The present invention relates to waterproofing a building structure, such as a building opening, a deck ledger or joist, a corner of an exterior wall, a roof-to-wall interface, a through-wall passage, or the like, and more particularly, the present invention relates to a flexible drainage-promoting flashing material and its method of manufacture.
By way of example, water leakage or seepage can occur through the joints of a window and/or window frame, and moisture infiltration within and around a window opening in a wall can be caused by blowing rain, melting snow or ice, and/or condensation of moisture vapor. Similar leakage and/or seepage can also occur via through-wall passages and other building openings, behind deck ledger boards, within a corner of an exterior wall or wall-to-roof interface, or at other areas of a building structure. Moisture that infiltrates these areas will likely become trapped within the building structure and over time will cause structural damage such as rotting of windowsills, framing elements, ledgers and joists, adjacent wall or roof sheathing and studs, and exterior sidewall and trim building materials. In addition, trapped moisture will also cause the undesired growth of mold within the wall or adjacent structure.
For purposes of preventing such damage with respect to window openings, it is conventional practice to install a sill pan or like flashing material to a window opening before a window is installed within the opening. The sill pan or like flashing material provides a water impermeable layer of material that prevents any moisture, which may infiltrate the opening, from contacting the generally wooden framework members of the sill and like surfaces within the wall. Preferably, the sill pan or flashing material should also permit and/or promote removal of moisture from the sill area to an area on an exterior side of the building envelope. Thus, the sill pan and flashing is used to prevent structural damage of the building structure about the window opening, drain moisture to an exterior of the building, and lessen the likelihood of mold forming within the walls of the structure.
By way of example, the following U.S. patents and U.S. published applications disclose various known sill pans, sill drainage systems, flashing, and like building materials: U.S. Application Publication Nos. 2008/0105363 A1 of Ford, 2008/0010917 A1 of Hopkins et al., 2006/0101726 A1 of Collins, 2005/0217189 A1 of Moffit, 2008/0178557 A1 of Parsons et al., 2006/0010788 A1 of Nettleton, 2007/0289226 A1 of Lokkart, 2006/0236618 A1 of Williams, 2006/0137263 A1 of Casey, 2003/0056444 A1 of Ackerman, Jr., 2003/0177727 A1 of Gatherum, 2006/0143994 A1 of Allen, 2007/0157528 A1 of Gawoski and 2005/0144856 A1 of Conlin and U.S. Pat. No. 6,676,779 B2 issued to Hopkins et al., U.S. Pat. No. 7,201,820 B2 issued to Wiercinski, U.S. Pat. No. 6,964,136 B2 issued to Collins et al., U.S. Pat. No. 1,677,130 issued to Cherry, U.S. Pat. No. 4,555,882 issued to Moffit et al., U.S. Pat. No. 7,222,462 B2 issued to Ellingson, U.S. Pat. No. 6,385,925 B1 issued to Wark, U.S. Pat. Nos. 5,822,933 and 5,921,038 issued to Burroughs et al., U.S. Pat. No. 7,367,164 B2 issued to Burton et al., U.S. Pat. No. 7,134,245 B2 issued to Burton, U.S. Pat. Nos. 6,401,402 and 6,401,401 issued to Williams, U.S. Pat. No. 6,725,610 B2 issued to Murphy et al, U.S. Pat. No. 6,305,130 B1 issued to Ackerman, Jr., and U.S. Pat. Nos. 7,059,087 B2 and 7,290,379 B2 issued to Allen.
Although the sill pans, flashing materials, assemblies, and methods disclosed in the above referenced patents and published applications may be satisfactory for their intended purpose, there is a need for an improved building material and method for waterproofing internal components of a through-wall opening or the like of a structure, wall corners, wall-to-roof interface areas, deck ledgers and joists and like structures and for removing moisture that penetrates into such openings or structures. The building material should be inexpensive to manufacture and require only a minimum of skill and labor to apply within an opening or on a structure.
A flashing material for a building structure is provided. The flashing material includes a water-resistive membrane sufficiently flexible to conform to underlying surfaces and a series of separate, laterally spaced-apart, elongate spacers bonded to an upper surface of the membrane. The elongate spacers are polymeric filaments and define an air space and drainage paths across the upper surface of the membrane.
The filaments are of a thickness that projects to a predetermined height above the upper surface of the membrane and that defines a thickness of the air space above the upper face of the membrane. The filaments have a series of depressions formed therein that do not extend to the predetermined height and that provide drainage paths in a direction transversely across the filaments, According to one contemplated embodiment of the present invention, the series of depressions are located at spaced intervals along a length of each filament and are formed by flattened sections of the filaments, and each filament is continuous and consists of an alternating array of the flattened sections and non-flattened full-size sections of the filament.
The membrane can be of multi-layer construction including an upper layer of polymeric material to which the filaments are bonded and a lower integral layer of adhesive providing an underside of the membrane. A release sheet can be used to cover the adhesive whereby the layer of adhesive can be exposed when the release sheet is removed from the membrane. Alternatively, the membrane can be provided without an adhesive layer and release sheet. In addition, an elongate flexible wedge can be secured to a rear edge portion of the underside of the membrane to provide the membrane with a forward slope from its rear edge toward its front edge. Alternatively, the membrane can be provided without the integral wedge component.
According to another aspect of the present invention, an assembly of a window, door, or like opening of a building is provided. The assembly includes framework defining an opening in an exterior wall of a building. The framework includes a sill member extending between opposite upright framing members. The assembly also includes an outer sheathing member applied to the wall below the opening. A flexible water-resistive membrane is applied over the sill member and is folded over a front edge of the opening and extends on the outer sheathing member. The membrane has a series of separate, laterally spaced-apart, elongate spacers bonded to an upper surface of the membrane, and the elongate spacers are polymeric filaments that define an air space and drainage paths across the upper surface of the membrane. Each of the filaments extends generally in a direction from one of the upright framing members to the opposite one of the upright framing members along the length of the sill member of the opening.
As discussed above, the filaments are of a thickness that projects to a predetermined height above the upper surface of the membrane and that defines a thickness of the air space above the upper face of the membrane, and the filaments have a series of depressions formed therein that do not extend to the predetermined height. The depressions provide the drainage paths which extend transversely across the filaments. Preferably, the series of depressions are located at spaced intervals along a length of each filament and are formed by flattened sections of the filaments, and each filament is continuous and consists of an alternating array of the flattened sections and non-flattened full-size sections of the filament.
The assembly can include a pre-applied layer of adhesive on the underside of the membrane to adhesively secure the membrane to the sill member and outer sheathing, and/or the assembly can include an elongate wedge or backdam secured to the sill member underneath a rear edge portion of the membrane to provide the membrane with a forward slope from its rear edge toward its front edge. In addition, the assembly can include a window or the like installed within the opening over the sill member and membrane. In this case, the air space and drainage paths are provided between the upper face of the membrane and lowermost framing elements of the window, including a lower window flange of a flanged window. In addition, the same membrane with filament spacers used on the sill can also be applied adjacent the jambs and header of the opening behind exterior window trim to promote drainage behind the trim.
A further aspect of the present invention is directed to a method of making a flashing material for an opening in an exterior wall of a building. A series of separate, laterally spaced-apart, elongate polymeric filaments are bonded on an upper surface of a flexible water-resistive membrane. The filaments are flattened at spaced intervals along their length to create drainage paths extending transversely across the filaments. The method can also include the steps of applying a layer of adhesive on an underside of the membrane and thereafter applying a release sheet to the underside of the membrane to cover the layer of adhesive. Further, the method can include the step of securing a wedge of flexible material to an underside of the membrane along a rear edge portion of the membrane.
The present invention is directed to a flexible membrane that can be used, for instance, to waterproof a sill surface of framework of a window opening of a building structure. However, the flexible membrane is not limited to use in window openings and can also be used to promote drainage at other locations within or adjacent an exterior wall and/or roof assembly of a building. Examples include use of the flexible membranes about building openings such as doors or the like, other through-wall openings such as for conduits, pipes, wires and the like, wall corner and wall-to-roof interfaces, and deck ledger boards and joists.
By way of example, the flexible membrane is applied to the window opening at the sill before the window is installed. After installation of the window and adjacent outer sidewall and trim building materials, the membrane is embedded within the structure and hidden from sight. The flexible membrane can also be utilized to promote drainage behind trim elements of an opening adjacent header and jamb surfaces and to protect the sill surfaces of doors. Of course, the flexible membrane can also be used to promote drainage within a wall corner or wall-to-roof interface and about deck ledger boards and joists as discussed above.
According to one example,
The membrane 20 can be at least slightly elastic so that it can be tightly fitted within and/or around corners of the window opening and can accommodate various-shaped underlying surfaces, edges, overhangs, uneven surfaces, and the like. Alternatively, the membrane 20 need only be flexible and not elastic. Preferably, the membrane 20 is sufficiently tear-resistant such that it does not tear during installation of the window or over the expected life of the window installation. If desired, additional tear-resistance can be provided by using a multilayer membrane that includes one or more reinforcing layers, such as a mesh reinforcing layer.
When the membrane 20 is applied to a window opening, it will typically be applied over a sloped sill area with a backdam or the like that prevents undesired flow of moisture on the sill toward the inside of the building. In some contemplated embodiments of the present invention, a wedge 22 of material is pre-applied, adhered, bonded, or otherwise secured to a rear portion 24 of the underside 26 of the membrane 20. See
The embodiment of
The wedge 22 can be made of any material having sufficient structural rigidity to maintain the rear portion 24 of the membrane 20 elevated when a structure (e.g., door or window) is installed on top of the membrane 20. Such material may include, without limitation, plastics, closed cell foams, and open celled foams. Another contemplated material is an openwork mat of polymeric filaments. It is desirable that the wedge 22 be formed of a flexible material such that the resulting membrane 20 is flexible for purposes of ease of installation.
In some contemplated embodiments of the present invention, the membrane can be formed of multiple layers. The upper surface 28 can be formed by a waterproof non-woven sheet layer such as known for use with respect to housewrap materials. The underside 26 of the membrane 20 can be provided by a separate waterproof adhesive layer that bonds to the upper layer and that is used to bond the membrane 20 directly to the surface of the underlying sill to which the membrane is applied. The adhesive layer eliminates the need for nails, staples or like fasteners to pierce the membrane 20 or the use of a separately applied layer of adhesive or sealant. As an alternative, the membrane can be provided without an adhesive layer and can be secured to the sill with fasteners, tape, adhesives, or the like.
The membrane 20 illustrated in
The upper surface 28 of the flexible membrane 20 according to the present invention carries a series of spacing elements 32 that ensure the presence of a small air space between the upper surface 28 of the membrane 20 and any other materials, such as the window frame or the like, applied over the membrane 20. The spacing elements 32 also provide drainage paths on the upper surface 28 enabling moisture to drain forward on the membrane 20 and over the front edge of the sill area thereby preventing moisture from accumulating long term in the sill area.
As best illustrated in
According to one contemplated embodiment of the present invention, the spacer elements 32 are filaments 34, such as continuous extruded polymeric filaments. Each filament 34 is bonded to the upper surface 28 of the membrane 12 where it contacts the membrane 20 and extends in a generally longitudinal direction generally following the direction of the front and rear edges, 36 and 38, of the membrane. Thus, when the membrane 20 is installed within a window opening, the filaments 34 extend generally along the longitudinal axis and front and rear edges of the windowsill and the longitudinal axis of the backdam or wedge 22. As an example, see
In the illustrated embodiment, the filaments 34 are laterally and uniformly spaced-apart, do not intersect, and generally extend in a wavy, undulating, serpentine or sinuous pattern. However, they can also extend substantially parallel to each other following a straighter path. Alternatively, the filaments 34 of the present invention can extend in non-linear, saw tooth, and/or random paths or the like and can intersect and/or cross at random locations or at uniform spaced intervals.
As best illustrated in
Drainage paths “P” are provided transversely across the series of filaments 34. Preferably, this is provided by a series of depressions 40 that are formed in the filaments 34. The depressions 40 can be created by flattening the filaments 34 at spaced-apart intervals along the length of the filaments 34. This is best illustrated in
The filaments 34 are preferably made of polymeric materials capable of being extruded directly onto the upper surface 28 of the membrane 20 or a surface of a conveyer, drum, or like transfer mechanism. As examples, the filaments 34 can be made of nylon, polypropylene, polyester, polyolefin, polyethylene, or like material. By way of example, and not by way of limitation, each filament 34 can be extruded such that it has a diameter “D” between about 1/64 to ¼ inch, can be flattened in intervals “I” of about 0.5 to 6 inches, and can be spaced a distance “S” of about ⅛ to 1 inch from adjacent filaments. Of course, other dimensions, shapes, patterns, etc. can also be utilized.
Preferably, the filaments 34 are thermally bonded to the membrane 20. The polymeric material of the filaments 34 and membrane 20 engage, melt and then solidify together to fuse the filaments 34 to the membrane 20 via the application of heat and/or pressure, particularly at the depressions 40. Thus, a separately applied adhesive is not required, and a strong bond can be formed. The depressed sections 40 of the filaments 34 that are flattened are particularly strongly fused to the membrane 20 since the pressure exerted on the filaments 34 to create the depressions 40 results in the formation of a strong bond between the filaments 34 and membrane 20. Alternatively, adhesive bonding, sonic bonding, mechanical bonding, or other techniques can be utilized depending on the materials of the filaments and membrane. Further, the upper surface 28 of the membrane 20 can be textured to strengthen the bond, for example, see the grid like textured areas “T” randomly shown in
If required, the wedge 22 can be cut away and removed from the opposite end sections, 56 and 58, of the membrane 20 that are adhered and/or secured to the studs 60 and 62. The remainder of the membrane 20 and wedge 22 extends on the horizontally-disposed sill member 64 and can be bonded thereto after the release sheet 30 is removed from the underside of the membrane 20 in a peel-and-stick manner. The wedge 22 extends under the rear portion 24 of the membrane 20 and can also be bonded or otherwise secured to the sill member 64 such that the wedge 22 forms a backdam along a rearward edge of the windowsill. The forward portion 66 of the membrane 20 is folded over the front edge of the windowsill 64 and adhered or secured to the outside surface of the vertically-disposed sheathing 68.
As best illustrated in
A window 54, door, or the like may be placed on the membrane 20 and sill 64 and installed within the opening 52. The wedge 22 forms a backdam or elevated area along the rearward edge of the windowsill 64. The forward edge portion 66 of the membrane 20 extends over the outside surface of the sheathing 68 and will be at an elevation lower than that of the rear portion 24 of the membrane 20 disposed over the wedge 22. Accordingly, the downward slope provides a flow path “P” across the depressions 40 of the filaments 34 and away from the rear of the sill 64 such that moisture is directed forwardly off the windowsill 64 underneath the window 54. See
The above described flexible membrane 20 having the filament spacers 34 can also be used at other locations within the assembly for drainage-promoting purposes, such as behind exterior window trim 70 (see
The filaments 34 provide drainage paths on the upper surface 28 of the membrane 20 underneath the trim 70. This is true regardless of the orientation of the filaments 34 on the membrane 20. For instance, drainage paths are provided between adjacent, spaced-apart filaments 34 as well as transversely across the filaments 34 via the depressions 40.
As stated above, the flexible membrane flashing material can be applied to other building openings, such as doors, skylights, and the like, as well as to through-wall openings for wires, cables, pipes or other conduits. The membrane can also be applied within and along wall corners and within and along wall-to-roof interfaces which form corner structures or the like.
Further, as illustrated in
While preferred flexible membranes, assemblies, and methods have been described in detail, various modifications, alterations, and changes may be made without departing from the spirit and scope of the present invention as defined in the appended claims.
This application claims the benefit under 35 USC §119(e) of U.S. Provisional Patent Application No. 61/120,503, filed Dec. 8, 2008.
Number | Date | Country | |
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61120503 | Dec 2008 | US |