US20050055983A1 - Wall cavity drain panel - Google Patents
Wall cavity drain panel Download PDFInfo
- Publication number
- US20050055983A1 US20050055983A1 US10/660,156 US66015603A US2005055983A1 US 20050055983 A1 US20050055983 A1 US 20050055983A1 US 66015603 A US66015603 A US 66015603A US 2005055983 A1 US2005055983 A1 US 2005055983A1
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- United States
- Prior art keywords
- fabric
- matrix
- panel
- brick
- cavity
- 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
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- 239000004744 fabric Substances 0.000 claims abstract description 76
- 239000011159 matrix material Substances 0.000 claims abstract description 55
- 239000004570 mortar (masonry) Substances 0.000 claims abstract description 32
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 27
- 239000011449 brick Substances 0.000 claims description 86
- 238000000034 method Methods 0.000 claims description 13
- 210000003608 fece Anatomy 0.000 claims description 6
- 239000006260 foam Substances 0.000 claims description 3
- 239000011810 insulating material Substances 0.000 claims 1
- 239000004745 nonwoven fabric Substances 0.000 claims 1
- 230000000284 resting effect Effects 0.000 claims 1
- HPNSNYBUADCFDR-UHFFFAOYSA-N chromafenozide Chemical compound CC1=CC(C)=CC(C(=O)N(NC(=O)C=2C(=C3CCCOC3=CC=2)C)C(C)(C)C)=C1 HPNSNYBUADCFDR-UHFFFAOYSA-N 0.000 description 12
- 230000008901 benefit Effects 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 241000723418 Carya Species 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 230000003466 anti-cipated effect Effects 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000009432 framing Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/70—Drying or keeping dry, e.g. by air vents
- E04B1/7038—Evacuating water from cavity walls, e.g. by using weep holes
- E04B1/7046—Evacuating water from cavity walls, e.g. by using weep holes using trays
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/70—Drying or keeping dry, e.g. by air vents
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/70—Drying or keeping dry, e.g. by air vents
- E04B1/7038—Evacuating water from cavity walls, e.g. by using weep holes
- E04B1/7061—Devices for preventing blockage of weep holes, e.g. a blockage caused by falling mortar
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/7608—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising a prefabricated insulating layer, disposed between two other layers or panels
- E04B1/7612—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising a prefabricated insulating layer, disposed between two other layers or panels in combination with an air space
- E04B1/7616—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only comprising a prefabricated insulating layer, disposed between two other layers or panels in combination with an air space with insulation-layer locating devices combined with wall ties
Definitions
- This invention relates to brick walls and insulating panels and more particularly to maintaining water flow from a cavity behind a brick wall through weep holes in brick courses defining a brick wall.
- a brick wall structure typically includes a veneer or facing of bricks laid in elongated courses outside of an interior or subwall of concrete block, of framing with insulating sheathing, or the like.
- the brick wall is set on a base, or on a flashing on a base, with bricks held together by mortar between adjacent bricks and between brick courses.
- a cavity is defined by weep holes between side-by-side bricks in a lower course, for example, and water finding its way into the cavity is anticipated to drain outwardly through these weep holes.
- weep holes can clog. Water can back up in the cavity, causing mold, odor, damage or other nasty results.
- the clogging of weep holes can be produced by a number of agencies, can cause weep hole clogging, primarily among them is mortar dropped from the setting process of laying one brick course on top of another. Excess mortar falls down the rear or interior surface of the brick wall and can clog the inlets of the lower weep holes.
- a further objective of the invention has been to provide improved brick wall structure to facilitate weep hole drainage.
- a further objective has been to provide an improved apparatus for reducing or preventing weep hole clogging in brick walls.
- a yet further object of the invention has been to provide improved methods of controlling water flow through weep holes in a course of bricks defining a brick wall and from a cavity defined between a brick wall and an interior wall.
- a preferred embodiment of the invention contemplates an improved dual-function panel for disposition in a wall cavity wherein the panel is manufactured of an insulative material such as foam.
- the panel has a grooved face over which is disposed a water permeable fabric attached to the face.
- Insulating panels having these features are available from T. Clear Corporation of Hamilton, Ohio under their brands “Therma-Dry” and “ThermaCav”.
- the panels are improved from the water control goals of this invention by having a lower edge of the fabric not attached to the panel and being extensible therefrom. To such an extensible portion is secured a preferably flexible, water permeable matrix.
- such panels form an insulating sheathing or panel exterior of a subwall of concrete block, for example, but interior of and spaced from the interior side of the brick wall to define, or reside in, a cavity.
- the lower edge of fabric is extended away from the panel, across the cavity toward the brick wall, then upwardly along a course of bricks above or over weep holes formed in or under a brick course.
- the fabric is flexed into a “U”-shaped channel above any wall base and along the cavity at its lower end.
- the matrix is attached to the fabric proximate the attachment of the fabric to the insulating panel, extends across the cavity with the fabric, and upwardly with it parallel to the rear surface of the brick wall.
- the matrix thus extends across the cavity and is flexed about ninety degrees upwardly in water-passing support of the fabric channel.
- a mortar catching channel is thus formed, catching any mortar falling off a brick course and stopping it before it can clog the inlet of a weep hole covered or under the laminate of fabric and matrix.
- Water can then pass through the fabric and matrix onto the cavity base or any flashing at the base, and out unclogged weep holes under or in a brick course.
- water in the cavity can flow through the fabric, down through grooves in the panel face behind the fabric, or onto the base or flashing, with mortar droppings retained by the above fabric and matrix laminate extending across the cavity.
- another significant benefit of this invention is the provision of the water flow controlling structure as described, together with an insulating panel used in a building process so no additional inserts, mats or other special forms are required.
- a contractor only needs to set the insulating panels with extensible fabric and matrix as desired, then fold the fabric and matrix laminate up along the rear surface of one of the early brick courses. In this way, an insulated brick wall structure is provided with the advantage of prevention of weep hole clogging by mortar droppings and without the need for other special inserts, mats or the like.
- FIG. 1 is an illustrative cross-sectional view of a brick cavity wall showing the invention
- FIG. 1A is a perspective drawing of the rear surface of a lower course of bricks in the wall of FIG. 1 ;
- FIG. 2 is an enlarged view of the lower portion of FIG. 1 ;
- FIG. 3 is a perspective view of a wall cavity drain panel according to the invention as also shown in FIGS. 1 and 2 but with a portion of the fabric and matrix peeled back for clarity.
- FIGS. 1 and 2 there is shown in FIGS. 1 and 2 a brick cavity wall structure defined by a brick wall 11 , a subwall 12 which, as shown in one embodiment, is a concrete block wall, and a cavity 13 defined therebetween.
- brick wall 11 is itself defined by a plurality of brick “courses”, i.e. single layers of end-to-end bricks, 15 - 23 , set on top of one another from the lower course 15 and so on as high as the wall 11 may be.
- weep holes 25 are formed, either in the bricks or defined by lateral spaces between the bricks of course 15 .
- These weep holes have an inlet communicating with cavity 13 , and extend outwardly so water can flow (arrow A) from cavity 15 through the holes to the exterior of the wall 10 at 25 a as shown in FIG. 1A .
- Concrete block wall 12 is defined by courses 26 - 28 , and so on, of concrete blocks.
- Brick wall 11 and subwall 12 rest on a base 32 of concrete or any other suitable material.
- Bricks in the courses 15 - 23 are set in mortar, such as mortar 34 between the courses, while the concrete blocks defining subwall 12 can also be set in mortar such as at 35 .
- a brick wall tie 37 is extended outwardly into cavity 13 from mortar 35 between concrete block courses 27 , 28 , for example.
- a wall tie 38 extends into cavity 13 from mortar 34 between brick courses 20 , 21 , for example, and is operably connected to tie 37 in any suitable fashion to facilitate stability of brick wall 11 . As many ties 37 , 38 as are needed are used.
- a bracket end 39 extends downwardly from tie 37 as shown in FIG. 1 , and as will further be described.
- An elongated flashing 41 shown in FIGS. 1 and 2 has a vertical section 42 extending upwardly along block course 26 , and a horizontal section 43 extending from block course 26 outwardly on base 32 under lower brick course 15 . Flashing 41 helps to direct water outwardly of any wall structure 10 .
- mortar 34 a under brick course 15 , lies on flashing 41 and is somewhat mashed or compressed by bricks thereon so it extends behind brick course 15 into cavity 13 .
- mortar 34 b and 34 c then is applied, as the courses are set, such mortar (as at 36 ) tends to drop down behind lower brick courses, into cavity 13 and toward or onto flashing 41 or onto base 32 in the absence of flashing.
- mortar 34 a, 34 b and 34 c can fill up or clot inlets from cavity 13 into weep holes 25 .
- Panel 50 includes an insulating member 51 , preferably of suitable insulating foam such as extruded polystyrene having a plurality of vertical grooves 52 and horizontal grooves 53 therein.
- FIG. 3 illustrates only a small portion of a panel 50 ,it being understood that such panels can be relatively larger, for example, two to four feet in vertical dimension and six to eight feet in horizontal dimension, or any other suitable size.
- Grooves 52 , 53 define blocks, such as at 55 , 56 , for example, therebetween and these blocks have faces 57 defining an outwardly directed face of insulating member 51 .
- Extending on member 51 and on some of the faces 57 is a flexible, water-permeable fabric 60 preferably of non-woven synthetic material of any suitable manufacture, although woven material could be used.
- Fabric 60 is preferably adhered to faces 57 of member 51 by any suitable adhesive or bonding process, and excepting the last two or three rows of blocks or faces 57 disposed at what will be the lower margin or edge 58 of panel 50 .
- the fabric 60 is curled backwards at 61 to illustrate the noted construction. It will thus be appreciated that fabric 60 is extensible away from member 51 and can be flexed into a U-shaped or channel-like configuration as shown in the drawings.
- a matrix 66 is attached to an inner face 62 of fabric 60 .
- Matrix 66 is open and water-permeable and can be of any suitable material such as a randomly deposited or applied filamentary synthetic.
- Matrix 66 is generally stiffer than fabric 60 , but rains flexible. It is adhered to fabric 60 in any suitable manner, such as by adhesives, heat bonding or the like.
- a panel 50 is shown oriented in cavity 13 between brick wall 11 and concrete block subwall 12 . In this configuration, panel 50 rests on or close to flashing 41 at the bottom of cavity 13 . Nevertheless, neither the fabric 60 nor matrix 66 touch or approach flashing 41 or base 32 .
- the fabric 41 is folded into a “U” or channel-like shape as shown so to extend outwardly from member 51 , across cavity 13 and then upwardly proximate a rear wall of the bricks in wall 11 .
- Matrix 66 also extends across cavity 13 , and upwardly against the backside of bricks in wall 11 and more particularly in this embodiment up along the back surface of bricks in lower course 15 .
- the fabric and matrix define in part a catch trough for any mortar droppings 36 which fall into cavity 13 from between the higher brick courses 16 - 23 , etc.
- the fabric 60 and matrix 66 extend across inlets into weep holes 25 (such as at 31 in FIG. 2 , for example), the inlets are thus protected and the fabric 60 and matrix 66 serve to prevent intrusion of clogging mortar into weep holes 25 .
- water W ( FIG. 2 ) in cavity 13 filters through fabric 60 on member 51 into grooves 52 , 53 and downwardly as indicated by the arrows.
- the catch trough provided by fabric 60 and matrix 55 prevents mortar droppings 36 from falling to the cavity bottom and blocking water flow. Yet water is free to flow through fabric 60 and matrix 66 to the bottom of cavity 13 and out weep holes 25 .
- a number of panels 50 may be used end-to-end for long walls.
- Other drain panels such as at 70 could be used on top of lower panels 50 , but the extended fabric 60 and matrix 66 is not necessary for these.
- bracket leg 39 holds the top of panel 50 in position in cavity 13 , preventing its forward tilt.
- bend 40 in tie 38 keeps the bottom edge 71 of upper panels 70 from scooting outwardly in cavity 13 , and so on.
- Multiple floors can each have a flashing and a lower panel 50 , if desired at those floor breaks.
- fabric 60 and matric 66 can be of any suitable manufacture, one form of suitable fabric is made by Reemay Inc. of Old Hickory, Tenn., under product designation Typar® and one suitable matrix 66 is made by Keene Building Products of Mayfield Heights, Ohio, under product designation DriWall Rainscreen.
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- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Acoustics & Sound (AREA)
- Finishing Walls (AREA)
Abstract
An improved wall cavity drain panel and wall cavity structure includes a grooved insulating panel with a water-permeable fabric over the grooved face and a water permeable matrix on the fabric at its lower edge and defining a mortar cath trough to prevent weep hole clogging.
Description
- This invention relates to brick walls and insulating panels and more particularly to maintaining water flow from a cavity behind a brick wall through weep holes in brick courses defining a brick wall.
- A brick wall structure typically includes a veneer or facing of bricks laid in elongated courses outside of an interior or subwall of concrete block, of framing with insulating sheathing, or the like. Typically, the brick wall is set on a base, or on a flashing on a base, with bricks held together by mortar between adjacent bricks and between brick courses. A cavity is defined by weep holes between side-by-side bricks in a lower course, for example, and water finding its way into the cavity is anticipated to drain outwardly through these weep holes.
- The problem is that the weep holes can clog. Water can back up in the cavity, causing mold, odor, damage or other nasty results. The clogging of weep holes can be produced by a number of agencies, can cause weep hole clogging, primarily among them is mortar dropped from the setting process of laying one brick course on top of another. Excess mortar falls down the rear or interior surface of the brick wall and can clog the inlets of the lower weep holes.
- A variety of solutions have been proposed to prevent weep hole clogging by mortar droppings. See, for example, only U.S. Pat. Nos. 5,343,661; 5,230,189; Re. 36,676; 6,0234,892; 5,937,594; 6,112,476 and 5,598673. In several of these, open cell or filamentatious bodies are inserted into the cavity between the bricks and the subwall; the “bodies” may have particularly shaped top surfaces and are placed without fixation devices, rest freely on the wall base, or have a thickness the same as the cavity width.
- Such systems require the insertion then of a separate member or “body” into the cavity and must be supplied as a separate building element. Moreover, there is no uniform procedure by which weep holes in upper floors, levels or courses can be protected.
- Accordingly, it has been one objective of the invention to improve the protection of weep holes in a brick wall from mortar clogging.
- A further objective of the invention has been to provide improved brick wall structure to facilitate weep hole drainage.
- A further objective has been to provide an improved apparatus for reducing or preventing weep hole clogging in brick walls.
- A yet further object of the invention has been to provide improved methods of controlling water flow through weep holes in a course of bricks defining a brick wall and from a cavity defined between a brick wall and an interior wall.
- To these ends, a preferred embodiment of the invention contemplates an improved dual-function panel for disposition in a wall cavity wherein the panel is manufactured of an insulative material such as foam. The panel has a grooved face over which is disposed a water permeable fabric attached to the face. Insulating panels having these features are available from T. Clear Corporation of Hamilton, Ohio under their brands “Therma-Dry” and “ThermaCav”. In addition, however, the panels are improved from the water control goals of this invention by having a lower edge of the fabric not attached to the panel and being extensible therefrom. To such an extensible portion is secured a preferably flexible, water permeable matrix.
- In use, such panels form an insulating sheathing or panel exterior of a subwall of concrete block, for example, but interior of and spaced from the interior side of the brick wall to define, or reside in, a cavity. The lower edge of fabric is extended away from the panel, across the cavity toward the brick wall, then upwardly along a course of bricks above or over weep holes formed in or under a brick course.
- Thus, the fabric is flexed into a “U”-shaped channel above any wall base and along the cavity at its lower end. The matrix is attached to the fabric proximate the attachment of the fabric to the insulating panel, extends across the cavity with the fabric, and upwardly with it parallel to the rear surface of the brick wall. The matrix thus extends across the cavity and is flexed about ninety degrees upwardly in water-passing support of the fabric channel. A mortar catching channel is thus formed, catching any mortar falling off a brick course and stopping it before it can clog the inlet of a weep hole covered or under the laminate of fabric and matrix.
- Water can then pass through the fabric and matrix onto the cavity base or any flashing at the base, and out unclogged weep holes under or in a brick course. In addition, water in the cavity can flow through the fabric, down through grooves in the panel face behind the fabric, or onto the base or flashing, with mortar droppings retained by the above fabric and matrix laminate extending across the cavity.
- In addition to the benefits of maintaining the weep holes free of mortar clogging, another significant benefit of this invention is the provision of the water flow controlling structure as described, together with an insulating panel used in a building process so no additional inserts, mats or other special forms are required. In particular, a contractor only needs to set the insulating panels with extensible fabric and matrix as desired, then fold the fabric and matrix laminate up along the rear surface of one of the early brick courses. In this way, an insulated brick wall structure is provided with the advantage of prevention of weep hole clogging by mortar droppings and without the need for other special inserts, mats or the like.
- These and other objects and advantages will become readily apparent from the following detailed written description and from the drawings in which:
-
FIG. 1 is an illustrative cross-sectional view of a brick cavity wall showing the invention; -
FIG. 1A is a perspective drawing of the rear surface of a lower course of bricks in the wall ofFIG. 1 ; -
FIG. 2 is an enlarged view of the lower portion ofFIG. 1 ; and -
FIG. 3 is a perspective view of a wall cavity drain panel according to the invention as also shown inFIGS. 1 and 2 but with a portion of the fabric and matrix peeled back for clarity. - Turning now to the drawings, there is shown in
FIGS. 1 and 2 a brick cavity wall structure defined by abrick wall 11, asubwall 12 which, as shown in one embodiment, is a concrete block wall, and acavity 13 defined therebetween. As shown inFIG. 1 ,brick wall 11 is itself defined by a plurality of brick “courses”, i.e. single layers of end-to-end bricks, 15-23, set on top of one another from thelower course 15 and so on as high as thewall 11 may be. - In a lower course of
bricks 15, preferably a plurality ofweep holes 25 are formed, either in the bricks or defined by lateral spaces between the bricks of course 15. These weep holes have an inlet communicating withcavity 13, and extend outwardly so water can flow (arrow A) fromcavity 15 through the holes to the exterior of thewall 10 at 25 a as shown inFIG. 1A . -
Concrete block wall 12 is defined by courses 26-28, and so on, of concrete blocks. -
Brick wall 11 andsubwall 12 rest on abase 32 of concrete or any other suitable material. - Bricks in the courses 15-23 are set in mortar, such as
mortar 34 between the courses, while the concreteblocks defining subwall 12 can also be set in mortar such as at 35. - A
brick wall tie 37 is extended outwardly intocavity 13 frommortar 35 betweenconcrete block courses wall tie 38 extends intocavity 13 frommortar 34 betweenbrick courses brick wall 11. Asmany ties - A bracket end39 extends downwardly from
tie 37 as shown inFIG. 1 , and as will further be described. - An
elongated flashing 41, shown inFIGS. 1 and 2 has avertical section 42 extending upwardly alongblock course 26, and ahorizontal section 43 extending fromblock course 26 outwardly onbase 32 underlower brick course 15. Flashing 41 helps to direct water outwardly of anywall structure 10. - As illustrated in
FIGS. 1, 1A and 2,mortar 34 a, underbrick course 15, lies on flashing 41 and is somewhat mashed or compressed by bricks thereon so it extends behindbrick course 15 intocavity 13. Whenmortar 34 b and 34 c then is applied, as the courses are set, such mortar (as at 36) tends to drop down behind lower brick courses, intocavity 13 and toward or onto flashing 41 or ontobase 32 in the absence of flashing. Without the use of the wall cavity drain panel of this invention, and to be described,mortar cavity 13 intoweep holes 25. - Turning now to drain
panel 50, according to the invention, its overall features are perhaps best seen inFIG. 3 .Panel 50 includes aninsulating member 51, preferably of suitable insulating foam such as extruded polystyrene having a plurality of vertical grooves 52 andhorizontal grooves 53 therein.FIG. 3 illustrates only a small portion of apanel 50,it being understood that such panels can be relatively larger, for example, two to four feet in vertical dimension and six to eight feet in horizontal dimension, or any other suitable size. -
Grooves 52, 53 define blocks, such as at 55, 56, for example, therebetween and these blocks have faces 57 defining an outwardly directed face of insulatingmember 51. - Extending on
member 51 and on some of thefaces 57 is a flexible, water-permeable fabric 60 preferably of non-woven synthetic material of any suitable manufacture, although woven material could be used. -
Fabric 60 is preferably adhered tofaces 57 ofmember 51 by any suitable adhesive or bonding process, and excepting the last two or three rows of blocks or faces 57 disposed at what will be the lower margin or edge 58 ofpanel 50. InFIG. 3 , thefabric 60 is curled backwards at 61 to illustrate the noted construction. It will thus be appreciated thatfabric 60 is extensible away frommember 51 and can be flexed into a U-shaped or channel-like configuration as shown in the drawings. - A
matrix 66 is attached to aninner face 62 offabric 60.Matrix 66 is open and water-permeable and can be of any suitable material such as a randomly deposited or applied filamentary synthetic.Matrix 66 is generally stiffer thanfabric 60, but rains flexible. It is adhered tofabric 60 in any suitable manner, such as by adhesives, heat bonding or the like. - Returning to
FIGS. 1 and 2 , apanel 50 is shown oriented incavity 13 betweenbrick wall 11 andconcrete block subwall 12. In this configuration,panel 50 rests on or close to flashing 41 at the bottom ofcavity 13. Nevertheless, neither thefabric 60 normatrix 66 touch or approach flashing 41 orbase 32. - Instead, the
fabric 41 is folded into a “U” or channel-like shape as shown so to extend outwardly frommember 51, acrosscavity 13 and then upwardly proximate a rear wall of the bricks inwall 11.Matrix 66 also extends acrosscavity 13, and upwardly against the backside of bricks inwall 11 and more particularly in this embodiment up along the back surface of bricks inlower course 15. - At the same time, the fabric and matrix define in part a catch trough for any
mortar droppings 36 which fall intocavity 13 from between the higher brick courses 16-23, etc. - Since the
fabric 60 andmatrix 66 extend across inlets into weep holes 25 (such as at 31 inFIG. 2 , for example), the inlets are thus protected and thefabric 60 andmatrix 66 serve to prevent intrusion of clogging mortar into weepholes 25. - Thus, water W (
FIG. 2 ) incavity 13 filters throughfabric 60 onmember 51 intogrooves 52, 53 and downwardly as indicated by the arrows. At the bottom 58 ofpanel 50, water flows onto flashing 41, ontomortar 34 a and into weepholes 25 from where it escapes outwardly ofbrick walls 11, as shown by arrow A, through weephole outlet 25 a. - The catch trough provided by
fabric 60 andmatrix 55 preventsmortar droppings 36 from falling to the cavity bottom and blocking water flow. Yet water is free to flow throughfabric 60 andmatrix 66 to the bottom ofcavity 13 and out weep holes 25. - A few other structural details are of interest. For example, a number of
panels 50 may be used end-to-end for long walls. Other drain panels such as at 70 could be used on top oflower panels 50, but theextended fabric 60 andmatrix 66 is not necessary for these. - In this regard, note that
bracket leg 39 holds the top ofpanel 50 in position incavity 13, preventing its forward tilt. Likewise, bend 40 intie 38 keeps the bottom edge 71 ofupper panels 70 from scooting outwardly incavity 13, and so on. - Multiple floors can each have a flashing and a
lower panel 50, if desired at those floor breaks. - While the drawings show
fabric 60 extending away frompanel member 51 at thelower-most face 57, theblocks lower edge 58 ofpanel member 51, withfabric 60 not adhered to the lower faces 57. - Moreover, even if
cavity 13 is wholly filled with mortar, water can still egress fromcavity 13 viagrooves 52, 53 and weepholes 25. - While
fabric 60 andmatric 66 can be of any suitable manufacture, one form of suitable fabric is made by Reemay Inc. of Old Hickory, Tenn., under product designation Typar® and onesuitable matrix 66 is made by Keene Building Products of Mayfield Heights, Ohio, under product designation DriWall Rainscreen. - In this way, there are no special inserts, bodies or other structures required to maintain drainage from a cavity wall. The wall is simply insulated, but with a particular form of
lower panel 50, then a mortar catch trough formed easily by the extensible fabric and matrix extensible across the cavity and upwards at least on the lower brick course, or higher. Weep holes so protected do not clog and drainage is secured. - These and other modifications and alternative embodiments will be readily apparent to one of ordinary skill in the art without departing from the scope of the invention and applicant intends to be bound only by the claims appended hereto.
Claims (31)
1. An insulating panel comprising:
a member of insulating material having at least a lower edge;
a water-permeable fabric disposed on one side of said member and extensible beyond said lower edge; and
a matrix attached to said fabric extensible beyond said edge of said panel member.
2. A panel as in claim 1 wherein said matrix is flexible.
3. A panel as in claim 1 wherein said matrix and the fabric to which it is attached comprises a flexible laminate.
4. A panel as in claim 1 wherein said member has a face defined by a plurality of grooves and said fabric and said matrix is fixed to said member at said grooved face.
5. A panel as in claim 1 wherein said fabric is a spun bond non-woven fabric.
6. A panel as in claim 5 wherein said matrix is a filamentatious fabric thicker than said water-permeable fabric.
7. A panel as in claim 6 wherein said matrix is water-permeable.
8. A panel as in claim 7 wherein said matrix is heat bonded to said water-permeable fabric.
9. A panel as in claim 1 wherein said fabric has one side attached to said member and said matrix is attached to said one side of said fabric.
10. An insulated water control panel for use between a brick wall structure formed from brick and mortar and a subwall interior of said brick wall structure, said panel comprising:
a foam member having a lower edge;
a water-permeable fabric disposed on one face of said member and extensible outwardly therefrom beyond said edge;
a water-permeable matrix attached to said fabric extensible beyond said edge of said member;
wherein said matrix has a length extendible from said member toward a brick wall when said panel is disposed adjacent thereto and thence extensible along a backside of a lower cource of bricks in said brick wall structure.
11. A panel as in claim 10 wherein said extensible fabric and said matrix are flexible.
12. A panel as in claim 11 wherein said fabric is fixed to an outer face of said member.
13. A panel as in claim 12 wherein said outer face of said member has groove comprising water passages.
14. A panel as in claim 12 wherein said matrix extends away from said outer face from a position inwardly of said lower edge.
15. A panel as in claim 14 wherein said matrix extensible along a backside of a lower course of bricks is parallel to and spaced from said member.
16. A panel as in claim 10 wherein said fabric has one face fixed to an outer face of said member, and said matrix is fixed to said one face of said fabric.
17. A brick wall structure comprising:
a brick wall defined by a plurality of brick courses;
an interior wall defining with an interior surface of said brick courses a cavity therebetween, said cavity having a distance thereacross;
a panel disposed in said cavity and spaced from said brick courses;
said panel having an insulating member with an outer face and lower edge;
a water-permeable fabric disposed on said outer face of said insulating member and extensible beyond said lower edge of said panel, said fabric having one side attached to said panel; and
a flexible, water-permeable matrix attached to said fabric beyond attachment of said fabric to said panel and having a width in excess of the distance across said cavity from said interior wall to said brick courses and of sufficient dimension to extend parallel along said interior surface of at least one of said brick courses.
18. A structure as in claim 17 wherein said matrix is extended across said cavity to a brick course and then upwardly alongside an interior surface of a brick course.
19. A structure as in claim 18 wherein said cavity is further defined by a base and wherein said matrix extending across said cavity is spaced from said base.
20. A structure as in claim 19 further including a flashing disposed over said base, said matrix extending across said cavity is spaced from said flashing.
21. A structure as in claim 17 further including weep holes within a course of bricks, and wherein water passing through said fabric and said matrix flows through said weep holes.
22. A structure as in claim 17 wherein said fabric has a surface, a portion of which is attached to said insulating member, said matrix being attached to said surface of said fabric and on the same side of said fabric as is attached to said insulating member.
23. A structure as in claim 17 further including a brick tie extending from said brick courses to said interior wall through said insulating member.
24. A structure as in claim 23 wherein said brick tie extends through said fabric disposed on said outer face of said insulating member.
25. A structure as in claim 24 wherein said matrix is fixed to said interior wall by said tie and said fabric.
26. A structure as in claim 17 wherein said fabric and said matrix attached thereto define a mortar catch channel for catching mortar droppings thereon from between bricks in brick courses, and wherein water passes through said fabric and said matrix attached thereto.
27. A method of controlling water flow through weep holes in a course of bricks defining a brick wall and from a cavity behind said wall defined by an interior wall, wherein a panel having a water-permeable facing fabric thereon is disposed in said cavity and a flexible matrix is attached to said fabric for extending across said cavity from said panel to said brick wall, said method comprising:
orienting said panel in said cavity with said fabric thereon facing an interior surface of said brick wall, a lower end of said panel resting on a base within said cavity;
extending said fabric and matrix away from said panel and across said cavity toward said interior surface of said brick wall;
orienting said matrix along said interior surface above said base, thereby forming a mortar catching trough of said fabric and matrix proximate said base, and
catching mortar dropping from brick courses onto said trough whereby mortar is prevented from clogging said weep holes and water in said cavity can pass through said fabric and matrix and outwardly of said brick wall through said weep holes.
28. A method as in claim 27 including the further method step of orienting said matrix includes orienting said matrix above and spaced from said base.
29. A method as in claim 27 including flexing said fabric into a channel shape above said base, and flexing said matrix thereon upwardly along an interior surface of a lower course of bricks and over an inlet of said weep holes.
30. A method as in claim 27 including the step of fixing said panel to said interior wall.
31. A method as in claim 27 wherein said panel comprises a grooved face to which said fabric is attached, the method comprising passing water through said fabric into grooves on said grooved face, passing water along said grooves to said base, and passing water through said weep holes under said matrix.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/660,156 US20050055983A1 (en) | 2003-09-11 | 2003-09-11 | Wall cavity drain panel |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/660,156 US20050055983A1 (en) | 2003-09-11 | 2003-09-11 | Wall cavity drain panel |
Publications (1)
Publication Number | Publication Date |
---|---|
US20050055983A1 true US20050055983A1 (en) | 2005-03-17 |
Family
ID=34273608
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/660,156 Abandoned US20050055983A1 (en) | 2003-09-11 | 2003-09-11 | Wall cavity drain panel |
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Country | Link |
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US (1) | US20050055983A1 (en) |
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