WO2023122019A1 - Reinforced moisture barrier - Google Patents

Reinforced moisture barrier Download PDF

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Publication number
WO2023122019A1
WO2023122019A1 PCT/US2022/053367 US2022053367W WO2023122019A1 WO 2023122019 A1 WO2023122019 A1 WO 2023122019A1 US 2022053367 W US2022053367 W US 2022053367W WO 2023122019 A1 WO2023122019 A1 WO 2023122019A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
barrier sheet
mesh
sheet
layer barrier
Prior art date
Application number
PCT/US2022/053367
Other languages
French (fr)
Inventor
Jagannathan Mohanraj
Cameron R. YATES
Stephen R. D'ARCY
Philip N. BULL
Original Assignee
Berry Global, Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Berry Global, Inc. filed Critical Berry Global, Inc.
Publication of WO2023122019A1 publication Critical patent/WO2023122019A1/en

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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

Definitions

  • the present disclosure relates to cavity walls and particularly, although not exclusively, to moisture barriers for cavity walls, including cavity trays and damp- proof courses.
  • FIG. 1 is a perspective view of a portion of a building including an interior wall and an exterior wall spaced apart from the interior wall to define a wall cavity between the interior wall and the exterior wall and showing a moisture barrier being installed to the building to extend across the wall cavity from the interior wall to the exterior wall to direct moisture resident in the wall cavity away from the interior wall and toward openings formed in the exterior wall to be released from the wall cavity through the openings;
  • FIG. 2 is an enlarged portion of Fig. 1 showing a multi-layer barrier sheet of the moisture barrier with portions cut way to expose an integral interior reinforcement mesh included in the multi-layer barrier sheet and configured to retain the multi-layer barrier sheet in one or more deformed shapes as the multi-layer barrier sheet is installed on the interior wall and the exterior wall so as to facilitate installation of the multi-layer barrier sheet on the building;
  • FIG. 3 is a cross sectional view of the multi-layer barrier sheet from Figs. 1 and 2 showing that the multi-layer barrier sheet includes an outer polymeric layer and the interior reinforcement mesh integrated within the polymeric layer so that the polymeric layer provides top and bottom sides of the multi-layer barrier sheet and extends through spaces between individual fiber weave or portions of the interior reinforcement mesh;
  • Fig. 4 is a series of views suggesting that forces are applied on the multilayer barrier sheet to deform portions thereof and conform those portions to fix the sheet to the interior wall and the exterior wall along a horizontal wall section of the building and along a comer section of the building and suggesting that the portions of the multilayer barrier sheet are retained in deformed positions corresponding to the wall section and the comer section by the interior reinforcement mesh so that other components of the moisture barrier can then be installed on the building without a user continuing to hold the multi-layer barrier sheet in the deformed positions;
  • Fig. 5 shows a process by which the moisture barrier is installed on the wall section of the building
  • Fig. 6 is a cross sectional view showing a joint formed between ends of first and second multi-layer barrier sheets and showing that the joint remains in place due to the interior reinforcement mesh of both the first and second multi-layer barrier sheet;
  • Fig. 7 is a cross sectional view taken along line 7-7 in Fig. 5 showing the multi-layer barrier sheet fully installed between the interior wall and the exterior wall of the building;
  • Fig. 8 shows a process by which the moisture barrier is installed on the comer section of the building and on another elevation of the building to provide a continuous moisture barrier around the comer of the building;
  • Fig. 9 shows a process by which the moisture barrier is installed on the comer section of the building and on another elevation of the building to provide a continuous moisture barrier around the comer of the building without a separate corner unit; and [0013] Fig. 10 shows another process by which the moisture barrier is installed on wall sections and a corner section of the building to provide a continuous moisture barrier around the comer section of the building using a comer-molded barrier sheet.
  • a moisture barrier system 10 for a building 12 is shown in Figs. 1-3.
  • the moisture barrier system 10 is adapted to be installed on building 12 between an interior wall 14 and an exterior wall 16 of the building 12.
  • the moisture barrier system 10 is configured to block passage of moisture between the exterior wall 16 and the interior wall 14 and is configured to direct accumulated moisture on portions of the moisture barrier system 10 toward exit apertures 18 (i.e. weep holes) formed in the exterior wall 16 as suggested in Fig. 7.
  • the moisture barrier system 10 is noncombustible.
  • the moisture barrier system 10 includes a multi-layer barrier sheet 20 acting as a cavity tray that extends through a wall cavity 19 defined between the interior wall 14 and the exterior wall 16 as shown in Fig. 1.
  • the multi-layer barrier sheet 20 may be initially rolled into a cylindrical shape and subsequently unrolled as the moisture barrier system 10 is installed along wall sections 22 and corner sections 24 (also called disruptions) of the building 12 as suggested in Figs. 1 and 4.
  • the moisture barrier system 10 may further include other optional components that reinforce the multi-layer barrier sheet 20 such as joint supports 50, sealant 52, a surface fixing system 54, and comer supports or molds 56 as shown in Figs. 5, 7, and 8.
  • the multi-layer barrier sheet 20 is constructed from materials that allow the multi-layer barrier sheet 20 to be self- supported in one or more deformed positions to facilitate installation of the multi-layer barrier sheet 20 on the building 12.
  • the multilayer barrier sheet 20 includes an outer polymeric layer 26 and an interior reinforcement mesh 28 as shown in Figs. 2 and 3.
  • the outer polymeric layer 26 is moisture impermeable and fully encapsulates the interior reinforcement mesh 28 at upper and lower surfaces of the multi-layer barrier sheet 20.
  • the interior reinforcement mesh 28 is made from a material that can retain the multi-layer barrier sheet 20 in a deformed position so that the multi-layer barrier sheet 20 can be molded to any desired shape along the interior wall 14 and the exterior wall 16.
  • the building 12 may further include other types of disruptions coupled to at least one of the interior wall 14 or the exterior wall 16 and/or located within the cavity 19 such as pylons, beams, studs, insulation, windows, doors, and vents, for example.
  • the multi-layer barrier sheet 20 may be deformed to accommodate any such disruption included in the building 12 so that the multi-layer barrier sheet 20 forms a continuous moisture barrier around the building 12.
  • the multi-layer barrier sheet 20 is installed on the building 12 in a manner that divides the wall cavity 19 into upper and lower cavity subsections 19U, 19L as shown in Fig. 1. Once installed, the multi-layer barrier sheet 20 includes an upper attachment section 20U, a lower attachment section 20L, and medial sloping section 20S between the upper attachment section 20U and the lower attachment section 20L.
  • the upper attachment section 20U is configured to be attached to or interface with the interior wall 14.
  • the lower attachment section 20L is configured to be attached to or interface with the exterior wall 16.
  • the sloping section 20S extends between and interconnects the upper attachment section 20U and the lower attachment section 20L at a downwardly sloping angle relative to vertical faces of the interior wall 14 and exterior wall 16 to direct accumulated moisture away from the upper attachment section 20U and toward the lower attachment section 20L.
  • the sloping section 20S can be installed vertically or at a gradient.
  • the multi-layer barrier sheet 20 provides both a damp-proof course and a cavity tray for the building 12 in the illustrative embodiment.
  • the upper attachment section 20U engages and is parallel with an outwardly facing surface 15 of the interior wall 14.
  • the upper attachment section 20U and the sloping section 20S cooperate to direct moisture downwardly toward openings 18 in exterior wall 16.
  • the upper attachment section 20U and the sloping section 20S also cooperate to block moisture from traveling upwardly from lower cavity subsection 19L to upper cavity subsection 19U.
  • the lower attachment section 20L engages and is parallel with an upwardly facing surface 17 of the exterior wall 16.
  • the upwardly facing surface 17 may be a part of one layer of masonry (i.e. bricks) or mortar that extend around a perimeter of the building 12. A second layer of masonry may then be placed on top of the lower attachment section 20L to locate the lower attachment section 20L between two layers of masonry and/or mortar.
  • Outer polymeric layer 26 formed from a moisture impermeable material to provide the damp proof course and the cavity tray for the building 12.
  • the outer polymeric layer 26 includes silicone.
  • the outer polymeric layer 26 includes polyurethane.
  • the outer polymeric layer 26 includes a thermoplastic.
  • the outer polymeric layer 26 includes rubber.
  • the outer polymeric layer 26 includes synthetic thermoplastic or thermoset rubber.
  • the outer polymeric layer 26 may be the only layer included in the multilayer barrier sheet 20 that provides moisture resistance for the multi-layer barrier sheet 20.
  • the multi-layer barrier sheet 20 is not laminated and is substantially free from adhesives and other materials that are combustible. Some examples of adhesives not included in the multi-layer barrier sheet include epoxies and phenolics.
  • the multi-layer barrier sheet 20 consists of the outer polymer layer 26 and the interior reinforcement mesh 28. In some embodiments, the multi-layer barrier sheet 20 consists essentially of the outer polymer layer 26 and the interior reinforcement mesh 28.
  • Inner reinforcement mesh 28 strengthens the outer polymeric layer 26 to increase puncture and tear resistance of the multi-layer barrier sheet 20.
  • Other barrier sheets may include fibers (i.e. glass fibers) suspended in a matrix to increase puncture and/or tear resistance of the sheet. However, such fibers are flexible and do not allow the sheet to retain a deformed position.
  • the multi-layer barrier sheet 20 may omit such fibers and includes the reinforcement mesh 28 in their place. The reinforcement mesh 28 allows the multi-layer barrier sheet 20 to retain itself in any deformed position during installation so that a user installing the sheet 20 need not hold the sheet 20 in a deformed position while installing other components of the moisture barrier system 10.
  • the reinforcement mesh 28 includes a metallic reinforcement material. In some embodiments, the reinforcement mesh 28 includes a mesh screen. In some embodiments, the reinforcement mesh 28 includes a perforated mesh. In some embodiments, the reinforcement mesh 28 includes a woven wire mesh. In some embodiments, the reinforcement mesh 28 includes a lattice screen. Other suitable materials that are able to retain a deformed position may also be used.
  • the reinforcement mesh 28 is formed to include a plurality of voids or openings 29.
  • the outer polymer layer 26 extends through the plurality of voids 29 to physically bond the outer polymer layer 26 on both sides of the reinforcement mesh 28 as shown in Fig. 3.
  • the portions of the outer polymeric layer 26 extending through the voids 29 retain the outer polymeric layer 26 to the reinforcement mesh 28 and to encapsulate to the reinforcement mesh 28 on both sides thereof.
  • the moisture barrier system 10 is installed on the building 12 using a process of forming a wall section barrier 100 and a process of forming a corner section barrier 200 as shown in Figs. 4, 5, and 8.
  • the process of forming a wall section barrier 100 includes applying the moisture barrier system 10 to both the interior wall 14 and the exterior wall 16 along a facade of the building 12.
  • the process of forming a comer section barrier 200 includes transitioning the moisture barrier system 10 from one elevation of the building 12 to another elevation of the building 12.
  • the process of forming the wall section barrier 100 may begin with a step 102 of preparing the building 12 to receive the multi-layer barrier sheet 20.
  • the interior wall 14 and the exterior wall 16 are formed to sufficient heights to allow the multi-layer barrier sheet 20 to be installed thereon.
  • Step 102 may include installing optional joint supports 50 on the building 12 at a location that coincides with lateral ends of two neighboring multi-layer barrier sheets 20, 20’ as suggested in Fig. 5.
  • Joint supports 50 are shaped to match a fully installed multi-layer barrier sheet 20 and may be formed from a rigid material to support the multi-layer barrier sheet 20, in some embodiments. However, because the multi-layer barrier sheet 20, 20’ includes the reinforcement mesh 28 and is self-supporting, the joint supports 50 may be omitted.
  • Step 102 may further include applying one or more beads of sealant 52 along the surface 15 of interior wall where the upper attachment section 20U of each multi-layer barrier sheet 20 is to be placed.
  • the process 100 further includes a step 104 of applying the multi-layer barrier sheet 20 on the building 12.
  • the step 104 includes deforming an upper end of the multi-layer barrier sheet 20 to form the upper attachment section 20U.
  • the multi-layer barrier sheet 20 is retained in a deformed position forming the upper attachment section 20U by the reinforcement mesh 28.
  • the sealant 52 may provide a seal between the upper attachment section 20U and the surface 15 of the interior wall 14.
  • the process 100 further includes a step 106 of deforming a lower end of the multi-layer barrier sheet 20 to form the lower attachment section 20L along the surface 17 of the exterior wall 16.
  • the multi-layer barrier sheet 20 is retained in a deformed position forming the lower attachment section 20L by the reinforcement mesh 28.
  • the lower attachment section 20L may be applied directly to a layer of masonry or to a layer of mortar on the layer of masonry.
  • the multi-layer sheet 20 is provided initially in a roll and may have a length sufficient to extend all the way around a perimeter of the building to provide a seamless moisture barrier system 10. If the multi-layer barrier sheet 20 does not have a length sufficient to extend all the way around a perimeter of the building 12, then the process 100 further includes a step 108 of joining ends of separate multi-layer barrier sheets 20, 20’ together.
  • the step 108 may include interlocking, fastening, sealing, adhering, taping, or any other suitable joining method.
  • the multi-layer sheets 20, 20’ are interlocked with one another at their neighboring ends to form a mechanically interlocked joint 60 as shown in Figs. 5 and 6.
  • each multi-layer barrier sheet 20, 20’ may be welted such that they are deformed relative to one another to form the mechanically interlocked joint 60.
  • the reinforcement mesh 28 retains the multi-layer barrier sheets 20, 20’ in a deformed position forming the interlocked joint 60, thereby allowing users to omit other components used for joining the two sheets 20, 20’ such as fasteners, sealants, adhesive, tape, etc.
  • the process 100 may further include a step 110 of deforming the second multi-layer sheet 20’ to form upper and lower attachment sections 20U’, 20L’ in the same manner discussed above in steps 104, 106. Steps 108 and 110 may continue along the length of a wall section 22 of the building until the entire wall section 22 includes a multi-layer barrier sheet 20 along a length of the wall section 22.
  • the process 100 may further include a step 112 of installing a DPC fixing strip and mechanical fastenings surface fixing system 54 on the upper attachment section 20U of each multi-layer barrier sheet 20 as shown in Figs. 5 and 7.
  • the surface fixing system 54 may include one or more fixing strips 70 and fasteners 72.
  • the attachment strip 70 is a long beam of rigid material that is placed over the upper attachment section 20U to locate the upper attachment section 20U between the surface 15 of interior wall 14 and the attachment strip 70.
  • Fasteners 72 may then extend through the attachment strip 70 and the upper attachment section 20U and into the interior wall 14 to secure the upper attachment section 20U to the interior wall 14.
  • the surface fixing system 54 may be omitted because the reinforcement mesh 28 retains the multi-layer barrier sheet 20 in a deformed position against the surface 15 of interior wall 14. Insulation 58 may be applied within cavity 19 and at least partially covering the drainage section 20S and the upper attachment section 20U of the multi-layer barrier sheet 20.
  • Process 200 may include an optional step of providing and using a corner mold 56 to shape the multi-layer barrier sheet to the comer section 24 as shown in Fig. 8.
  • the comer mold 56 may be placed on the corner section 24 of the building 12 and then the multi-layer barrier sheet may be deformed around the comer mold 56.
  • the process 200 further includes a step 204 of deforming the multi-layer barrier sheet 20 to match a contour of the comer mold 56 or of the comer section 24 without the comer mold 56.
  • the reinforcement mesh 28 retains the multi-layer barrier sheet 20 in a deformed position corresponding to the comer section 24.
  • the step 204 of deforming the multi-layer barrier sheet 20 may include folding portions of the multi-layer barrier sheet 20 to accommodate the shape of the dismption or corner that the sheet 20 is being applied on.
  • the multi-layer barrier sheet 20 may be site-formed to match the required profile of the comer section 24 or disruption by deforming the multi-layer barrier sheet 20 against the corner mold 56 while the corner mold 56 is removed from the building 12. The multi-layer barrier sheet 20 may then be transported to the building 12 and installed on the comer section 24 while retaining its deformed position by the reinforcement mesh 28 through step 204.
  • the process 200 may further include a step 206 of joining neighboring ends of two adjacently placed multi-layer barrier sheets 20, 20’ as shown in Fig. 8. Step 206 may be performed in substantially the same manner described above in step 108.
  • the process 200 may further include an optional step 208 of applying a surface fixing system 54 to the corner section 24 and wall sections 22 in substantially the same manner described above in step 112.
  • the multi-layer barrier sheet 20 is rolled around a disruption, such as a corner, to provide a seamless moisture barrier over the disruption.
  • the process 200 may include a step 210 of applying the multi-layer barrier sheet 20 along a wall section 22 toward the disruption.
  • the process 200 may then include a step 212 of deforming the multi-layer barrier sheet 20 to the dismption and continuing along an adjacent wall section 22.
  • the multi-layer barrier sheet 20 may be cut to transition from one wall section 22 to another and form a corner section 24.
  • the process 200 may further include a step of cutting the multi-layer barrier sheet along a comer of the building 12 to provide an installed portion of the multi-layer barrier sheet 20 and a remaining portion that is not installed on the building 12. The remaining portion of the multi-layer barrier sheet 20 can then be shaped or cut to match an edge of the installed portion.
  • the process may include a step of reusing the remaining portion by joining with the installed portion 20 of the multi-layer barrier sheet 20 to form a corner section 24 of the moisture barrier system 10.
  • the ends of each portion of the multi-layer barrier sheet 20 may be joined to one another in substantially the same manner as described in step 108.
  • the multiple segments of barrier sheets 20, 20’, 20” may be used to transition from one wall section 22 to another and to form a comer section 24 as shown in Fig. 10.
  • the process 200 may include a step 214 of applying a first barrier sheet 20 along a first wall section 22 and ending the first barrier sheet 20 before the corner section 24.
  • the process 200 may further include a step 216 of forming a corner-molded barrier sheet 20” and applying the comer-molded barrier sheet 20” to an end of the first barrier sheet 20 an to form the corner section 24.
  • the process 200 may further include a step 218 of applying a second barrier sheet 20’ to an end of the corner- molded barrier sheet 20’ ’ opposite the end of the first barrier sheet 20 and to extend along a second wall of the building 12.
  • the ends of each barrier sheet 20, 20’, 20” may be joined to one another in substantially the same manner as described in step 108 or any other suitable joining manner such as by stitching the sheets 20, 20’, 20” together or sealing between the sheets 20, 20’, 20” with sealant.
  • Each barrier sheet 20, 20’, 20” may be formed from the same material in the illustrative embodiment.
  • the corner-molded barrier sheet 20’ ’ may be preformed into the shape of a comer section 24.
  • Pre-forming the comer- molded barrier sheet 20’ ’ may include cutting a strip of barrier sheet material to a predetermined size and shape and stitching or bonding the strip in predetermined areas to form predetermined features that define the corner section 24.
  • the moisture barrier system 10 may combine the multi-layer barrier sheet 20 with other sheets to fit various disruptions along a wall section 22 and/or corner section 24. Reference is hereby made to U.S. Patent Application No. 17/876,821, filed July 29, 2022, U.S.
  • the multi-layer barrier sheet 20 may be applied to the building 12 on both sides of a disruption, and then a sheet may be applied over the disruption and interconnect the two multi-layer barrier sheets 20 on each side of the disruption.
  • the sheet applied to the disruption is free from an interior reinforcement mesh 28 so that the sheet may be cut and/or worked around the disruption without cutting any multi-layer barrier sheet 20.
  • Sealant 52, adhesives, tape, etc. may be used to join any multi-layer barrier sheet 20 with another sheet and to join the sheet to the disruption to provide a seal therebetween.
  • external masonry walls of modern buildings are generally cavity walls; that is, they are formed by an inner leaf and an outer leaf of masonry, often tied together, but separated by an air gap or cavity.
  • the cavity minimizes moisture transmitting from the outer leaf to the inner leaf. It can also provide a ventilation space, allowing moisture within the wall construction to vent to the outside, and can provide a space for the installation of cavity wall insulation.
  • cavity trays may block moisture that is travelling downwards from being carried to the inner leaf, whereas damp-proof courses may be used to minimize rising damp.
  • a cavity tray can be thought of as a damp-proof course that crosses the cavity of a cavity wall in order to block dampness from permeating the internal skin of a wall.
  • cavity trays can be formed using a pliable material such as lead, but may be pre-formed either on-site or off-site (for example from plastics materials), with a wide range of shapes allowing for different cavity widths, corners, stop ends, steps, lintel shapes, arch shapes and sometimes incorporating external flashing.
  • a pliable material such as lead
  • off-site for example from plastics materials
  • a consideration when installing moisture barriers is the fire risk that may be posed by their introduction.
  • the polymer layer 26 may be referred to as a matrix material, and the matrix material may comprise one or more of: silicones, polyurethane, epoxy, phenolics, polyester, vinyl ester.
  • the matrix material may comprise a thermoset or thermoplastic material.
  • the matrix material comprises a silicone.
  • the matrix material consists of a silicone.
  • the damp proof course of the present disclosure may be formed as a cavity tray.
  • the present disclosure also provides a cavity tray comprising a damp-proof course as described herein.
  • the present disclosure may provide a cavity wall having a damp-proof course as described herein, or a cavity tray as described herein.
  • aspects and embodiments of the present disclosure may provide a cavity tray with one or more of the following features: water and damp resistant, flexible, easy to install, high puncture resistance, reinforced product, and available in rolls or discreet pieces.
  • damp proof courses or DPCs may be inserted into the wall structure to stop the movement of moisture from rising up the wall or moving from one part of the structure to another (often seen 150 mm above external ground level).
  • the DPC When used in wider widths, the DPC is draped across the cavity stepping up a minimum of 150 mm from the outer to the inner leaf over a lintel.
  • the DPC may include a cavity tray.
  • the cavity tray may have a wider width of DPC; 450 mm and above, for example. Any rainwater seeping through the outer leaf of the wall and trickling down the cavity face of the outer leaf is collected by the cavity tray and diverted toward weepholes in the outer leaf.
  • a discontinuous cavity tray When used above a window or doorway it may be referred to as a discontinuous cavity tray extending at least to the ends of the lintel. Rainwater is blocked from running off the ends of the tray by creating stop ends with the DPC material itself by turning it up the full height of the outer leaf perpend (vertical joint in the masonry) or using preformed stop ends units.
  • the DPC and/or cavity tray continually bridges the cavity e.g. fire stops or brickwork support angles.
  • the tray is continuous and runs right the way around the building. When it reaches comers preformed corner units may be used which match the profile of the cavity tray and structures of the building.
  • the cavity tray profiles are built into the inner leaf. If the inner leaf is a structural framing system, the cavity tray would be surface fixed to the inner leaf.
  • the cavity tray may be partially embedded into the inner leaf.
  • a system includes the DPC, the preformed cavity tray(s), mastic sealant, joint support(s), and fixing strip(s).
  • the DPC may be rolled due to its flexibility and may include one of the following, non-limiting heights: 450 mm, 500 mm, 600 mm, 700 mm, 800 mm & 900 mm.
  • the mastic sealant 52 may be contained within a cartridge.
  • Other damp-proof courses may require overlap of at least 900 mm at adjoining ends of neighboring damp-proof courses. Sealant is placed between the two courses at the overlap in such embodiments.
  • the illustrative embodiment of the present disclosure does not require as large of an overlap because the adjoining ends may be mechanically interlocked, thereby maximizing the effective length of each multi-layer sheet 20. Additionally, sealant may not be needed at the mechanically interlocked joints.
  • the cavity tray comers are formed to match a contour of the building.
  • each cavity tray comer may include a series of steps or slopped surfaces along its height.
  • the cavity tray comers may be formed from a metal such as stainless steel or another suitable material.
  • the joint supports are arrange to lie beneath overlapping ends of DPC and/or beneath ends of DPC and a cavity tray.
  • Each joint support may include a metal material such as stainless steel or another suitable material.
  • a lower flange of the joint supports may be formed to include an aperture.
  • Masonry material used to join external wall building materials i.e. bricks
  • Each joint support can be shaped to match surfaces or structures of the building.
  • the fixing strip(s) are an elongated strip that extends along an upper end of the DPC.
  • Each fixing strip(s) is formed to include apertures that receive fasteners to secure the DPC and the joint support to the inner leaf.
  • the fixing strip(s) may be made from a metal material such as stainless steel or any other suitable material.
  • Embodiments may be designed to achieve an Al or A2 non-combustibility classification accordingly to BS EN13501-1 (Fire Test to Building Material). There are multiple tests to measure combustibility properties of a product, which are described in the table of Fig. 3. Some embodiments of the present disclosure meet A2, si (smoke propagation), and dO (flaming droplets and particles) requirements according to BS EN13501-1 at the time of filing this application.
  • Test 1 EN ISO 1716:2018 Bomb calorimetry test
  • Sample is fully combusted in a sealed container and internal energy change is measured. This is a test for all the components in the product.
  • Test 2 BS EN 13823:2010 Single burning item
  • the smoke growth rate should be less than 30 m2/s2 and total smoke production should be less than 50 m2.
  • Clause 1 A method of installing a moisture barrier on a building having an interior wall structure and an exterior wall structure spaced apart from the interior wall structure to define a cavity there between.
  • Clause 2 The method of clause 1, any other suitable clause, or any suitable combination of clauses, including applying a bead of mastic to an exterior-facing surface of the interior wall in a line extending horizontally at least partially around the interior wall of the building.
  • Clause 3 The method of clause 2, any other suitable clause, or any suitable combination of clauses, including providing a multi-layer barrier sheet.
  • Clause 4 The method of clause 3, any other suitable clause, or any suitable combination of clauses, including applying an upper section of the multi-layer barrier sheet to the exterior-facing surface of the interior wall over the bead of mastic.
  • Clause 5. The method of clause 4, any other suitable clause, or any suitable combination of clauses, including deforming the upper section of the multi-layer barrier sheet such that the upper section of the multi-layer barrier sheet lies parallel with the exterior-facing surface of the interior wall and a middle section of the multi-layer barrier sheet extends at a downward-sloping angle toward the outer wall.
  • Clause 6 The method of clause 5, any other suitable clause, or any suitable combination of clauses, including applying a lower section of the multi-layer barrier sheet to the exterior wall.
  • Clause 7 The method of clause 6, any other suitable clause, or any suitable combination of clauses, including deforming the lower section of the multi-layer barrier sheet such that the lower section of the multi-layer barrier sheet extends away from the interior wall and is arranged substantially perpendicular to the upper section of the multi-layer barrier sheet.
  • Clause 8 The method of clause 7, any other suitable clause, or any suitable combination of clauses, wherein the upper section and the lower section of the multi-layer barrier sheet are self-supported in deformed positions after deforming the upper section and the lower section of the multi-layer barrier sheet.
  • Clause 9. The method of clause 8, any other suitable clause, or any suitable combination of clauses, wherein a second multi-layer barrier sheet is sealed, adhered, or deformed by mechanically interlocking opposing longitudinal ends of each sheet with the first barrier sheet.
  • Clause 10 The method of clause 9, any other suitable clause, or any suitable combination of clauses, wherein the opposing ends of the multi-layer barrier sheets are self-supported in deformed positions.
  • Clause 13 The method of clause 12, any other suitable clause, or any suitable combination of clauses, wherein the polymer extends through the plurality of voids to locate the polymer on both sides of the metallic mesh such that the multi-layer barrier sheet includes a first layer comprising the metallic mesh and a second layer comprising the polymer that penetrates through the plurality of voids in the metallic mesh.
  • Clause 14 The method of clause 13, any other suitable clause, or any suitable combination of clauses, wherein the polymer includes silicone.
  • Clause 15 The method of clause 13, any other suitable clause, or any suitable combination of clauses, wherein the polymer includes polyurethane.
  • Clause 16 The method of clause 13, any other suitable clause, or any suitable combination of clauses, wherein the polymer includes a thermoplastic.
  • Clause 20 The method of clause 13, any other suitable clause, or any suitable combination of clauses, wherein the metallic mesh includes a perforated mesh.
  • Clause 21 The method of clause 13, any other suitable clause, or any suitable combination of clauses, wherein the metallic mesh includes a woven wire mesh.
  • Clause 22 The method of clause 13, any other suitable clause, or any suitable combination of clauses, wherein the metallic mesh includes a metal lattice screen.
  • Clause 23 The method of clause 8, any other suitable clause, or any suitable combination of clauses, wherein applying the upper section of the multi-layer barrier sheet and applying the lower section of the multi-layer barrier sheet is performed on a wall section of the building and the method further comprises applying the upper section and lower section of the multi-layer barrier sheet to a disruption of the building.
  • Clause 24 The method of clause 23, any other suitable clause, or any suitable combination of clauses, wherein applying the upper and lower sections of the multi-layer barrier sheet to the disruption includes deforming at least one of the upper section and the lower section to form a deformed position around the disruption and wherein the multi-layer barrier sheet is self- supported in the deformed position.
  • a multi-layer sheet for a moisture barrier adapted to be installed on a building having an interior wall structure and an exterior wall structure spaced apart from the interior wall structure to define a cavity there between.
  • Clause 26 The multi-layer sheet of clause 25, any other suitable clause, or any suitable combination of clauses, including a metallic reinforcement mesh.
  • Clause 27 The multi-layer sheet of clause 26, any other suitable clause, or any suitable combination of clauses, including an outer polymeric layer encapsulating the metallic reinforcement mesh.
  • Clause 28 The multi-layer sheet of clause 27, any other suitable clause, or any suitable combination of clauses, wherein the metallic reinforcement mesh is formed to include a plurality of voids and the polymer extends through the plurality of voids to physically bond the outer polymer layer on both sides of the metallic mesh.
  • Clause 29 The multi-layer sheet of clause 28, any other suitable clause, or any suitable combination of clauses, wherein the metallic reinforcement mesh is configured to retain the outer polymeric layer in a deformed position as the multi-layer sheet is installed on the interior wall structure and the exterior wall structure.
  • Clause 30 The multi-layer sheet of clause 29, any other suitable clause, or any suitable combination of clauses, wherein the metallic reinforcement mesh includes a mesh screen and the outer polymeric layer includes silicone.

Abstract

A moisture barrier system, comprising a reinforced multi-layer sheet, adapted to be installed on a building having an interior wall structure and an exterior wall structure spaced apart from the interior wall structure to define a cavity there between. The moisture barrier system being in the form of a multi-layer barrier sheet that is deformed to form multiple sections that are self-supporting in deformed positions.

Description

REINFORCED MOISTURE BARRIER
PRIORITY CLAIM
[0001] This application claims priority to U.S. Patent Application Serial No. 63/291,636 filed on December 20, 2021, the entire disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] The present disclosure relates to cavity walls and particularly, although not exclusively, to moisture barriers for cavity walls, including cavity trays and damp- proof courses.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0003] The detailed description particularly refers to the accompanying figures in which:
[0004] Fig. 1 is a perspective view of a portion of a building including an interior wall and an exterior wall spaced apart from the interior wall to define a wall cavity between the interior wall and the exterior wall and showing a moisture barrier being installed to the building to extend across the wall cavity from the interior wall to the exterior wall to direct moisture resident in the wall cavity away from the interior wall and toward openings formed in the exterior wall to be released from the wall cavity through the openings;
[0005] Fig. 2 is an enlarged portion of Fig. 1 showing a multi-layer barrier sheet of the moisture barrier with portions cut way to expose an integral interior reinforcement mesh included in the multi-layer barrier sheet and configured to retain the multi-layer barrier sheet in one or more deformed shapes as the multi-layer barrier sheet is installed on the interior wall and the exterior wall so as to facilitate installation of the multi-layer barrier sheet on the building;
[0006] Fig. 3 is a cross sectional view of the multi-layer barrier sheet from Figs. 1 and 2 showing that the multi-layer barrier sheet includes an outer polymeric layer and the interior reinforcement mesh integrated within the polymeric layer so that the polymeric layer provides top and bottom sides of the multi-layer barrier sheet and extends through spaces between individual fiber weave or portions of the interior reinforcement mesh;
[0007] Fig. 4 is a series of views suggesting that forces are applied on the multilayer barrier sheet to deform portions thereof and conform those portions to fix the sheet to the interior wall and the exterior wall along a horizontal wall section of the building and along a comer section of the building and suggesting that the portions of the multilayer barrier sheet are retained in deformed positions corresponding to the wall section and the comer section by the interior reinforcement mesh so that other components of the moisture barrier can then be installed on the building without a user continuing to hold the multi-layer barrier sheet in the deformed positions;
[0008] Fig. 5 shows a process by which the moisture barrier is installed on the wall section of the building;
[0009] Fig. 6 is a cross sectional view showing a joint formed between ends of first and second multi-layer barrier sheets and showing that the joint remains in place due to the interior reinforcement mesh of both the first and second multi-layer barrier sheet; [0010] Fig. 7 is a cross sectional view taken along line 7-7 in Fig. 5 showing the multi-layer barrier sheet fully installed between the interior wall and the exterior wall of the building;
[0011] Fig. 8 shows a process by which the moisture barrier is installed on the comer section of the building and on another elevation of the building to provide a continuous moisture barrier around the comer of the building;
[0012] Fig. 9 shows a process by which the moisture barrier is installed on the comer section of the building and on another elevation of the building to provide a continuous moisture barrier around the comer of the building without a separate corner unit; and [0013] Fig. 10 shows another process by which the moisture barrier is installed on wall sections and a corner section of the building to provide a continuous moisture barrier around the comer section of the building using a comer-molded barrier sheet.
DETAILED DESCRIPTION
[0014] A moisture barrier system 10 for a building 12 is shown in Figs. 1-3. The moisture barrier system 10 is adapted to be installed on building 12 between an interior wall 14 and an exterior wall 16 of the building 12. The moisture barrier system 10 is configured to block passage of moisture between the exterior wall 16 and the interior wall 14 and is configured to direct accumulated moisture on portions of the moisture barrier system 10 toward exit apertures 18 (i.e. weep holes) formed in the exterior wall 16 as suggested in Fig. 7. In some embodiments, the moisture barrier system 10 is noncombustible.
[0015] The moisture barrier system 10 includes a multi-layer barrier sheet 20 acting as a cavity tray that extends through a wall cavity 19 defined between the interior wall 14 and the exterior wall 16 as shown in Fig. 1. The multi-layer barrier sheet 20 may be initially rolled into a cylindrical shape and subsequently unrolled as the moisture barrier system 10 is installed along wall sections 22 and corner sections 24 (also called disruptions) of the building 12 as suggested in Figs. 1 and 4. The moisture barrier system 10 may further include other optional components that reinforce the multi-layer barrier sheet 20 such as joint supports 50, sealant 52, a surface fixing system 54, and comer supports or molds 56 as shown in Figs. 5, 7, and 8.
[0016] The multi-layer barrier sheet 20 is constructed from materials that allow the multi-layer barrier sheet 20 to be self- supported in one or more deformed positions to facilitate installation of the multi-layer barrier sheet 20 on the building 12. The multilayer barrier sheet 20 includes an outer polymeric layer 26 and an interior reinforcement mesh 28 as shown in Figs. 2 and 3. The outer polymeric layer 26 is moisture impermeable and fully encapsulates the interior reinforcement mesh 28 at upper and lower surfaces of the multi-layer barrier sheet 20. The interior reinforcement mesh 28 is made from a material that can retain the multi-layer barrier sheet 20 in a deformed position so that the multi-layer barrier sheet 20 can be molded to any desired shape along the interior wall 14 and the exterior wall 16.
[0017] The building 12 may further include other types of disruptions coupled to at least one of the interior wall 14 or the exterior wall 16 and/or located within the cavity 19 such as pylons, beams, studs, insulation, windows, doors, and vents, for example. The multi-layer barrier sheet 20 may be deformed to accommodate any such disruption included in the building 12 so that the multi-layer barrier sheet 20 forms a continuous moisture barrier around the building 12.
[0018] The multi-layer barrier sheet 20 is installed on the building 12 in a manner that divides the wall cavity 19 into upper and lower cavity subsections 19U, 19L as shown in Fig. 1. Once installed, the multi-layer barrier sheet 20 includes an upper attachment section 20U, a lower attachment section 20L, and medial sloping section 20S between the upper attachment section 20U and the lower attachment section 20L. The upper attachment section 20U is configured to be attached to or interface with the interior wall 14. The lower attachment section 20L is configured to be attached to or interface with the exterior wall 16. The sloping section 20S extends between and interconnects the upper attachment section 20U and the lower attachment section 20L at a downwardly sloping angle relative to vertical faces of the interior wall 14 and exterior wall 16 to direct accumulated moisture away from the upper attachment section 20U and toward the lower attachment section 20L. The sloping section 20S can be installed vertically or at a gradient.
[0019] The multi-layer barrier sheet 20 provides both a damp-proof course and a cavity tray for the building 12 in the illustrative embodiment. The upper attachment section 20U engages and is parallel with an outwardly facing surface 15 of the interior wall 14. The upper attachment section 20U and the sloping section 20S cooperate to direct moisture downwardly toward openings 18 in exterior wall 16. The upper attachment section 20U and the sloping section 20S also cooperate to block moisture from traveling upwardly from lower cavity subsection 19L to upper cavity subsection 19U. The lower attachment section 20L engages and is parallel with an upwardly facing surface 17 of the exterior wall 16. The upwardly facing surface 17 may be a part of one layer of masonry (i.e. bricks) or mortar that extend around a perimeter of the building 12. A second layer of masonry may then be placed on top of the lower attachment section 20L to locate the lower attachment section 20L between two layers of masonry and/or mortar.
[0020] Outer polymeric layer 26 formed from a moisture impermeable material to provide the damp proof course and the cavity tray for the building 12. In some embodiments, the outer polymeric layer 26 includes silicone. In some embodiments, the outer polymeric layer 26 includes polyurethane. In some embodiments, the outer polymeric layer 26 includes a thermoplastic. In some embodiments, the outer polymeric layer 26 includes rubber. In some embodiments, the outer polymeric layer 26 includes synthetic thermoplastic or thermoset rubber.
[0021] The outer polymeric layer 26 may be the only layer included in the multilayer barrier sheet 20 that provides moisture resistance for the multi-layer barrier sheet 20. The multi-layer barrier sheet 20 is not laminated and is substantially free from adhesives and other materials that are combustible. Some examples of adhesives not included in the multi-layer barrier sheet include epoxies and phenolics. In some embodiments, the multi-layer barrier sheet 20 consists of the outer polymer layer 26 and the interior reinforcement mesh 28. In some embodiments, the multi-layer barrier sheet 20 consists essentially of the outer polymer layer 26 and the interior reinforcement mesh 28.
[0022] Inner reinforcement mesh 28 strengthens the outer polymeric layer 26 to increase puncture and tear resistance of the multi-layer barrier sheet 20. Other barrier sheets may include fibers (i.e. glass fibers) suspended in a matrix to increase puncture and/or tear resistance of the sheet. However, such fibers are flexible and do not allow the sheet to retain a deformed position. In the illustrative embodiment, the multi-layer barrier sheet 20 may omit such fibers and includes the reinforcement mesh 28 in their place. The reinforcement mesh 28 allows the multi-layer barrier sheet 20 to retain itself in any deformed position during installation so that a user installing the sheet 20 need not hold the sheet 20 in a deformed position while installing other components of the moisture barrier system 10.
[0023] In some embodiments, the reinforcement mesh 28 includes a metallic reinforcement material. In some embodiments, the reinforcement mesh 28 includes a mesh screen. In some embodiments, the reinforcement mesh 28 includes a perforated mesh. In some embodiments, the reinforcement mesh 28 includes a woven wire mesh. In some embodiments, the reinforcement mesh 28 includes a lattice screen. Other suitable materials that are able to retain a deformed position may also be used.
[0024] The reinforcement mesh 28 is formed to include a plurality of voids or openings 29. The outer polymer layer 26 extends through the plurality of voids 29 to physically bond the outer polymer layer 26 on both sides of the reinforcement mesh 28 as shown in Fig. 3. The portions of the outer polymeric layer 26 extending through the voids 29 retain the outer polymeric layer 26 to the reinforcement mesh 28 and to encapsulate to the reinforcement mesh 28 on both sides thereof.
[0025] The moisture barrier system 10 is installed on the building 12 using a process of forming a wall section barrier 100 and a process of forming a corner section barrier 200 as shown in Figs. 4, 5, and 8. The process of forming a wall section barrier 100 includes applying the moisture barrier system 10 to both the interior wall 14 and the exterior wall 16 along a facade of the building 12. The process of forming a comer section barrier 200 includes transitioning the moisture barrier system 10 from one elevation of the building 12 to another elevation of the building 12.
[0026] The process of forming the wall section barrier 100 may begin with a step 102 of preparing the building 12 to receive the multi-layer barrier sheet 20. The interior wall 14 and the exterior wall 16 are formed to sufficient heights to allow the multi-layer barrier sheet 20 to be installed thereon. Step 102 may include installing optional joint supports 50 on the building 12 at a location that coincides with lateral ends of two neighboring multi-layer barrier sheets 20, 20’ as suggested in Fig. 5. Joint supports 50 are shaped to match a fully installed multi-layer barrier sheet 20 and may be formed from a rigid material to support the multi-layer barrier sheet 20, in some embodiments. However, because the multi-layer barrier sheet 20, 20’ includes the reinforcement mesh 28 and is self-supporting, the joint supports 50 may be omitted. Step 102 may further include applying one or more beads of sealant 52 along the surface 15 of interior wall where the upper attachment section 20U of each multi-layer barrier sheet 20 is to be placed.
[0027] The process 100 further includes a step 104 of applying the multi-layer barrier sheet 20 on the building 12. The step 104 includes deforming an upper end of the multi-layer barrier sheet 20 to form the upper attachment section 20U. The multi-layer barrier sheet 20 is retained in a deformed position forming the upper attachment section 20U by the reinforcement mesh 28. The sealant 52 may provide a seal between the upper attachment section 20U and the surface 15 of the interior wall 14.
[0028] The process 100 further includes a step 106 of deforming a lower end of the multi-layer barrier sheet 20 to form the lower attachment section 20L along the surface 17 of the exterior wall 16. The multi-layer barrier sheet 20 is retained in a deformed position forming the lower attachment section 20L by the reinforcement mesh 28. The lower attachment section 20L may be applied directly to a layer of masonry or to a layer of mortar on the layer of masonry.
[0029] In some embodiments, the multi-layer sheet 20 is provided initially in a roll and may have a length sufficient to extend all the way around a perimeter of the building to provide a seamless moisture barrier system 10. If the multi-layer barrier sheet 20 does not have a length sufficient to extend all the way around a perimeter of the building 12, then the process 100 further includes a step 108 of joining ends of separate multi-layer barrier sheets 20, 20’ together. The step 108 may include interlocking, fastening, sealing, adhering, taping, or any other suitable joining method. In the illustrative embodiment, the multi-layer sheets 20, 20’ are interlocked with one another at their neighboring ends to form a mechanically interlocked joint 60 as shown in Figs. 5 and 6. The neighboring ends of each multi-layer barrier sheet 20, 20’ may be welted such that they are deformed relative to one another to form the mechanically interlocked joint 60. The reinforcement mesh 28 retains the multi-layer barrier sheets 20, 20’ in a deformed position forming the interlocked joint 60, thereby allowing users to omit other components used for joining the two sheets 20, 20’ such as fasteners, sealants, adhesive, tape, etc.
[0030] The process 100 may further include a step 110 of deforming the second multi-layer sheet 20’ to form upper and lower attachment sections 20U’, 20L’ in the same manner discussed above in steps 104, 106. Steps 108 and 110 may continue along the length of a wall section 22 of the building until the entire wall section 22 includes a multi-layer barrier sheet 20 along a length of the wall section 22.
[0031] The process 100 may further include a step 112 of installing a DPC fixing strip and mechanical fastenings surface fixing system 54 on the upper attachment section 20U of each multi-layer barrier sheet 20 as shown in Figs. 5 and 7. The surface fixing system 54 may include one or more fixing strips 70 and fasteners 72. The attachment strip 70 is a long beam of rigid material that is placed over the upper attachment section 20U to locate the upper attachment section 20U between the surface 15 of interior wall 14 and the attachment strip 70. Fasteners 72 may then extend through the attachment strip 70 and the upper attachment section 20U and into the interior wall 14 to secure the upper attachment section 20U to the interior wall 14. However, in some embodiments, the surface fixing system 54 may be omitted because the reinforcement mesh 28 retains the multi-layer barrier sheet 20 in a deformed position against the surface 15 of interior wall 14. Insulation 58 may be applied within cavity 19 and at least partially covering the drainage section 20S and the upper attachment section 20U of the multi-layer barrier sheet 20.
[0032] Once an installer reaches a comer section 24 of the building 12 while installing the moisture barrier system 10, the multi-layer barrier sheet 20 is then applied to the comer section 24 through process 200. Process 200 may include an optional step of providing and using a corner mold 56 to shape the multi-layer barrier sheet to the comer section 24 as shown in Fig. 8. The comer mold 56 may be placed on the corner section 24 of the building 12 and then the multi-layer barrier sheet may be deformed around the comer mold 56.
[0033] The process 200 further includes a step 204 of deforming the multi-layer barrier sheet 20 to match a contour of the comer mold 56 or of the comer section 24 without the comer mold 56. The reinforcement mesh 28 retains the multi-layer barrier sheet 20 in a deformed position corresponding to the comer section 24. The step 204 of deforming the multi-layer barrier sheet 20 may include folding portions of the multi-layer barrier sheet 20 to accommodate the shape of the dismption or corner that the sheet 20 is being applied on.
[0034] In some embodiments, the multi-layer barrier sheet 20 may be site-formed to match the required profile of the comer section 24 or disruption by deforming the multi-layer barrier sheet 20 against the corner mold 56 while the corner mold 56 is removed from the building 12. The multi-layer barrier sheet 20 may then be transported to the building 12 and installed on the comer section 24 while retaining its deformed position by the reinforcement mesh 28 through step 204.
[0035] The process 200 may further include a step 206 of joining neighboring ends of two adjacently placed multi-layer barrier sheets 20, 20’ as shown in Fig. 8. Step 206 may be performed in substantially the same manner described above in step 108. The process 200 may further include an optional step 208 of applying a surface fixing system 54 to the corner section 24 and wall sections 22 in substantially the same manner described above in step 112.
[0036] In some embodiments, the multi-layer barrier sheet 20 is rolled around a disruption, such as a corner, to provide a seamless moisture barrier over the disruption. The process 200 may include a step 210 of applying the multi-layer barrier sheet 20 along a wall section 22 toward the disruption. The process 200 may then include a step 212 of deforming the multi-layer barrier sheet 20 to the dismption and continuing along an adjacent wall section 22.
[0037] In some embodiments, the multi-layer barrier sheet 20 may be cut to transition from one wall section 22 to another and form a corner section 24. The process 200 may further include a step of cutting the multi-layer barrier sheet along a comer of the building 12 to provide an installed portion of the multi-layer barrier sheet 20 and a remaining portion that is not installed on the building 12. The remaining portion of the multi-layer barrier sheet 20 can then be shaped or cut to match an edge of the installed portion. The process may include a step of reusing the remaining portion by joining with the installed portion 20 of the multi-layer barrier sheet 20 to form a corner section 24 of the moisture barrier system 10. The ends of each portion of the multi-layer barrier sheet 20 may be joined to one another in substantially the same manner as described in step 108.
[0038] In some embodiments, the multiple segments of barrier sheets 20, 20’, 20” may be used to transition from one wall section 22 to another and to form a comer section 24 as shown in Fig. 10. The process 200 may include a step 214 of applying a first barrier sheet 20 along a first wall section 22 and ending the first barrier sheet 20 before the corner section 24. The process 200 may further include a step 216 of forming a corner-molded barrier sheet 20” and applying the comer-molded barrier sheet 20” to an end of the first barrier sheet 20 an to form the corner section 24. The process 200 may further include a step 218 of applying a second barrier sheet 20’ to an end of the corner- molded barrier sheet 20’ ’ opposite the end of the first barrier sheet 20 and to extend along a second wall of the building 12. The ends of each barrier sheet 20, 20’, 20” may be joined to one another in substantially the same manner as described in step 108 or any other suitable joining manner such as by stitching the sheets 20, 20’, 20” together or sealing between the sheets 20, 20’, 20” with sealant.
[0039] Each barrier sheet 20, 20’, 20” may be formed from the same material in the illustrative embodiment. However, the corner-molded barrier sheet 20’ ’ may be preformed into the shape of a comer section 24. Pre-forming the comer- molded barrier sheet 20’ ’ may include cutting a strip of barrier sheet material to a predetermined size and shape and stitching or bonding the strip in predetermined areas to form predetermined features that define the corner section 24. [0040] In some embodiments, the moisture barrier system 10 may combine the multi-layer barrier sheet 20 with other sheets to fit various disruptions along a wall section 22 and/or corner section 24. Reference is hereby made to U.S. Patent Application No. 17/876,821, filed July 29, 2022, U.S. Provisional Patent Application No. 63/243,953, filed September 14, 2021, and to U.S. Provisional Patent Application No. 63/227,551, filed July 30, 2021, each of which is expressly incorporated by reference herein for the purpose of describing a moisture barrier sheet (i.e. a damp-proof course) that can be used with the moisture barrier system 10. For example, the multi-layer barrier sheet 20 may be applied to the building 12 on both sides of a disruption, and then a sheet may be applied over the disruption and interconnect the two multi-layer barrier sheets 20 on each side of the disruption. In one example, the sheet applied to the disruption is free from an interior reinforcement mesh 28 so that the sheet may be cut and/or worked around the disruption without cutting any multi-layer barrier sheet 20. Sealant 52, adhesives, tape, etc. may be used to join any multi-layer barrier sheet 20 with another sheet and to join the sheet to the disruption to provide a seal therebetween.
[0041] In some embodiments, external masonry walls of modern buildings are generally cavity walls; that is, they are formed by an inner leaf and an outer leaf of masonry, often tied together, but separated by an air gap or cavity. The cavity minimizes moisture transmitting from the outer leaf to the inner leaf. It can also provide a ventilation space, allowing moisture within the wall construction to vent to the outside, and can provide a space for the installation of cavity wall insulation.
[0042] In some embodiments, cavity trays may block moisture that is travelling downwards from being carried to the inner leaf, whereas damp-proof courses may be used to minimize rising damp. A cavity tray can be thought of as a damp-proof course that crosses the cavity of a cavity wall in order to block dampness from permeating the internal skin of a wall.
[0043] In some embodiments, cavity trays can be formed using a pliable material such as lead, but may be pre-formed either on-site or off-site (for example from plastics materials), with a wide range of shapes allowing for different cavity widths, corners, stop ends, steps, lintel shapes, arch shapes and sometimes incorporating external flashing. A consideration when installing moisture barriers is the fire risk that may be posed by their introduction.
[0044] In some embodiments, the polymer layer 26 may be referred to as a matrix material, and the matrix material may comprise one or more of: silicones, polyurethane, epoxy, phenolics, polyester, vinyl ester. The matrix material may comprise a thermoset or thermoplastic material. In some embodiments the matrix material comprises a silicone. In some embodiments the matrix material consists of a silicone.
[0045] In some embodiments, the damp proof course of the present disclosure may be formed as a cavity tray. The present disclosure also provides a cavity tray comprising a damp-proof course as described herein. The present disclosure may provide a cavity wall having a damp-proof course as described herein, or a cavity tray as described herein.
[0046] In some embodiments, aspects and embodiments of the present disclosure may provide a cavity tray with one or more of the following features: water and damp resistant, flexible, easy to install, high puncture resistance, reinforced product, and available in rolls or discreet pieces.
[0047] In some embodiments, damp proof courses or DPCs may be inserted into the wall structure to stop the movement of moisture from rising up the wall or moving from one part of the structure to another (often seen 150 mm above external ground level). When used in wider widths, the DPC is draped across the cavity stepping up a minimum of 150 mm from the outer to the inner leaf over a lintel. The DPC may include a cavity tray. The cavity tray may have a wider width of DPC; 450 mm and above, for example. Any rainwater seeping through the outer leaf of the wall and trickling down the cavity face of the outer leaf is collected by the cavity tray and diverted toward weepholes in the outer leaf.
[0048] When used above a window or doorway it may be referred to as a discontinuous cavity tray extending at least to the ends of the lintel. Rainwater is blocked from running off the ends of the tray by creating stop ends with the DPC material itself by turning it up the full height of the outer leaf perpend (vertical joint in the masonry) or using preformed stop ends units. The DPC and/or cavity tray continually bridges the cavity e.g. fire stops or brickwork support angles. The tray is continuous and runs right the way around the building. When it reaches comers preformed corner units may be used which match the profile of the cavity tray and structures of the building. The cavity tray profiles are built into the inner leaf. If the inner leaf is a structural framing system, the cavity tray would be surface fixed to the inner leaf. The cavity tray may be partially embedded into the inner leaf.
[0049] In some embodiments, a system includes the DPC, the preformed cavity tray(s), mastic sealant, joint support(s), and fixing strip(s). The DPC may be rolled due to its flexibility and may include one of the following, non-limiting heights: 450 mm, 500 mm, 600 mm, 700 mm, 800 mm & 900 mm.
[0050] In some embodiments, the mastic sealant 52 may be contained within a cartridge. Other damp-proof courses may require overlap of at least 900 mm at adjoining ends of neighboring damp-proof courses. Sealant is placed between the two courses at the overlap in such embodiments. The illustrative embodiment of the present disclosure does not require as large of an overlap because the adjoining ends may be mechanically interlocked, thereby maximizing the effective length of each multi-layer sheet 20. Additionally, sealant may not be needed at the mechanically interlocked joints.
[0051] In some embodiments, the cavity tray comers are formed to match a contour of the building. In this way, each cavity tray comer may include a series of steps or slopped surfaces along its height. The cavity tray comers may be formed from a metal such as stainless steel or another suitable material.
[0052] In some embodiments, the joint supports are arrange to lie beneath overlapping ends of DPC and/or beneath ends of DPC and a cavity tray. Each joint support may include a metal material such as stainless steel or another suitable material. A lower flange of the joint supports may be formed to include an aperture. Masonry material used to join external wall building materials (i.e. bricks) can flow through the aperture to bind the joint supports to the building. Each joint support can be shaped to match surfaces or structures of the building.
[0053] In some embodiments, the fixing strip(s) are an elongated strip that extends along an upper end of the DPC. Each fixing strip(s) is formed to include apertures that receive fasteners to secure the DPC and the joint support to the inner leaf. The fixing strip(s) may be made from a metal material such as stainless steel or any other suitable material.
[0054] Non combustibility tests:
[0055] Embodiments may be designed to achieve an Al or A2 non-combustibility classification accordingly to BS EN13501-1 (Fire Test to Building Material). There are multiple tests to measure combustibility properties of a product, which are described in the table of Fig. 3. Some embodiments of the present disclosure meet A2, si (smoke propagation), and dO (flaming droplets and particles) requirements according to BS EN13501-1 at the time of filing this application.
[0056] Test 1: EN ISO 1716:2018 Bomb calorimetry test
[0057] Sample is fully combusted in a sealed container and internal energy change is measured. This is a test for all the components in the product. The fiber used for some embodiments, which may be the significant component in the construction, passed Al classification.
[0058] Test 2: BS EN 13823:2010 Single burning item
[0059] Product constructed in situ and allowed to burn for a defined duration. Gas burner at 30kW directly on the sample for 21 minutes. Combustion gases are collected to determine smoke growth rate and total smoke production for a 10 minute duration.
[0060] To pass A2 requirements, the smoke growth rate should be less than 30 m2/s2 and total smoke production should be less than 50 m2.
[0061] The following numbered clauses include embodiments that are contemplated and non-limiting: [0062] Clause 1. A method of installing a moisture barrier on a building having an interior wall structure and an exterior wall structure spaced apart from the interior wall structure to define a cavity there between.
[0063] Clause 2. The method of clause 1, any other suitable clause, or any suitable combination of clauses, including applying a bead of mastic to an exterior-facing surface of the interior wall in a line extending horizontally at least partially around the interior wall of the building.
[0064] Clause 3. The method of clause 2, any other suitable clause, or any suitable combination of clauses, including providing a multi-layer barrier sheet.
[0065] Clause 4. The method of clause 3, any other suitable clause, or any suitable combination of clauses, including applying an upper section of the multi-layer barrier sheet to the exterior-facing surface of the interior wall over the bead of mastic. [0066] Clause 5. The method of clause 4, any other suitable clause, or any suitable combination of clauses, including deforming the upper section of the multi-layer barrier sheet such that the upper section of the multi-layer barrier sheet lies parallel with the exterior-facing surface of the interior wall and a middle section of the multi-layer barrier sheet extends at a downward-sloping angle toward the outer wall.
[0067] Clause 6. The method of clause 5, any other suitable clause, or any suitable combination of clauses, including applying a lower section of the multi-layer barrier sheet to the exterior wall.
[0068] Clause 7. The method of clause 6, any other suitable clause, or any suitable combination of clauses, including deforming the lower section of the multi-layer barrier sheet such that the lower section of the multi-layer barrier sheet extends away from the interior wall and is arranged substantially perpendicular to the upper section of the multi-layer barrier sheet.
[0069] Clause 8. The method of clause 7, any other suitable clause, or any suitable combination of clauses, wherein the upper section and the lower section of the multi-layer barrier sheet are self-supported in deformed positions after deforming the upper section and the lower section of the multi-layer barrier sheet. [0070] Clause 9. The method of clause 8, any other suitable clause, or any suitable combination of clauses, wherein a second multi-layer barrier sheet is sealed, adhered, or deformed by mechanically interlocking opposing longitudinal ends of each sheet with the first barrier sheet.
[0071] Clause 10. The method of clause 9, any other suitable clause, or any suitable combination of clauses, wherein the opposing ends of the multi-layer barrier sheets are self-supported in deformed positions.
[0072] Clause 11. The method of clause 8, any other suitable clause, or any suitable combination of clauses, wherein the multi-layer barrier sheet includes a metallic reinforcement mesh and a polymer encapsulating the metallic reinforcement mesh.
[0073] Clause 12. The method of clause 11, any other suitable clause, or any suitable combination of clauses, wherein the metallic reinforcement mesh is a metallic mesh having a plurality of wire strands that define a plurality of voids between each strand.
[0074] Clause 13. The method of clause 12, any other suitable clause, or any suitable combination of clauses, wherein the polymer extends through the plurality of voids to locate the polymer on both sides of the metallic mesh such that the multi-layer barrier sheet includes a first layer comprising the metallic mesh and a second layer comprising the polymer that penetrates through the plurality of voids in the metallic mesh.
[0075] Clause 14. The method of clause 13, any other suitable clause, or any suitable combination of clauses, wherein the polymer includes silicone.
[0076] Clause 15. The method of clause 13, any other suitable clause, or any suitable combination of clauses, wherein the polymer includes polyurethane.
[0077] Clause 16. The method of clause 13, any other suitable clause, or any suitable combination of clauses, wherein the polymer includes a thermoplastic.
[0078] Clause 17. The method of clause 13, any other suitable clause, or any suitable combination of clauses, wherein the polymer includes rubber. [0079] Clause 18. The method of clause 17, any other suitable clause, or any suitable combination of clauses, wherein the polymer includes thermoplastic or thermoset synthetic rubber.
[0080] Clause 19. The method of clause 13, any other suitable clause, or any suitable combination of clauses, wherein the metallic mesh includes a mesh screen.
[0081] Clause 20. The method of clause 13, any other suitable clause, or any suitable combination of clauses, wherein the metallic mesh includes a perforated mesh.
[0082] Clause 21. The method of clause 13, any other suitable clause, or any suitable combination of clauses, wherein the metallic mesh includes a woven wire mesh. [0083] Clause 22. The method of clause 13, any other suitable clause, or any suitable combination of clauses, wherein the metallic mesh includes a metal lattice screen.
[0084] Clause 23. The method of clause 8, any other suitable clause, or any suitable combination of clauses, wherein applying the upper section of the multi-layer barrier sheet and applying the lower section of the multi-layer barrier sheet is performed on a wall section of the building and the method further comprises applying the upper section and lower section of the multi-layer barrier sheet to a disruption of the building. [0085] Clause 24. The method of clause 23, any other suitable clause, or any suitable combination of clauses, wherein applying the upper and lower sections of the multi-layer barrier sheet to the disruption includes deforming at least one of the upper section and the lower section to form a deformed position around the disruption and wherein the multi-layer barrier sheet is self- supported in the deformed position.
[0086] Clause 25. A multi-layer sheet for a moisture barrier adapted to be installed on a building having an interior wall structure and an exterior wall structure spaced apart from the interior wall structure to define a cavity there between.
[0087] Clause 26. The multi-layer sheet of clause 25, any other suitable clause, or any suitable combination of clauses, including a metallic reinforcement mesh. [0088] Clause 27. The multi-layer sheet of clause 26, any other suitable clause, or any suitable combination of clauses, including an outer polymeric layer encapsulating the metallic reinforcement mesh.
[0089] Clause 28. The multi-layer sheet of clause 27, any other suitable clause, or any suitable combination of clauses, wherein the metallic reinforcement mesh is formed to include a plurality of voids and the polymer extends through the plurality of voids to physically bond the outer polymer layer on both sides of the metallic mesh.
[0090] Clause 29. The multi-layer sheet of clause 28, any other suitable clause, or any suitable combination of clauses, wherein the metallic reinforcement mesh is configured to retain the outer polymeric layer in a deformed position as the multi-layer sheet is installed on the interior wall structure and the exterior wall structure.
[0091] Clause 30. The multi-layer sheet of clause 29, any other suitable clause, or any suitable combination of clauses, wherein the metallic reinforcement mesh includes a mesh screen and the outer polymeric layer includes silicone.

Claims

1. A method of installing a moisture barrier on a building having an interior wall structure and an exterior wall structure spaced apart from the interior wall structure to define a cavity there between, the method comprising: applying a bead of mastic to an exterior-facing surface of the interior wall in a line extending horizontally at least partially around the interior wall of the building, providing a multi-layer barrier sheet, applying an upper section of the multi-layer barrier sheet to the exteriorfacing surface of the interior wall over the bead of mastic, deforming the upper section of the multi-layer barrier sheet such that the upper section of the multi-layer barrier sheet lies parallel with the exterior-facing surface of the interior wall and a middle section of the multi-layer barrier sheet extends at a downward- sloping angle toward the outer wall, applying a lower section of the multi-layer barrier sheet to the exterior wall, deforming the lower section of the multi-layer barrier sheet such that the lower section of the multi-layer barrier sheet extends away from the interior wall and is arranged substantially perpendicular to the upper section of the multi-layer barrier sheet, wherein the upper section and the lower section of the multi-layer barrier sheet are self- supported in deformed positions after deforming the upper section and the lower section of the multi-layer barrier sheet.
2. The method of claim 1, further comprising a second multi-layer barrier sheet which is sealed, adhered, or deformed by mechanically interlocking opposing longitudinal ends of each sheet with the first barrier sheet.
3. The method of claim 2, wherein the opposing ends of the multilayer barrier sheets are self- supported in deformed positions.
4. The method of claim 1, wherein the multi-layer barrier sheet includes a metallic reinforcement mesh and a polymer encapsulating the metallic reinforcement mesh.
5. The method of claim 4, wherein the metallic reinforcement mesh is a metallic mesh having a plurality of wire strands that define a plurality of voids between each strand.
6. The method of claim 5, wherein the polymer extends through the plurality of voids to locate the polymer on both sides of the metallic mesh such that the multi-layer barrier sheet includes a first layer comprising the metallic mesh and a second layer comprising the polymer that penetrates through the plurality of voids in the metallic mesh.
7. The method of claim 6, wherein the polymer includes silicone.
8. The method of claim 6, wherein the polymer includes polyurethane.
9. The method of claim 6, wherein the polymer includes a thermoplastic.
10. The method of claim 6, wherein the polymer includes rubber.
11. The method of claim 10, wherein the polymer includes thermoplastic or thermoset synthetic rubber.
12. The method of claim 6, wherein the metallic mesh includes a mesh screen.
13. The method of claim 6, wherein the metallic mesh includes a perforated mesh.
14. The method of claim 6, wherein the metallic mesh includes a woven wire mesh.
15. The method of claim 6, wherein the metallic mesh includes a metal lattice screen.
16. The method of claim 1, wherein applying the upper section of the multi-layer barrier sheet and applying the lower section of the multi-layer barrier sheet is performed on a wall section of the building and the method further comprises applying the upper section and lower section of the multi-layer barrier sheet to a disruption of the building.
17. The method of claim 16, wherein applying the upper and lower sections of the multi-layer barrier sheet to the disruption includes deforming at least one of the upper section and the lower section to form a deformed position around the disruption and wherein the multi-layer barrier sheet is self-supported in the deformed position.
18. A multi-layer sheet for a moisture barrier adapted to be installed on a building having an interior wall structure and an exterior wall structure spaced apart from the interior wall structure to define a cavity there between, the multi-layer sheet comprising: a metallic reinforcement mesh and an outer polymeric layer encapsulating the metallic reinforcement mesh, wherein the metallic reinforcement mesh is formed to include a plurality of voids and the polymer extends through the plurality of voids to physically bond the outer polymer layer on both sides of the metallic mesh.
19. The multi-layer sheet of claim 18, wherein the metallic reinforcement mesh is configured to retain the outer polymeric layer in a deformed position as the multi-layer sheet is installed on the interior wall structure and the exterior wall structure.
20. The multi-layer sheet of claim 19, wherein the metallic reinforcement mesh includes a mesh screen and the outer polymeric layer includes silicone.
PCT/US2022/053367 2021-12-20 2022-12-19 Reinforced moisture barrier WO2023122019A1 (en)

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US202163291636P 2021-12-20 2021-12-20
US63/291,636 2021-12-20

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070054086A1 (en) * 2005-09-02 2007-03-08 Stephanie Pagel Weatherable corrosion-resistant flashing
US20070186501A1 (en) * 2006-02-10 2007-08-16 Peter Kuelker Hangerless precast cladding panel system
US20100287862A1 (en) * 2009-05-18 2010-11-18 Moisture Management, Llc Exterior wall assembly including dynamic moisture removal feature
WO2021084047A1 (en) * 2019-10-30 2021-05-06 Acs Stainless Steel Fixings Limited Cavity tray system with jointing structures
US20210189718A1 (en) * 2018-03-12 2021-06-24 Scott W. Sander Method and apparatus for sealing grout space

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20070054086A1 (en) * 2005-09-02 2007-03-08 Stephanie Pagel Weatherable corrosion-resistant flashing
US20070186501A1 (en) * 2006-02-10 2007-08-16 Peter Kuelker Hangerless precast cladding panel system
US20100287862A1 (en) * 2009-05-18 2010-11-18 Moisture Management, Llc Exterior wall assembly including dynamic moisture removal feature
US20210189718A1 (en) * 2018-03-12 2021-06-24 Scott W. Sander Method and apparatus for sealing grout space
WO2021084047A1 (en) * 2019-10-30 2021-05-06 Acs Stainless Steel Fixings Limited Cavity tray system with jointing structures

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