cavity 1134 to a suitable height. Seals 1010 are assembled on both sides of bottom portion 1125 to secure the MTS 1124a within drain assembly 1121. In one embodiment, the planar bottom portion 1125 is positioned to terminate at top plate 1174 of drain assembly 1121 and insulation 1006a extends to above top plate 1174. In one embodiment, a nylon mesh 1009 and a rayon staple 1011 are adhered to the dimples/protrusions of MTS 1124 and insulation 1006a is applied as a spray foam insulation. Nylon mesh 1009 and rayon staple 1011 provide a drainage plane within the wall assembly and a surface for which spray foam insulation 1006a can be applied.
In one embodiment, wherein exterior wall 1101 is formed as a masonry block wall, moisture is transported only along an interior side of MTS 1124 above the bottom dimple and then transported along both sides of MTS 1124 below the bottom dimple. In this manner, fluid entering the wall assembly from weep hole 1178 is transported into drain assembly 1121 as well as moisture from the interior side of MTS 1124. In one embodiment, wherein exterior wall 1101 is formed as a concrete wall, moisture is transported only along an interior side of MTS 1124.
During assembly, coupler 1180 is joined with drain assembly 1120 on either side. Accordingly, first section 1182 is inserted into a first length of drain assembly 1120 and second section 1184 is inserted into a second length of drain assembly 1120. Adhesive, such as pvc cement, may be used to adhere coupler 1180 to drain assembly 1120. In one embodiment, drain assembly coupler 1180 is not fully adhered along one of either first section 1182 or second section 1184 to allow for expansion within the building. For example, drain assembly coupler 1180 may not be fully adhered at a location of a building expansion joint. First section 1182 and/or second section 1184 extend a distance within the drain assembly 1120 to provide for the expansion and appropriate sealing. In one embodiment, first section 1182 and second section 1184 extend 1″ from collar 1186. Coupler 1180 may be configured as a straight coupler or configured for an angled connection such as a corner.
First member 1222 includes a bottom plate 1218 and a vertical leg, or face plate, 1219 extending at a right angle from bottom plate 1218. Bottom plate 1218 is installed with a bottom face adjacent to vapor barrier 1212. Sealant 1214 is disposed between bottom plate 1218 and vapor barrier 1212 to provide a seal. Vertical leg 1219 includes an angled leg 1224 including a horizontal portion 1226 and a vertical portion 1228. Second member 1223 is slidably disposed over vertical portion 1228. Vertical leg 1219 in conjunction with angled leg 1224 and second member 1223 forms a sealing cavity 1230 and a transfer cavity 1232. Seals 1010 are disposed in sealing cavity 1230 on both side of MTS 1124 and wicking sheets 1008. In one embodiment, horizontal portion 1226 of angled leg 1224 is positioned along a top side of concrete slab 1210. A drainage cavity 1234 extends between horizontal portion 1226 and bottom plate 1220. As typical with previous embodiments, sealing cavity 1230, transfer cavity 1232, and drainage cavity 1234 fluidly communicate with one another and are configured in a serial configuration along the vertical leg 1219. This configuration allows slab 1210 to be in contact with exterior wall system 1202 and transfer necessary structural loads as required by building codes.
With further reference to
As illustrated in
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof.
This Utility patent application is a continuation-in-part application to Utility patent application Ser. No. 12/612,380, entitled BUILDING ENVELOPE ASSEMBLY INCLUDING MOISTURE TRANSPORTATION FEATURE, which is herein incorporated by reference, which is a continuation-in-part application to Utility patent application Ser. No. 12/467,902, now U.S. Pat. No. 8,001,736, entitled EXTERIOR WALL ASSEMBLY INCLUDING MOISTURE TRANSPORTATION, which is herein incorporated by reference. Additionally, this Utility patent application is related to commonly assigned Utility patent application Ser. No. 12/467,912, now U.S. Pat. No. 8,074,409, entitled EXTERIOR WALL ASSEMBLY INCLUDING DYNAMIC MOISTURE REMOVAL FEATURE, Provisional Utility Patent Application Ser. No. 61/249,497 entitled EXTERIOR WALL ASSEMBLY FASTENER and Utility patent application Ser. No. 12/900,445 entitled FASTENER ASSEMBLY CONFIGURED FOR ATTACHING BOARD IN EXTERIOR WALL, which are herein incorporated by reference.
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| Number | Date | Country | |
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| Number | Date | Country | |
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| Parent | 12612380 | Nov 2009 | US |
| Child | 13544792 | US | |
| Parent | 12467902 | May 2009 | US |
| Child | 12612380 | US |
