Patent Application
20250092631
The present invention relates to vapor barrier systems, and more particularly, to a pre-formed vapor barrier wrap for a building foundation pier.
A crawlspace is a low or narrow space, such as one beneath the upper or lower story of a building that gives workers access to items such as plumbing or wiring equipment. In residential structures, typically, this space is defined by the structure foundation walls so that the crawlspace is enclosed under the lowest floor of the structure. Additionally, a series of foundation piers are typically also included to support the floor structure of the building. Foundation walls and piers are generally composed of concrete blocks or poured concrete. The bottom of the crawlspace is generally ground, which in most cases is simply dirt or sand. In other cases, the ground floor may be poured concrete. The floor above the crawlspace is generally made of wood. Additionally, the crawlspace dirt floor is generally lower than the soil surrounding the structure. Further, the crawlspace is generally not well insulated, and due to leaks, cracks, and vents, is generally exposed to the outside environment.
Due to limited airflow in a crawlspace, moisture that seeps out of the ground and into the crawlspace causes the crawlspace to become damp and may stay damp for extended periods of time. This moisture can be very damaging to the structure's foundation walls, foundation piers, floor joists, and other structural components, often leading to premature deterioration of the structure and costly repairs. Additionally, mold, mildew, insects and other undesirable conditions can develop in the crawlspace which can affect the foundation walls, piers, and floor structure resulting in an unhealthy environment for inhabitants within the living spaces of the structure above. Additionally, the non-insulated crawlspace allows for the temperature differential between the living space of a home and the crawlspace to approach or be equal to the temperature differential between the living space and the outdoors.
By applying a covering such as a plastic sheet vapor barrier to the foundation walls, piers, and ground, much of the moisture that enters a crawlspace can be eliminated. A problem arises, however, in quickly and efficiently wrapping the foundation piers and securing the pier wrap to the ground floor vapor barrier sheets in a consistent, uniform and leak free manner. In particular, the corners of the piers (for square shaped piers) and the transition from the base to the ground layer vapor barrier are problematic and require lots of time to cut the plastic sheet vapor barrier to cover the corners, extend up the sides of the pier and still smoothly attach to the ground barrier. This typically required lots of tape to seal the various slits and attach the vapor barrier portions into a single cohesive arrangement with no gaps. This results in unnecessary large amounts of time to wrap each pier and large amounts of seam tape that can separate and fail over time allow gaps in the vapor barrier, particularly at the base of corner around the foundation piers.
Accordingly, the objects of the present invention are to provide a foundation pier vapor barrier wrap that is pre-formed to apply around a foundation pier in a quick and efficient matter that will not leak over time and has only a single seam to seal the wrap around the foundation pier.
The above objectives are accomplished according to the present invention by providing a pre-formed foundation pier vapor barrier wrap comprising a lower skirt having a lower interior edge defining an open interior area for receiving a foundation pier, wherein said lower skirt extends horizontally outward from the lower interior edge when disposed around a foundation pier; an upper wrap extending upward from the lower interior edge of the lower skirt and further defining said open interior area for receiving a foundation pier; said lower skirt and said upper wrap each having a first end portion and a second end portion with the second end portion disposed opposite said first end portion; the first end portion of said upper wrap includes an overlap portion that extends and overlaps with the second end portion of the upper wrap when in a closed configuration disposed around a foundation pier and is separated from the second end portion of the upper wrap in an open configuration; the first end portion of said lower skirt includes an overlap portion that extends and overlaps with the second end portion of the lower skirt when in the closed configuration disposed around a foundation pier and is separated from the second end portion of the lower skirt in the open configuration; whereby the lower skirt and upper wrap extend around a foundation pier such that the upper wrap is disposed adjacent to and extends up at least a portion of the foundation pier and the lower skirt extends horizontally outward from the base of the foundation pier.
In a further advantageous embodiment, said lower skirt and said upper wrap are defined by a single continuous sheet of moisture impervious material.
In a further advantageous embodiment, said single continuous sheet of material is selected from the group consisting of plastic film sheeting and rubberized sheeting.
In a further advantageous embodiment, said single continuous sheet of material comprises a multilayered plastic film sheet ranging in thickness from about 1 mil to 25 mil.
In a further advantageous embodiment, said single continuous sheet of material includes at least one characteristic selected from the group consisting of an antimicrobial property, a fire-retardant property, reinforcing puncture and abrasion resistance property, and a UV resistance property.
In a further advantageous embodiment, said single continuous sheet of material is selected from the group consisting of polypropylene, polyester, polyethylene, nylon, polyvinyl chloride, and various mixtures thereof and arranged in one or more layers.
In a further advantageous embodiment, a transition area of the material interconnecting the lower skirt and the upper wrap is curved.
In a further advantageous embodiment, the upper wrap extends upward in a uniform arrangement from the lower interior edge of said lower skirt.
In a further advantageous embodiment, a top edge of the upper wrap is at a consistent height relative to the lower skirt.
In a further advantageous embodiment, a first adhesion strip is carried by at least one of said first and second end portions of each said upper and lower skirts, wherein said first adhesion strip bonds and seals said first end portions to said second end portions within the overlap portion for each said upper and lower skirts in said closed configuration.
In a further advantageous embodiment, a second adhesion strip is carried by said lower skirt for bonding and sealing to a ground vapor barrier.
In a further advantageous embodiment, said second adhesion strip extends along an entire perimeter portion of said lower skirt to form a continuous gapless seal between said lower skirt and the ground vapor barrier.
The above objectives are further accomplished according to the present invention by providing a pre-formed foundation pier vapor barrier wrap comprising a lower skirt extending horizontally; an upper wrap extending upward from the lower skirt; an open interior area defined by said lower skirt and upper wrap for receiving a foundation member; said lower skirt and said upper wrap each having a first end portion and a second end portion with the second end portion disposed opposite said first end portion so that the first and second end portions of the lower skirt and upper warp overlap when in a closed configuration and separate in an open configuration; and, wherein said lower skirt and said upper wrap are defined by a single continuous sheet of moisture impervious material molded so that a transition area of the material interconnecting the lower skirt and the upper wrap is curved; whereby the lower skirt and upper wrap extend around a foundation pier such that the upper wrap is disposed adjacent to and extends up at least a portion of the foundation pier and the lower skirt extends horizontally outward from the base of the foundation pier.
In a further advantageous embodiment, said single continuous sheet of material comprises a multilayered plastic film sheet ranging in thickness from about 1 mil to 25 mil.
In a further advantageous embodiment, said single continuous sheet of material includes at least one characteristic selected from the group consisting of an antimicrobial property, a fire-retardant property, reinforcing puncture and abrasion resistance property, and a UV resistance property.
In a further advantageous embodiment, a first adhesion strip is carried by at least one of said first and second end portions of each said upper and lower skirts, wherein said first adhesion strip bonds and seals said first end portions to said second end portions within the overlap portion for each said upper and lower skirts in said closed configuration; and, a second adhesion strip is carried along a perimeter portion of said lower skirt for bonding and sealing to a ground vapor barrier.
The above objectives are further accomplished according to the present invention by a pre-formed foundation pier vapor barrier wrap comprising a lower skirt extending horizontally; an upper wrap extending upward from the lower skirt; an open interior area defined by said lower skirt and upper wrap for receiving a foundation member; said lower skirt and said upper wrap each having a first end portion and a second end portion with the second end portion disposed opposite said first end portion so that the first and second end portions of the lower skirt and upper warp overlap when in a closed configuration and separate in an open configuration; a first adhesion strip carried by at least one of said first and second end portions of each said upper and lower skirts, wherein said first adhesion strip bonds and seals said first end portions to said second end portions when overlapped in said closed configuration; and, a second adhesion strip carried by said lower skirt along a perimeter portion for bonding and sealing to a ground vapor barrier; whereby the lower skirt and upper wrap extend around a foundation pier such that the upper wrap is disposed adjacent to and extends up at least a portion of the foundation pier and the lower skirt extends horizontally outward from the base of the foundation pier.
In a further advantageous embodiment, said lower skirt and said upper wrap are defined by a single continuous sheet of moisture impervious material molded so that a transition area of the material interconnecting the lower skirt and the upper wrap is curved.
In a further advantageous embodiment, said single continuous sheet of material comprises a multilayered plastic film sheet ranging in thickness from about 1 mil to 25 mil and includes at least one layer having a characteristic selected from the group consisting of an antimicrobial property, a fire-retardant property, reinforcing puncture and abrasion resistance property, and a UV resistance property.
In a further advantageous embodiment, the upper wrap extends upward in a uniform arrangement from the lower skirt so that a top edge of the upper wrap is at a consistent height relative to the lower skirt.
The system designed to carry out the invention will hereinafter be described, together with other features thereof. The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown and wherein:
It will be understood by those skilled in the art that one or more aspects of this invention can meet certain objectives, while one or more other aspects can meet certain other objectives. Each objective may not apply equally, in all its respects, to every aspect of this invention. As such, the preceding objects can be viewed in the alternative with respect to any one aspect of this invention. These and other objects and features of the invention will become more fully apparent when the following detailed description is read in conjunction with the accompanying figures and examples. However, it is to be understood that both the foregoing summary of the invention and the following detailed description are of a preferred embodiment and not restrictive of the invention or other alternate embodiments of the invention. In particular, while the invention is described herein with reference to a number of specific embodiments, it will be appreciated that the description is illustrative of the invention and is not constructed as limiting of the invention. Various modifications and applications may occur to those who are skilled in the art, without departing from the spirit and the scope of the invention, as described by the appended claims. Likewise, other objects, features, benefits and advantages of the present invention will be apparent from this summary and certain embodiments described below, and will be readily apparent to those skilled in the art. Such objects, features, benefits and advantages will be apparent from the above in conjunction with the accompanying examples, data, figures and all reasonable inferences to be drawn therefrom, alone or with consideration of the references incorporated herein.
With reference to the drawings, the invention will now be described in more detail. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the presently disclosed subject matter belongs. Although any methods, devices, and materials similar or equivalent to those described herein can be used in the practice or testing of the presently disclosed subject matter, representative methods, devices, and materials are herein described.
Unless specifically stated, terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. Likewise, a group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should also be read as “and/or” unless expressly stated otherwise.
Furthermore, although items, elements or components of the disclosure may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated. The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent.
A typical residential structure often includes a crawlspace underneath the living space that contains vents allowing air to pass into the crawlspace from the exterior of the structure. Moisture can seep into the crawlspace through foundation walls, airflow and from the crawlspace ground floor. Additionally, the airflow from the vents causes the air in the crawlspace to be approximately the same temperature as that of the ambient air in the outside environment. By installing a covering such as a plastic sheet vapor barrier, along foundation walls, foundation piers, and the ground floor, the introduction of moisture into the crawlspace can be reduced and the flow of air upward through the structure better controlled.
Referring to
In one embodiment, the wrap 10 is pre-formed as a single piece through a molding process, such as a vacuum forming or pressure molding process, and the like well known to those skilled in the art. Alternatively, the lower skirt 12 can be sewn or heat sealed together with the upper wrap portion 14, as long as the seams are fully welded or otherwise secured together in a water proof arrangement with no gaps that would allow moisture to penetrate through the material at the seam. In a preferred embodiment, the molding process is done from a single piece of moisture impervious sheet material so that the transition area 19 of material between the lower skirt portion 12 and upper wrap portion 14 is curved and/or bends upward to facilitate a smooth uninterrupted transition. The curved transition area 19 helps stabilize the upper wrap portion 14 on lower skirt portion 12 to prevent any wrinkles, kinks or tears in the material that can lead to a material failure and leaks.
In one embodiment, the moisture impervious sheet material used to form wrap 10 is selected from the group consisting of plastic film sheeting and rubberized sheeting. In a further embodiment, the material selected to form the wrap 10 can be any water-resistant vapor barrier, reinforced or non-reinforced plastic sheet liner. The moisture impervious sheets used for wrap 10 are preferably highly puncture-resistant and may include an antimicrobial property treatment to inhibit mold and bacteria that may cause staining, unpleasant odors, and premature deterioration. Preferably, the selected moisture impervious sheet includes a fire-retardant treatment. The fire retardant and antimicrobial properties may be inherent in the specific materials used to create wrap 10 or may be added by chemical treatment as is known to those skilled in the art. Preferably, the wrap 10 includes nylon or other reinforcing materials for providing puncture-resistance and abrasion resistance. Additionally, wrap 10 is preferably white in color so that it is easier to see whether mold, insects or other items invade the crawlspace after the vapor barrier wrap and other elements of the crawlspace encapsulation system are installed. In a preferred embodiment, as illustrated in
In one embodiment, the moisture impervious sheet material forming wrap 10 is comprised of materials such as polypropylene, polyester, polyethylene, nylon, polyvinyl chloride, and various mixtures of these materials in one or more layered arrangements. Preferably, wrap 10 comprises a multilayered polyethylene film molded to form as detailed herein below. The multilayered polyethylene film includes at least one reinforcement layer, such as a nylon fiber layer, which is extremely puncture and abrasion resistant. The layers allow for the addition of not just nylons, but soil gas prohibitor, color or mix additives, UV protection, antimicrobial, abrasion resistance, fire retardant, and the like.
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The material feeding and cutting section 30 rotatably carries a roll of moisture impervious material 36, which in one embodiment comprises a solid single layered vinyl sheet ranging in thickness from about 1 mil to 25 mil. The moisture impervious material 36 is fed off the roll and advanced to a cutting unit 38 having a cutting blade 40 vertically operated to slice through the material 36 at a desired length as the material is drawn off the roll. The cutting unit 38 includes a pressure plate 42 that is placed against the material 36 to hold it in place as the cutting blade 40 slices through the material 36. Pressure plate 42 is spring biased 44 for maintaining a consistent desire downward force on the material as the cutting blade is lowered through the material.
The cut portion of sheet material 36a comprises a single sheet that is then molded in first molding section 32 and second molding section 34 to form the wrap.
First molding section 32 includes a series of horizontally spaced and vertically extending wedges 46 carried on a vertically movable wedge mounting plate 48. A wedge pressure plate 50 is disposed below the wedges 46 and includes a series of wedge slots 52. Wedge pressure plate 50 moves vertically with wedge mounting plate 48 and is spring biased 54 against wedge mounting plate 48. The wedge mounting plate 48 is lowered toward the material 36a so that wedge pressure plate 50 presses the material against a skirt molding plate 56 to hold the material 36a in place. As wedge mounting plate 48 is lowered, wedges 46 extend through wedge slots 52 in the wedge pressure plate 50 to engage the material 36a. As wedge mounting plate 48 continues to lower, wedges 46 engage the material 36a and extend through wedge slots 58 in skirt molding plate 56 so that the wedges are pushed into the material, which stretches out the material to form the corners of the upper wrap 14. Thus, the sheet material 36a is positioned on top of the skirt molding plate 56 and the wedges 46 stretch out the material forming the corners of the upper wrap as the wedges are moved downwardly through the wedge slots 52 and 58 of the pressure and skirt plates 50 and 56, respectively. Once the wedges have stretched the material, the wedge mounting plate is retracted.
Next, in first molding section 32, once the wedge mounting plate 48 is retracted, the skirt molding plate 56 is rotated upward from a flat horizontal position to a 90° angle and engages a vertically arranged backing plate 60, which bends the material 36a to form the lower skirt 12. Backing plate 60 also includes a series of secondary wedges 62 that engage the stretched portions of the material 36a forming the corners and continue stretching and maintaining the corner shape of the material as it is pressed against backing plate 60 forming the lower skirt 12. In a preferred embodiment, wedges 46 and 62 are removable and replaceable with different sized wedges depending on the material thickness in order to achieve sufficient stretching of the material to form the corners. The thicker the material the bigger the wedges 46, 62 required for properly stretching the material to mold the corners of upper wrap 14.
After forming lower skirt 12, the sheet material 36a is transitioned to second molding section 34. In this final section, the final shape of the upper wrap 14 and lower skirt is molded. The sheet material is positioned over a center mold 64. An upper mold press 66, a first side mold press 68, and a second side mold press 70 are actuated to engage material 36a and press the material against center mold 64, which forms all four sides and finalizes the corner shape of the upper wrap 14, as well as forming the curved transition between lower skirt 12 and upper wrap 14. Once molded, the presses 66, 68 and 70 are retracted, as well as center mold 64, which allow the finished wrap 10 to drop into a collection bin 72.
In practice, the problems associated with wrapping piers includes working in tight confined spaces where it is difficult to crawl around the foundation pier several times to wrap the pier, for example, with the same sheet material as the ground cover. This method further required many cuts to the sheet material to attempt to form it around the pier and large amounts of seam tape to attempt to seal the wrap to the pier and to the ground cover. The corners are always a problem and almost impossible to get sealed properly with seam tape and the like. The corners are the biggest problem with allowing water intrusion through the vapor barrier and into the crawlspace or basement. Even the best seam tape will not stay unless it's a clean flat compressed adhesion which is highly difficult to obtain in the crawlspace environment when trying to connect various pieces of wrap material that have been but in a variety of places in an attempt to conform to the pier and transition to the ground cover. Even the smallest gap can create moisture that can immediately cause the seams to fail. Thus, no matter the time spent, it is very difficult to properly seal the corners and panels around the foundation pier and connect it with the ground vapor barrier with tape, which is the most common point of failure in a crawlspace encapsulation system.
The present invention solves these problems with the pre-formed wrap 10 that can be applied from one side of a foundation pier 16 and simply pulled around the pier and sealed along a single seam, eliminating corner taping and saving large amounts of time and material while also providing a more reliable and longer lasting vapor barrier without having to worry out sealing corner seams to the transition between the pier and the ground vapor barrier.
While the present subject matter has been described in detail with respect to specific exemplary embodiments and methods thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art using the teachings disclosed herein. The scope of the invention should, therefore, be determined not with reference to the above description, but should instead be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. The omission in the following claims of any aspect of subject matter that is disclosed herein is not a disclaimer of such subject matter, nor should it be regarded that the inventor did not consider such subject matter to be part of the disclosed inventive subject matter.
| Number | Date | Country | |
|---|---|---|---|
| 63583369 | Sep 2023 | US |
