Protective drainage wraps

• US 20060211321A1
• Filed: 03/03/2006
• Published: 09/21/2006
• Est. Priority Date: 02/20/2001
• Status: Active Grant

• Current Assignee: Kingspan Insulation LLC (Kingspan Group PLC)
• Original Assignee: Kingspan Insulation LLC (Kingspan Group PLC)
• Inventors: Lubker, John W. II
• Granted Patent: US 9,656,445 B2
• Time in Patent Office: Days
• US Class Current: 442/208
• CPC Class Codes: B32B 21/10 Next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2307/7246 Water vapor barrier
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 27/02 in the form of fibres or filaments not used
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 5/02 characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: D03D 15/283 synthetic polymer-based, e.g. polyamide or polyester fibres cellulose-based artificial fibres D03D15/225
• CPC Class Codes: D03D 15/46 Flat yarns, e.g. tapes or films
• CPC Class Codes: D03D 9/00 Open-work fabrics
• CPC Class Codes: D06N 2209/103 Resistant to mechanical forces, e.g. shock, impact, puncture, flexion, shear, compression, tear
• CPC Class Codes: D06N 2209/123 Breathable
• CPC Class Codes: D06N 3/045 with polyolefin or polystyrene (co-)polymers
• CPC Class Codes: D06N 3/123 with polyesters
• CPC Class Codes: D06N 3/125 with polyamides
• CPC Class Codes: D06N 3/14 with polyurethanes
• CPC Class Codes: D10B 2321/02 polyolefins
• CPC Class Codes: D10B 2321/021 polyethylene
• CPC Class Codes: D10B 2321/022 : polypropylene
• CPC Class Codes: D10B 2331/02 : polyamides D10B2331/08 takes precedence
• CPC Class Codes: D10B 2331/04 : polyesters, e.g. polyethylene terephthalate [PET]
• CPC Class Codes: D10B 2505/20 : for civil engineering, e.g. geotextiles
• CPC Class Codes: E04B 1/625 : Sheets or foils allowing passage of water vapor but impervious to liquid water; house wraps
• CPC Class Codes: E04B 1/70 : Drying or keeping dry, e.g. by air vents using damp-proof courses E04B1/644; using sealings, e.g. sealing masses or foils, E04B1/66; during erection E04G21/28
• CPC Class Codes: E04B 2/707 : obturation by means of panels
• CPC Class Codes: E04D 12/002 : Sheets of flexible material, e.g. roofing tile underlay
• CPC Class Codes: E04F 13/0864 : composed of superposed elements which overlap each other and of which the flat outer surface includes an acute angle with the surface to cover
• CPC Class Codes: Y10T 442/322 : Warp differs from weft

Abstract

A protective drainage wrap comprises a cross-woven material portion, cross-laminate material portion or mesh material portion in first and second directions and a breathable solid layer portion. The material in the first and second directions comprises a polyolefin, polyester, nylon or combinations thereof. The first direction being roughly perpendicular to the second direction. The cross-woven, cross-laminate or mesh material portions being adapted to facilitate a drainage path. The breathable solid layer portion is attached to the cross-woven material portion, cross-laminate material portion or mesh material portion. The breathable solid layer portion is adapted to allow water vapor to flow therethrough.

Claims

1. A protective drainage wrap comprising:

a cross-woven material portion, cross-laminate material portion or mesh material portion in a first direction and in a second direction, the material in the first direction comprising a polyolefin, polyester, nylon or combinations thereof, the material in the second direction comprising a polyolefin, polyester, nylon or combinations thereof, the first direction being roughly perpendicular to the second direction, the cross-woven material portion, cross-laminate material portion or mesh material portion being adapted to facilitate a drainage path; and

a breathable solid layer portion being attached to the cross-woven material portion, cross-laminate material portion or mesh material portion, the breathable solid layer portion being adapted to allow water vapor to flow therethrough.

2. The protective wrap of claim 1 wherein the first direction material has a first thickness, the second direction material having a second thickness, the second thickness being at least about 2 times greater than the first thickness so as to assist in providing drainage for moisture build-up.

3. The protective wrap of claim 2 wherein the second thickness is at least about 4 times greater than the first thickness.

4. The protective wrap of claim 1 wherein the protective wrap includes the cross-woven material portion.

5. The protective wrap of claim 1 wherein the protective wrap includes the cross-laminate material portion.

6. The protective wrap of claim 1 wherein the protective wrap includes the mesh material portion.

7. The protective wrap of claim 1 wherein the first direction is the machine direction material and the second direction is the transverse direction material.

8. The protective wrap of claim 1 wherein the first direction material and the second direction material independently comprise polypropylene, polyethylene or combinations thereof.

9. The protective wrap of claim 1 wherein the first direction material and the second direction material are the same.

10. The protective wrap of claim 1 wherein the first direction material and the second direction material are different.

11. The protective wrap of claim 1 wherein the first direction material comprises a rectangular tape and the second direction material comprises generally oval or generally circular filaments.

12. The protective wrap of claim 1 wherein the breathable solid layer portion is a breathable coating.

13. The protective wrap of claim 12 wherein the breathable coating is polyolefins, polyurethane or nylon.

14. The protective wrap of claim 12 wherein the breathable coating includes a polyolefin and a mineral or inorganic filler.

15. The protective wrap of claim 1 wherein the breathable solid layer portion is a breathable film.

16. The protective wrap of claim 15 wherein the breathable film includes polyolefins, polyurethanes and nylons.

17. The protective wrap of claim 15 wherein the breathable film includes a polyolefin and a mineral or inorganic filler.

18. A protective drainage wrap comprising:

a cross-woven material portion, cross-laminate material portion or mesh material portion in a first direction and in a second direction, the material in the first direction comprising a polyolefin, polyester, nylon, yarn or combinations thereof, the material in the second direction comprising a polyolefin, polyester, nylon, yarn or combinations thereof, the first direction being roughly perpendicular to the second direction, the cross-woven material portion, cross-laminate material portion or mesh material portion being adapted to facilitate a drainage path, at least one of the materials in the first direction and the second direction being yarn; and

a breathable solid layer portion being attached to the cross-woven material portion, cross-laminate material portion or mesh material portion, the breathable solid layer portion being adapted to allow water vapor to flow therethrough.

19. The protective wrap of claim 18 wherein the yarn is spun yarn, bulk continuous process yarn or natural yarn.

20. The protective wrap of claim 18 wherein the yarn comprises polypropylene, polyethylene or combinations thereof.

21. The protective wrap of claim 18 wherein the breathable solid layer portion is a breathable coating.

22. The protective wrap of claim 21 wherein the breathable coating is polyolefins, polyurethane or nylon.

23. The protective wrap of claim 21 wherein the breathable coating includes a polyolefin and a mineral or inorganic filler.

24. The protective wrap of claim 18 wherein the breathable solid layer portion is a breathable film.

25. The protective wrap of claim 24 wherein the breathable film includes polyolefins, polyurethanes and nylons.

26. The protective wrap of claim 24 wherein the breathable film includes a polyolefin and a mineral or inorganic filler.

27. A method of using a protective wrap in a building, the method comprising the acts of:

providing a protective wrap including a cross-woven material portion, cross-laminate material portion or mesh material portion in a first direction and in a second direction and a breathable solid layer portion, the material in the first direction comprising a polyolefin, polyester, nylon, yarn or combinations thereof, the material in the second direction comprising a polyolefin, polyester, nylon, yarn or combinations thereof, the first direction being roughly perpendicular to the second direction, the cross-woven material portion, cross-laminate material portion or mesh material portion being adapted to facilitate a drainage path, the breathable solid layer portion being attached to the cross-woven material portion, cross-laminate material portion or mesh material portion, the breathable solid layer portion being adapted to allow water vapor to flow therethrough;

providing at least one framing member; and

installing the protective wrap over at least one of the framing members.

28. The method of claim 27 further comprising providing an exterior covering selected from siding, brick, masonry, stucco or concrete veneer and installing the exterior covering over the protective wrap.

29. The method of claim 27 wherein the framing member is plywood or oriented-strand board.

30. The method of claim 27 further including providing a sheathing, the sheathing being located between the protective wrap and the framing members.

31. The method of claim 27 wherein the breathable solid layer portion is a breathable coating.

32. The method of claim 31 wherein the breathable coating includes a polyolefin and a mineral or inorganic filler.

33. The method of claim 27 wherein the breathable solid layer portion is a breathable film.

34. The method of claim 33 wherein the breathable film includes a polyolefin and a mineral or inorganic filler.

35. A method of using a protective wrap in a building, the method comprising the acts of:

providing a protective wrap including a cross-woven material portion, cross-laminate material portion or mesh material portion in a first direction and in a second direction and a breathable solid layer portion, the material in the first direction comprising a polyolefin, polyester, nylon, yarn or combinations thereof, the material in the second direction comprising a polyolefin, polyester, nylon, yarn or combinations thereof, the first direction being roughly perpendicular to the second direction, the cross-woven material portion, cross-laminate material portion or mesh material portion being adapted to facilitate a drainage path, the breathable solid layer portion being attached to the cross-woven material portion, cross-laminate material portion or mesh material portion, the breathable solid layer portion being adapted to allow water vapor to flow therethrough;

providing a sheathing; and

installing the protective wrap over the sheathing.

36. The method of claim 35 further comprising providing an exterior covering selected from siding, brick, masonry, stucco or concrete veneer and installing the exterior covering over the protective wrap.

37. The method of claim 35 wherein the breathable solid layer portion is a breathable coating.

38. The method of claim 37 wherein the breathable coating includes a polyolefin and a mineral or inorganic filler.

39. The method of claim 35 wherein the breathable solid layer portion is a breathable film.

40. The method of claim 39 wherein the breathable film includes a polyolefin and a mineral or inorganic filler.

41. A method of forming a protective drainage wrap, the method comprising the acts of:

providing a cross-woven material portion, cross-laminate material portion or mesh material portion in a first direction and in a second direction, the material in the first direction comprising a polyolefin, polyester, nylon, yarn or combinations thereof, the material in the second direction comprising a polyolefin, polyester, nylon, yarn or combinations thereof, the first direction being roughly perpendicular to the second direction, the cross-woven material portion, cross-laminate material portion or mesh material portion being adapted to facilitate a drainage path; and

applying a breathable solid layer portion to the cross-woven material portion, cross-laminate material portion or mesh material portion;

-the breathable solid layer portion being attached to the cross-woven material portion, cross-laminate material portion or mesh material portion, the breathable solid layer portion being adapted to allow water vapor to flow therethrough.

42. The method of claim 41 wherein the breathable solid portion is a breathable film.

43. The method of claim 42 wherein the breathable film is laminated to the cross-woven material portion, cross-laminate material portion or mesh material portion.

44. The method of claim 42 wherein the breathable film is stretched before being laminated to the cross-woven material portion, cross-laminate material portion or mesh material portion.

45. The method of claim 41, wherein the breathable solid layer portion is a breathable coating.

46. The method of claim 45 further including extruding material to form the breathable coating.

47. The method of claim 45 further including extruding material onto the cross-woven material portion, cross-laminate material portion or mesh material portion and further processing the extruded material and cross-woven material portion, cross-laminate material portion or mesh material portion to form a breathable coating.

48. The method of claim 47 wherein the further processing is stretching.

49. The method of claim 47 wherein the breathable coating comprises a polyolefin and a mineral or inorganic filler.

50. The method of claim 41, wherein the breathable solid layer portion is applied to the cross-woven material portion, cross-laminate material portion or mesh material portion using an adhesive.

51. The method of claim 41, wherein the breathable solid portion is applied to the cross-woven material portion, cross-laminate material portion or mesh material portion by thermobonding.