Patent Application
20070175169
This invention relates to the field of buildings, and more specifically to a system and method of building construction.
When constructing a building, such as a single family dwelling, insulating and sealing the basement can lead to problems. For instance, when insulation for a living space is on the inside of a basement wall, mold can be a problem because of condensation between the insulation and the wall.
Some builders have a placed a spray-applied membrane directly to an outer surface of the wall to seal the wall and then apply a sheet of rigid insulation over the membrane. However, this system does not allow a wall to breathe to expel moisture.
In one aspect, the present system includes a method of building construction including mounting a rigid insulation sheet over an outer vertical surface of a concrete wall and applying a flexible membrane sheet over at least an above-grade portion of the rigid insulation sheet.
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. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the present invention. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents.
In one embodiment, building 100 is constructed so as to allow moisture to breathe through wall 120 and not condense inside the house. For example, a first layer over wall 120 includes a drainage sheet, such as a dimpled sheet 130. Dimpled sheet 130 includes a plurality of raised hemispherical areas that provide for small spaces between wall 120 and sheet 130. This helps condensing moisture drain down the outside of the wall. In one example, sheets 130 can be DELTA brand dimpled sheets. Over sheet 130 is a rigid insulation sheet 140. Insulation sheets 140 have a portion above grade G and a portion below the grade and extend up to the top of wall 120. Over the insulation sheet 140 is a flexible membrane sheet 150 which extends up to and over the top surface of wall 120. As used herein, “over” and “cover” mean that the item is over, but not necessarily adjacent to another item. Thus, “over” and “cover” are not limited to mean that another item cannot be between a pair of items when one item is over another or covers another item.
As can be seen on the right hand side of
Adjacent to and covering over the dimpled sheet 130 is rigid insulation sheet 140. Insulation sheet 140 can be a rigid foam insulation sheet sized 4′×8′, such as a 1-inch thick or greater insulation. Some embodiments use up to a 2¼″ insulation or greater. Rigid insulation sheet 140 can have an R value of about R-4 to R-16. In some embodiments, a top edge 232 of the rigid insulation sheet is beveled, having an angle of about 45 degrees, for example. In other examples, the angle can vary from about 25 to 75 degrees. As will be explained below, the beveled edge allows the flexible sheet 150 to be more easily mounted over the insulation.
Exposed on the outer surface of the wall is flexible membrane sheet 150 which covers insulation sheet 140 over at least an above-grade portion of the insulation sheet. In some embodiments, the flexible sheet 150 can extend over the entire surface of the insulation. In some examples, the flexible sheet includes a TPO membrane sheet. For example, a GENFLEX brand TPO sheet having a thickness of between 36-60 mils can be used. Such a product typically comes in an 18″ to 8′ roll. Individual pieces can be cut on the roll and attached to the building as described herein. In some examples, the flexible membrane can include a rubber sheet. In some embodiments, the sheet 150 includes a watertight sheet. In some examples, the flexible sheet includes a single-ply membrane. The flexible membrane sheet 150 can be chosen to be watertight, UV-resistant, durable, reinforced, and aesthetic. Different colors can be used as desired. The sheet covers over the insulation to provide a watertight, aesthetic finish and protect the insulation from damage.
The entire wall system of
In one embodiment, to construct the building, the outer vertical surface of the wall 120 is covered with a plurality of dimpled sheets 130. The dimpled sheets can be mounted using nails, screws, or adhesive. Then the rigid insulation sheets 140 are placed over the dimpled sheets. Again, nails, screws, adhesive, or other fastening methods can be used to mount the rigid insulation sheets to the wall. Then the flexible sheet 150 is applied over the insulation.
One method of applying the flexible sheet 150 includes first fastening the sheet along a sill plate 240 using bolts 242, staples, nails, or other fasteners. Flexible membrane sheet 150 is then pulled down tautly over the insulation sheet 140. As noted above, providing a beveled edge on the top of the insulation sheet can help provide a more taut application. Nails 250, rivets, screws, or adhesive can then be used to hold the flexible sheet 150 in place over the insulation sheet 140. The sheet 150 can extend at least to the grade level G of the building (See
The present system can be used to cover a wall or the outer insulation of a wall of almost any shape. The flexible membrane sheets discussed herein are flexible enough to be cut and folded into almost any configuration allowing them to then be attached to each by heat sealing, for example, and providing a sealed outer covering to protect the insulation and provide an aesthetic finish.
It is understood that the above description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.
