AU2010308401A1 - Article for controlling attic moisture - Google Patents
Article for controlling attic moisture Download PDFInfo
- Publication number
- AU2010308401A1 AU2010308401A1 AU2010308401A AU2010308401A AU2010308401A1 AU 2010308401 A1 AU2010308401 A1 AU 2010308401A1 AU 2010308401 A AU2010308401 A AU 2010308401A AU 2010308401 A AU2010308401 A AU 2010308401A AU 2010308401 A1 AU2010308401 A1 AU 2010308401A1
- Authority
- AU
- Australia
- Prior art keywords
- attic
- tray
- breathable membrane
- attic tray
- sheath
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000012528 membrane Substances 0.000 claims abstract description 39
- 239000000853 adhesive Substances 0.000 claims description 10
- 230000001070 adhesive effect Effects 0.000 claims description 10
- 239000000835 fiber Substances 0.000 claims description 10
- -1 polypropylene Polymers 0.000 claims description 9
- 230000002787 reinforcement Effects 0.000 claims description 8
- 239000002131 composite material Substances 0.000 claims description 7
- 229920000728 polyester Polymers 0.000 claims description 6
- 239000004698 Polyethylene Substances 0.000 claims description 5
- 229920000573 polyethylene Polymers 0.000 claims description 5
- 239000004743 Polypropylene Substances 0.000 claims description 4
- 229920001903 high density polyethylene Polymers 0.000 claims description 4
- 229920001155 polypropylene Polymers 0.000 claims description 4
- 239000004700 high-density polyethylene Substances 0.000 claims description 3
- 239000004744 fabric Substances 0.000 claims description 2
- 229920001474 Flashspun fabric Polymers 0.000 claims 2
- 239000004751 flashspun nonwoven Substances 0.000 claims 2
- 239000000463 material Substances 0.000 description 15
- 238000000034 method Methods 0.000 description 8
- 238000009434 installation Methods 0.000 description 6
- 239000002184 metal Substances 0.000 description 4
- 239000006260 foam Substances 0.000 description 3
- 239000003292 glue Substances 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 229920003023 plastic Polymers 0.000 description 3
- 239000011120 plywood Substances 0.000 description 3
- 229920000114 Corrugated plastic Polymers 0.000 description 2
- 229920000690 Tyvek Polymers 0.000 description 2
- 238000003490 calendering Methods 0.000 description 2
- 239000011111 cardboard Substances 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 239000004035 construction material Substances 0.000 description 2
- 239000012943 hotmelt Substances 0.000 description 2
- 239000000123 paper Substances 0.000 description 2
- 230000002093 peripheral effect Effects 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- 229920000119 Coroplast Polymers 0.000 description 1
- 239000004831 Hot glue Substances 0.000 description 1
- 239000004775 Tyvek Substances 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 239000010426 asphalt Substances 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000009435 building construction Methods 0.000 description 1
- 238000010411 cooking Methods 0.000 description 1
- 230000032798 delamination Effects 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 238000000643 oven drying Methods 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 238000010926 purge Methods 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 230000029058 respiratory gaseous exchange Effects 0.000 description 1
- 238000007665 sagging Methods 0.000 description 1
- 239000003351 stiffener Substances 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 238000009423 ventilation Methods 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D12/00—Non-structural supports for roofing materials, e.g. battens, boards
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
- E04D13/17—Ventilation of roof coverings not otherwise provided for
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D12/00—Non-structural supports for roofing materials, e.g. battens, boards
- E04D12/002—Sheets of flexible material, e.g. roofing tile underlay
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Building Environments (AREA)
Abstract
An attic tray (1) made from a breathable membrane (100) for use in controlling moisture in a building attic and improving the energy efficiency of the building achieved by installing the tray (1) above the roof rafters thereby providing the presence of an air gap between the breathable membrane and the roof deck such that energy that normally passes from the living space into the attic and out the top of the building is conserved.
Description
WO 2011/049741 PCT/US2010/051563 TITLE ARTICLE FOR CONTROLLING MOISTURE BACKGROUND OF THE INVENTION 5 1. Field of the Invention The invention relates to an improved building construction material for controlling attic moisture and improving the energy efficiency of a building. 2. Description of the Prior Art 10 Some types of buildings have a space known as an attic located directly underneath the roof structure and above the useful living space. It is common in this type of building to use rafters and decking in the attic space. It is typical to use airflow to control the moisture level in the attic by ventilating air from the eaves of the building to the ridge vent at the highest point of the 15 roof. Air is allowed to flow by means of convection from open spaces along the eaves (between the walls of the building and the bottom of the roofline) to an open space along the ridge(s) at the top of the roof, e.g., a ridge vent. This flow of air purges the attic of moisture before it can build up in the attic. Moisture commonly enters the attic from the living space in the form of vapor. 20 Sources of moisture in the living space include human respiration, use of bathtubs and showers, cooking, houseplants, etc. Typically, the attic is open to the flow of air from the living space and from the exterior of the building surrounding the eaves. While this allows for good moisture control in the attic, it is not energy-efficient since the living 25 space is not sealed and energy from the climate-controlled living space leaks to the exterior of the building through the ridge vent along with the airflow. Expandable foams have been used to insulate and seal attics. The foams are sprayed under the roof decking and inside the roof rafters, or on 30 the "floor" of the attic. While this can effectively seal the attic, this method does not prevent moisture from building up in the attic since the typical foams 1 WO 2011/049741 PCT/US2010/051563 are not breathable and do not permit air to flow through the attic, therefore this is not acceptable for many climates. A common method of providing attic ventilation is a vacuum formed plastic tray that has flanges that attach onto the top edge of the rafters. The design of these products does not allow for 5 any variation of space between the rafters, and they are formed from rigid materials such as plastic and cardboard which are not vapor permeable. United States Patent Publication 2006/0260265 to Zatkulak, assigned to E.I. DuPont de Nemours and Company, Wilmington DE (DuPont) discloses a method for controlling attic moisture utilizing a breathable membrane 10 positioned over the top of the rafters. In order to lay the membrane over the rafters securely, large pieces of membrane must be handled by those installing the materials. This has been found to be cumbersome. It is difficult to attach the membrane to the underside of the rafters as large pieces of membrane are difficult to maneuver in an attic space, especially when trusses 15 are used along with their accompanying cross braces. It is desirable to provide construction materials and methods that eliminate the exchange of air between the living space and the attic, while providing good control of moisture in the attic, along with safer and easier installation. 20 SUMMARY OF THE INVENTION This invention is an attic tray comprising a breathable membrane having first and second opposing edges and top and bottom opposing edges, 25 with side supports adhesively attached at the first and second opposing edges, and an upper overlap at the top edge, wherein at least a portion is coated with adhesive, and a lower overlap at the bottom edge. 30 2 WO 2011/049741 PCT/US2010/051563 BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a view of an assembled attic tray folded for installation. 5 Figures 2A -2C show cross-sectional and side views of installed attic trays. DETAILED DESCRIPTION OF THE INVENTION Definitions 10 The term "active air space" refers to an air space in which air is allowed to move freely both within the air space and in and out of the air space in response to conditions that influence airflow, e.g., thermal gradients. The term "roof deck" is used interchangeably with the term "roof 15 decking" and refers to the structural board on which roofing material (e.g., shingles) is installed, such as plywood or oriented strand board (OSB). The term "eave" herein refers generally to the intersection between the roof and the wall of a building. 20 The term "ridge vent" herein refers generally to the space between differing planes of roof decking along their uppermost edges, typically protected by a cap. 25 The term "peripheral building wrap" herein refers to the use of a flexible sheet material to wrap the unfinished walls of a building, such as a weather-resistive barrier. The term "rafter" is used herein to refer to discrete structural load 30 bearing elements that form the upper portion of a building's attic (also commonly referred to as joists, beams, or trusses). 3 WO 2011/049741 PCT/US2010/051563 The term "rafter opening" is used herein to refer to the space between adjacent rafters. 5 The invention provides an attic tray to form an active air space directly below a roof deck for the active flow of air entering the air space at the eaves and exiting the building at a roof ridge. As shown in Fig. 2A, active air space 6 is the space between the attic tray 1 and roof deck 10. The active air space removes water vapor as indicated by the arrow from the attic space to avoid 10 moisture building up in the wood of the rafters 12 and roof deck 10. The invention also seals the attic, thereby minimizing air exchange between the living space and the attic and providing considerable energy savings.. As depicted in Fig. 1, the attic tray of the invention comprises a breathable membrane 100 having side supports 200 attached to the first and 15 second opposing edges, which can be fastened to rafters. The membrane is typically rectangular and may be depicted and described as such herein, but is not limited by shape. In one embodiment, the membrane can be about 20 inches wide by 44 inches long in order to form an attic tray with a width to fit a rafter opening with 16-inch on-center studs. 20 The side supports 200 hold the breathable membrane in place and the primary purpose of the supports is to provide a stiffener to the breathable membrane to allow an installer to handle the attic tray without its flopping. The side supports may be constructed from rigid or semi-rigid materials, as some flexibility is found to be helpful in positioning the attic tray. Some 25 suitable materials are corrugated plastic, such as Coroplast@ (available fromCoroplast, Inc, Dallas TX), cardboard, plastic and wood. A preferred material is corrugated plastic. There are no limitations on the size of the supports but it has been found that a 2.75 inches wide by 44 inches long piece would be suitable. The side support may optionally be provided with 30 perforations 210 as shown in Fig. 1 to allow a portion of the side support to be bent to form a flange 212. The flange will form a nailing surface to attach the 4 WO 2011/049741 PCT/US2010/051563 attic tray to a horizontal surface of a rafter. A large perforation will allow the side support to bend inward or outward, thus allowing the attic tray to be formed in a manner to allow installation from the attic space below or from the rooftop above, as shown in Figs 2C and 2B, respectively. 5 Optionally, a dead folding reinforcement 400 as shown in Fig 1 may be utilized to maintain the bent position of the side supports. Any material with the ability to take and hold a fold without springing back, known as a dead fold, may be used as a dead fold reinforcement. Suitable materials are metal 10 wire, metal sheets, biaxially oriented polyester and HDPE sheet. The preferred dead fold reinforcement is made of metal wire. The dead fold reinforcement may span across the joints of side supports to cross supports, across perforations, or both. When metal wire is used for the dead fold reinforcement, an optional hook shape 400a as shown in Fig 1 has been 15 found to prevent the wire from working loose. Optionally, cross supports 300 as shown in Fig. 1 may be provided to span from the side support along one edge to the side support on the opposite edge to provide increased rigidity during installation and prevent the breathable membrane from sagging after installation. The cross supports 20 may be about 2 inches wide by 14.5 inches long. The attic tray of the invention is formed by adhesively attaching the supports to the breathable membrane, as depicted in Fig. 1. Any adhesive known to bond to nonwoven fabrics may be used; such as hot melt glues and acrylic glues. The preferred adhesive is hot melt glue such as Duro-Tak 4233 25 hot melt adhesive supplied by Nacan Products Limited, Brampton, Ontario, Canada. The side supports and optional cross supports may be a unitary construction that is cut from a single piece of material, or built up from various pieces. Perforations to allow bending are placed at the folds between side supports and cross supports when the attic tray is formed as a unitary 30 construction, with optional reinforcements to maintain the fold. Cross supports are butted up against the side supports when formed from built-up 5 WO 2011/049741 PCT/US2010/051563 pieces. Dead fold reinforcements are preferred for the joints between side supports and cross supports when built-up from pieces. To allow each attic tray to form a continuous breathable membrane 5 with the other attic trays installed within a rafter opening and the wall below it, a sealing means is required to connect them. It has been found that a length of breathable membrane that extends from each end of the section of breathable membrane framed by the supports provides a suitable means to overlap one tray onto another tray. Fig. 1 depicts an assembled attic tray with 10 a lower overlap 130 at the bottom of the membrane and an upper overlap 120 at the top of the membrane. The upper overlap incorporates at least a portion which is coated with an adhesive 110 which can be covered with a release paper (not shown). Any adhesive known to adhere to a nonwoven material may be used. 15 The attic tray is installed by placing the folded tray into place in a rafter opening and fastening it into place and sealing the joint with any attic tray or wall surface adjacent to it. Attic trays are placed as is typically done in roofing processes by completing a course along one eave of the building structure and then proceeding to install subsequent attic trays in the row 20 above it. The upper attic tray is sealed to the lower attic tray by peeling away the release paper, if present, to reveal the adhesive strip and pressing the lower overlap 130 of the upper attic tray onto the upper overlap 120 of the lower attic tray. In situations where no second attic tray abuts the end of a first attic tray, the overlap is sealed to peripheral building wrap. Roof decking 25 is then constructed using typical roofing materials such as sheathing and asphalt roofing shingles. It has been found especially useful to apply sheathing after each course of attic trays is installed. The subsequent course of attic trays may be safely installed by using the sheathing as a work platform by the installer. The attic tray may also be fastened to the bottom of 30 the rafter. Mounting the attic tray to the bottom of the rafters allows the 6 WO 2011/049741 PCT/US2010/051563 workman to work from the attic and avoid any falling hazards inherent to roofing. In another embodiment of the invention, the attic tray is formed into a roll. The roll is nailed and sealed at the peak of the roof and unrolled to the 5 eave, forming a continuous attic tray. The invention utilizes a breathable membrane 100. The breathable membrane can be any vapor permeable material, preferably having a moisture vapor transmission rate of at least about 20 US perms as tested according to ASTM E96 Method A. The breathable membrane allows 10 moisture to diffuse through it from the attic space into the active air space where moisture is carried by the flowing air to the exterior through the ridge vent. It is found that the chimney effect formed by the active air space enhances the removal of moisture from the attic space. Preferably, the breathable membrane is durable and UV resistant. A preferred membrane 15 has a tensile strength (according to ASTM test method D828) of at least about 34 lb/in (59 N/cm) in the machine direction and about 30 lb/in (52 N/cm) in the cross direction. Preferably, the membrane does not lose strength after exposure to 25 cycles of accelerated aging consisting of oven drying at 120OF for 3 hours, immersion in water at room temperature for 3 hours and air 20 drying for 18 hours at room temperature (73 0 F). Also preferably, the membrane does not lose strength and shows no visible signs of damage after exposure to UV radiation for 210 hours (10 hours/day for 21 days) with 5.0 Watts/m2 irradiance at a wavelength of 315-400 nm, wherein the membrane is held at a distance of one meter from the UV source at a membrane 25 temperature of 140 0 F. An example of a suitable breathable membrane is a two-layer composite sheet with Tyvek@ high density polyethylene (available from DuPont) as the inner layer and a durable spunbond polypropylene sheet as the outer layer. The composite sheet can be made by joining the two layers 30 with an adhesive and subjecting them to a thermal calendering process. The temperature of the calendering process should be sufficient to melt the 7 WO 2011/049741 PCT/US2010/051563 adhesive, and the nip pressure should be sufficient to force the molten adhesive around the fibers of the two layers to lock the two layers together mechanically and ensure high delamination strength of the composite sheet. Other examples of materials suitable for use as the breathable 5 membrane in the invention are spunbond polyolefin nonwoven sheets, including for instance a three-layer spunbonded polypropylene fabric such as the roofing underlayment sold under the trade name Roofshield@ (available from the A. Proctor Group, Ltd., UK). Other materials suitable for use as the breathable membrane are a nonwoven sheet comprising sheath-core 10 bicomponent melt spun fibers, such as described in U. S. Patent Number 5,885,909, herein incorporated by reference; and a composite sheet comprising multiple layers of sheath-core bicomponent melt spun fibers and side-by-side bicomponent meltblown fibers, such as described in U. S. Patent Numbers 6,548,431, 6,797,655 and 6,831,025, herein incorporated by 15 reference. For instance, the bicomponent melt spun fibers can have a sheath of polyethylene and a core of polyester. If a composite sheet comprising multiple layers is used, the bicomponent meltblown fibers can have a polyethylene component and a polyester component and be arranged side by-side along the length thereof. Typically, the side-by-side and the 20 sheath/core bicomponent fibers separate layers in the multiple layer arrangement. Description of a Typical Installation of Trays 25 1. A flat attic tray was bent along the wire-reinforced junction of the side supports with the cross supports to form a tray. 2. The side supports were folded along the perforations to form a flange. 3. The attic tray was placed in a roof rafter opening, starting at one end of an eave. 30 4. Staples were driven through the flange to the top surfaces of the roof rafters. 8 WO 2011/049741 PCT/US2010/051563 5. Staples were driven through the side supports to the inside walls of each roof rafter. 6. The bottom overlap was wrapped around the eave and overlapped onto the wall housewrap and sealed with Tyvek tape. 5 7. Steps one through six were repeated for all rafter spaces in the row along the eave. 8. Roof deck plywood was installed over attic trays using standard nailing protocol. 9. Using the plywood decking as a working platform, additional attic trays 10 were installed above the attic trays that were installed in the row previously installed along the eaves. 10.The release tape was removed from the top overlap of the previously installed attic tray and sealed to the bottom overlap of the attic tray installed above it. 15 11. Steps 8 - 10 were repeated for all remaining rafter openings. 9
Claims (9)
1. An attic tray comprising, a breathable membrane having first and second opposing edges and top and bottom opposing edges, and side supports adhesively attached at the first and second opposing edges, and an upper overlap at the top edge, 10 wherein at least a portion is coated with adhesive, and a lower overlap at the bottom edge.
2. The attic tray of claim 1, comprising one or more cross supports extending 15 from the side support on the first edge to the side support on the second edge and adhesively attached to the breathable membrane.
3. The attic tray of claim 2, comprising perforations in the side supports. 20
4. The attic tray of claim 3, comprising dead fold reinforcements across the perforations.
5. The attic tray of claim 4, wherein the breathable membrane is a three-layer spunbonded polypropylene fabric. 25
6. The attic tray of claim 4, wherein the breathable membrane is a two-layer composite sheet of a flashspun high-density polyethylene sheet and a spunbond polypropylene sheet. 30
7. The attic tray of claim 4, wherein the breathable membrane is a flashspun high-density polyethylene sheet. 10 WO 2011/049741 PCT/US2010/051563
8. The attic tray of claim 4, wherein the breathable membrane is a nonwoven sheet of sheath-core bicomponent melt spun fibers, wherein the sheath is polyethylene and the core is polyester. 5
9. The attic tray of claim 4, wherein the breathable membrane is a composite of a layer of sheath/core bicomponent melt spun fibers and a layer of side-by side bicomponent meltblown fibers, wherein the bicomponents are polyethylene and polyester and the sheath is polyethylene and the core is 10 polyester in the sheath/core bicomponent. 11
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/581,288 | 2009-10-19 | ||
US12/581,288 US20110088334A1 (en) | 2009-10-19 | 2009-10-19 | Article and method for controlling moisture |
PCT/US2010/051563 WO2011049741A1 (en) | 2009-10-19 | 2010-10-06 | Article for controlling attic moisture |
Publications (1)
Publication Number | Publication Date |
---|---|
AU2010308401A1 true AU2010308401A1 (en) | 2012-04-12 |
Family
ID=43413467
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
AU2010308401A Abandoned AU2010308401A1 (en) | 2009-10-19 | 2010-10-06 | Article for controlling attic moisture |
Country Status (8)
Country | Link |
---|---|
US (2) | US20110088334A1 (en) |
EP (1) | EP2491198A1 (en) |
JP (1) | JP2013508575A (en) |
KR (1) | KR20120099045A (en) |
CN (1) | CN102575472A (en) |
AU (1) | AU2010308401A1 (en) |
CA (1) | CA2775598A1 (en) |
WO (1) | WO2011049741A1 (en) |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2011115506A1 (en) * | 2010-03-17 | 2011-09-22 | Isola As | Air gap barrier |
US9816264B2 (en) * | 2013-08-01 | 2017-11-14 | Ewald Doerken Ag | Adherent water vapour permeable air and moisture barrier sheet material |
USD939630S1 (en) * | 2020-02-04 | 2021-12-28 | Brilliant Graphics Group, LLC | Bi-fold roofing material display |
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-
2009
- 2009-10-19 US US12/581,288 patent/US20110088334A1/en not_active Abandoned
-
2010
- 2010-10-06 KR KR1020127012885A patent/KR20120099045A/en not_active Application Discontinuation
- 2010-10-06 CN CN2010800473132A patent/CN102575472A/en active Pending
- 2010-10-06 AU AU2010308401A patent/AU2010308401A1/en not_active Abandoned
- 2010-10-06 EP EP10768645A patent/EP2491198A1/en not_active Withdrawn
- 2010-10-06 JP JP2012534223A patent/JP2013508575A/en active Pending
- 2010-10-06 US US13/502,405 patent/US20120204507A1/en not_active Abandoned
- 2010-10-06 WO PCT/US2010/051563 patent/WO2011049741A1/en active Application Filing
- 2010-10-06 CA CA2775598A patent/CA2775598A1/en not_active Abandoned
Also Published As
Publication number | Publication date |
---|---|
WO2011049741A1 (en) | 2011-04-28 |
EP2491198A1 (en) | 2012-08-29 |
CN102575472A (en) | 2012-07-11 |
KR20120099045A (en) | 2012-09-06 |
US20110088334A1 (en) | 2011-04-21 |
CA2775598A1 (en) | 2011-04-28 |
US20120204507A1 (en) | 2012-08-16 |
JP2013508575A (en) | 2013-03-07 |
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Legal Events
Date | Code | Title | Description |
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MK4 | Application lapsed section 142(2)(d) - no continuation fee paid for the application |