Reference will now be made to the accompanying drawings, which at least assist in illustrating the various pertinent features of the present invention. In this regard, the following description that utilizes a flexible membrane to form a sill pan in a window opening is presented for purposes of illustration and description. Furthermore, the description is not intended to limit the invention to the form disclosed herein. Consequently, variations and modifications commensurate with the following teachings, and skill and knowledge of the relevant art, are within the scope of the present invention. It will be appreciated that various aspects of the invention have utility for applications other than forming sill pans for windows and doors, for example, applications where it is desirable to remove moisture from a structure. The embodiments described herein are further intended to explain the best modes known of practicing the invention and to enable others skilled in the art to utilize the invention in such, or other embodiments and with various modifications required by the particular application(s) or use(s) of the present invention.
In the present embodiment, the membrane 10 is formed using an adhesive sheet member 20 having first and second opposing surfaces. For purposes of the discussion, the opposing surfaces are referred to as the top surface 22 and bottom surface 24. However, it will be appreciated that other naming conventions may be utilized. The construction of the adhesive sheet member of 20 may be varied. For instance, the adhesive sheet member 20 may be formed from any flexible sheet-like material that provides the desired level of impermeability. For instance, the sheet member 20 may be formed from a plastic sheet and have an adhesive applied to one or both of the top and bottom surfaces 22, 24. In an alternate arrangement, the adhesive sheet member 20 may be formed of a material that provides both waterproofing properties (e.g., impermeability) as well as adhesive properties. In one particular arrangement, the adhesive sheet 20 is formed from a bitumen-containing material. Such bitumen-containing materials may allow a bitumen-containing layer to provide adhesive qualities for the membrane 10 as well as provide waterproofing qualities for the membrane 10. Additionally, the sheet member 20 may itself be a multilayered structure. For instance, the sheet member 20 may be constructed having one or more reinforcing layers (e.g., mesh layers), base sheet layers (e.g., plastic sheet layers) and/or various adhesive layers (e.g., bitumen-containing layers).
Non-limiting examples of suitable materials for use in producing an adhesive sheet layer having waterproofing properties that include bitumen-containing materials such as various tar adhesives and rubberized asphalts, as well as natural and/or synthetic rubber (e.g., butyl-rubber) certain butyl-rubber compounds. For instance, the adhesive sheet member 20 may be at least partially constructed from a modified, rubberized asphalt material. The rubberized asphalt material may include a combination of petroleum, asphalt/road flux components (e.g., bituminous components) and/or miscellaneous additives.
The use of the bitumen-containing adhesive sheet member 20 allows for conveniently interconnecting the wicking material 30 to the top surface 22 of the sheet member 20. In this regard, the wicking material 30 also be formed in a sheet and may be applied to an exposed adhesive surface of the sheet member 20 in order to adhere the wicking member to that surface. Such application may be performed utilizing compressive rollers in a manner similar to that disclosed in U.S. Pat. No. 6,676,779 entitled “Air and moisture barrier laminate apparatus” the entire contents of which are incorporated herein by reference.
The wicking material 30 may be any material that is operative to effect the movement of moisture utilizing capillary action. In one embodiment, the wicking material is formed from an industrial felt. However, it will be appreciated that numerous other natural and synthetic materials may also be utilized.
In order to attach the membrane 10 to a surface, the bottom surface 24 of the adhesive sheet member 20 may be adapted for adhesive interconnection to a contacting surface. For instance, the membrane 10 may incorporate a release sheet 40 that is removably interconnected to the bottom surface 24 of the membrane 10. In this regard, the release sheet 40 may be removed from the bottom surface 24 such that adhesive associated with the bottom surface 24 may be contacted with a surface for which waterproofing is desired. Many different foils, films, papers or other sheet materials are suitable for use in constructing the release sheet 40. For example, the release sheet 40 may be formed from metals, plastics, or papers treated with silicon or other substances to provide a low level of adhesion to the underlying adhesive associated with the sheet member 20. In any case, it is desirable that the release sheet 40 be easily removable from the adhesive sheet 20.
In the embodiment illustrated in
To permit the second portion 28 of the top surface 22 to be adhesively attached to a surface, a second release sheet 42 may cover an adhesive surface associated with the second portion 28. Further, to allow the second portion 28 of the membrane 10 to be adhered to a surface that is transverse to the first portion of the membrane 10, the bottom surface 24 beneath the second section 28 may be formed from a non-adhesive backing member 50. For instance, the backing member 50 may be formed from a sheet of plastic that is permanently adhered to a portion of the bottom surface 24 of the sheet number 20. This may allow the top surface of the second portion 28 of the membrane 10 to be adhered to a surface in a first plane while the bottom surface of the first portion 26 of the membrane 10 is adhered to a surface in a second transverse plane.
The second sheet number 160 includes an adhesive top surface 162 and a bottom surface 164. In the present embodiment, the bottom surface 164 is covered by a non-adhesive backing material 166 (e.g., a plastic sheet) to prevent the bottom surface 164 of the second sheet member 160 from adhering to a surface. A portion of the adhesive top surface 162 is adhered to the bottom surface 24 of the first sheet member 20. In this regard, the mating potions of the top surface 162 and bottom surface 24 may each be adhesive surfaces that are exposed and contacted together to interconnect the first and second sheet members 20, 160. The remaining portion of the adhesive top surface 162 of the second sheet member 160 is covered by a release sheet 170. This release sheet 170 may be selectively removed as will be discussed herein.
As noted above, one application for the wicking membrane 10 is to form a still pan for use with a door or window.
As shown in
The sill pan 100 may be formed prior to being positioned within the window opening or the sill plan 100 may be formed in place. In the latter regard, a first end of the membrane 10 may be positioned adjacent to one of the studs, for example, stud 110 and a dog-ear corner 60 may be formed. As shown, this may permit forming a side wall 72 along the stud 110 and a back dam 70 that extends between studs 110, 112. An installer may tack or nail the folded ear 60 to the stud 110 to maintain the position of the sill pan 100 within window opening while the second end of the sill pan is formed adjacent to the other stud 112. As will be appreciated, the membrane 10 may come in any lengths and maybe cut to an appropriate length such that a second end of the membrane adjacent to stud 112 is of an appropriate length to form a second sidewall against the opposing stud 112. The back dam 70 and sidewalls 72 generally form a open fronted pan that is operative to receive any water that drains to the surface of the window sill and direct that water outside the building structure, as will be discussed herein.
Once appropriately sized and formed, the bottom surface of the sill pan 100 may be adhered to the top of the windowsill. In this regard, the release sheet 40 may be removed from the bottom surface 26 of the membrane 10. See for example
At this point, the sill pan 100 is fully installed and the wicking material 30 disposed on the top surface of the membrane 10 may extend from the back edge of the windowsill (i.e., adjacent to the back dam 70) across the width of the windowsill and downwardly onto the outside surface of the sheathing material 114. As will be appreciated, this may allow directing water from within the envelope of a building to an outside surface of the building. Specifically, as the wicking material 30 on the outside surface of the sheathing material 114 is disposed below the wicking material 30 on the generally horizontal window sill, capillary action will draw water across the sill. Further, the wicking material may be operative draw water over the sill even when the windowsill is not perfectly level. That is, the capillary action of the wicking material 30 may allow for wicking moisture up and over the front edge of a windowsill and to the outside surface of the sheathing material 114. In any case, the wicking material 30 directs water which penetrates a window outside of the a building envelope.
While the wicking material allows for removing water from the windowsill, the impermeability of the membrane 10 prevents water from contacting the generally wooden windowsill. This combination of the wicking and waterproofing properties may prevent structural damage of the windowsill and lessen the likelihood of mold forming within the walls of a completed structure.
The adhesive surface of the back dam 70 may then be utilized to adhere the back dam 70 to the window frame 140. As may be appreciated, this may provide support for the generally flexible back dam 70 between the upright studs 110, 112. To adhere the front surface of the back dam to the window frame,140, the window my be properly positioned and the release sheet 42 on the surface of the back dam 70 may be removed. An installer then adhesively secures the back dam across the length of the window frame 140. With this construction, moisture that leaks into the window through window flange 142 or the window itself can be wicked across the windowsill and out of the structure. Further, such moisture is prevented from penetrating the interior of a structure by the back dam 70.
When installing the membrane 10 as a window of doorsill pan, it should be appreciated that the elasticity of the membrane 10 generally allows an installer to pull and position the portion of the membrane 10 that extends beyond the sill onto the sheathing material 114 or other outside surface as desired. The membrane 10 may have a construction, which is air and moisture impermeable to define a long-lasting, effective sealing gasket, which is waterproof, and is mold and mildew resistant. As a result, subfloors and sills are prevented from rotting, swelling and warping, finish flooring is not destroyed and energy losses are abated with a noticeable savings in energy costs.
Once the membranes 80, 82 are affixed to the inside corners of the opening, a membrane 10 may be disposed across the surface of the windowsill 116 (See
As in the above-noted embodiment, a forward edge of the membrane 10 may be folded over the outside surface of the sheathing 114. At this time, a window may be placed on the top surface of the membrane 10. Accordingly, the rearward portion of the membrane 10 may be folded against and adhered to the rearward end of the window in order to create a back dam for the resulting sill pan.
To facilitate the use of a back dam material with the membrane 10, back dam or spacer material 90 may be incorporated onto the flexible membrane. As shown in
The flexible sheet member 20 has a top surface that is covered by a wicking material 30. Further, the remainder of the bottom surface of the sheet member 20 is covered by a release sheet 40 that allows for the membrane 10 to be adhered to a surface upon the selective removal of the release sheet 40. Of note, the sheet material 20 and/or wicking material 30 may not extend entirely over the surface of the spacer material 90. Further, the spacer material 90 may incorporate an upward projection 92 that extends above the wicking material 30. In this regard, the spacer material 90 may be aligned across a sill plate and as the wicking material does not extend over the upward extension 92 the spacer material 90 will prevent wicking of moisture into the opening.
While the invention has been described with reference to a preferred embodiment, those skilled in the art will appreciate that certain substitutions, alterations and omissions may be made without departing from the spirit thereof. Accordingly, the foregoing description is meant to be exemplary only and should not be deemed limitative on the scope of the invention set forth with the following claims.