DRAINAGE CHANNEL FOR USE IN A BUILDING WALL

• US 20190309509A1
• Filed: 04/10/2019
• Published: 10/10/2019
• Est. Priority Date: 04/10/2018
• Status: Active Grant

• Current Assignee: Innovation Calumet LLC
• Original Assignee: Innovation Calumet LLC
• Inventors: Johnson, Gary R.
• Granted Patent: US 10,745,911 B2
• Time in Patent Office: Days
• CPC Class Codes: E04B 1/7046 using trays
• CPC Class Codes: E04B 1/7604 fillings for cavity walls
• CPC Class Codes: E04C 2/46 specially adapted for making walls E04C2/52, E04C2/54 take precedence; structure of slab-shaped elements E04B1/02; walls of elements of relatively thin form E04B2/72
• CPC Class Codes: E04F 13/06 Edge-protecting borders borders for joints between plaster layers and window or door frames or like E06B1/62
• CPC Class Codes: E04F 2013/065 for lower edges of outer insulation layers

Abstract

The disclosure provides example drainage channels, drainage systems, building walls and methods. An example drainage channel includes a drainage panel for conveying water within a building wall. The drainage panel is impermeable and has a first end and a second end. A support panel is coupled to the first end or the second end of the drainage panel such that the support panel is configured to be arranged vertically relative to the building wall. The drainage panel is configured to be arranged either perpendicular to an exterior sheathing of the building wall or angled downward from the first end of the drainage panel toward both the second end of the drainage panel and the exterior sheathing of the building wall.

Claims

1. A drainage channel comprising:

a drainage panel for conveying water within a building wall, wherein the drainage panel is impermeable and comprises a first end and a second end; and

a support panel coupled to the first end or the second end of the drainage panel such that the support panel is configured to be arranged vertically relative to the building wall, wherein the drainage panel is configured to be arranged either perpendicular to an exterior sheathing of the building wall or angled downward from the first end of the drainage panel toward both the second end of the drainage panel and the exterior sheathing of the building wall.

2. The drainage channel of claim 1, wherein the drainage panel is configured to be positioned horizontally within the building wall such that the first end of the drainage panel is positioned outboard of the second end of the drainage panel relative to an exterior sheathing of the building wall, wherein the support panel is a rear panel coupled to the second end of the drainage panel, and wherein the rear panel is configured to be fastened to the exterior sheathing of the building wall and inboard of an insulating material of the building wall.

3. The drainage channel of claim 1, wherein the drainage panel is configured to be positioned horizontally within the building wall such that the first end of the drainage panel is positioned outboard of the second end of the drainage panel, wherein the support panel is a front panel coupled to the first end of the drainage panel, and wherein the front panel is configured to be fastened to a lath member of the building wall, outboard of an insulating material of the building wall.

4. The drainage channel of claim 1, wherein the drainage panel is angled downward from the first end of the drainage panel toward both the second end of the drainage panel and the exterior sheathing of the building wall.

5. The drainage channel of claim 1, wherein the support panel comprises a rear panel, the drainage channel further comprising:

the rear panel having a top end and a bottom end;

an intermediate panel having a top end and a bottom end, wherein the intermediate panel is parallel to the rear panel;

a bottom panel connecting the bottom end of the rear panel to the bottom end of the intermediate panel and forming a drainage well between the rear panel and the intermediate panel;

a front panel having a top end and a bottom end, wherein the front panel is parallel to the rear panel; and

wherein the drainage panel couples the bottom end of the front panel to the top end of the intermediate panel.

6. The drainage channel of claim 5, wherein the bottom panel comprises a plurality of apertures configured to drain water therethrough.

7. The drainage channel of claim 2, wherein the rear panel comprises a plurality of apertures for receiving a fastener therethrough.

8. The drainage channel of claim 3, wherein the front panel comprises a plurality of apertures for coupling the front panel of the drainage channel with a lath member of the building wall.

9. The drainage channel of claim 5, further comprising:

a shelf extending from and arranged perpendicular to either a front face of the intermediate panel or a front face of the rear panel.

10. The drainage channel of claim 9, wherein the shelf comprises a plurality of apertures therethrough for coupling the shelf with a second flange of a corner bead.

11. The drainage channel of claim 1, further comprising one or more lines scored along a longitudinal length of the drainage panel, wherein a respective portion of the drainage panel is foldable about each of the scored lines to position the respective portion of the drainage panel parallel to the rear panel, and wherein the front panel is foldable about a connection of the front panel and the drainage panel to position the front panel substantially coplanar with the respective portion of the drainage panel.

12. The drainage channel of claim 11, wherein each of the one or more scored lines comprises a respective longitudinal notch defined in a top surface of the drainage panel.

13. The drainage channel of claim 11, wherein each of the one or more scored lines comprises a respective longitudinal notch defined in a bottom surface of the drainage panel.

14. The drainage channel of claim 1, wherein the drainage panel has a width extending from the first end of the drainage panel to the second end of the drainage panel of at least 1 inch.

15. The drainage channel of claim 5, wherein the rear panel has a height extending from the top end to the bottom end of the rear panel, wherein the intermediate panel has a height extending from the top end to the bottom end of the intermediate panel, wherein the front panel has a height extending from the top end to the bottom end of the front panel, and wherein the height of the rear panel is greater than a combined height of the intermediate panel and the front panel.

16. The drainage channel of claim 1, wherein the drainage panel and the support panel are formed from at least one of a polymer-based material, a metal material, a metal alloy material, or a composite material.

17. The drainage channel of claim 1, wherein the drainage channel is integrally formed as a single component.

18. The drainage channel of claim 5, wherein the drainage channel is formed from at least a first drainage channel component comprising the rear panel and the bottom panel, and a second drainage channel component comprising the front panel and the drainage panel, and wherein the intermediate panel includes a first intermediate panel of the first drainage channel component positioned adjacent to a second intermediate panel of the second drainage channel component.

19. The drainage channel of claim 18, wherein a rear face of the first intermediate panel is positioned adjacent to a front face of the second intermediate panel, such that the first drainage channel component forms a front face of the intermediate panel, and wherein the second intermediate panel forms a rear face of the intermediate panel.

20. A drainage system for attachment to an exterior sheathing of a panel structure, the drainage system comprising:

a weather resistive barrier coupled to the exterior sheathing, wherein the weather resistive barrier forms a secondary drainage plane of the drainage system;

an insulating material coupled to the exterior sheathing, wherein the insulating material is positioned outboard of and adjacent to the weather resistive barrier;

a water channel material coupled to the exterior sheathing, wherein the water channel material is positioned outboard of and adjacent to the insulating material, and wherein the water channel material forms a primary drainage plane of the drainage system;

a lath member coupled to the exterior sheathing, wherein the lath member is positioned outboard of and adjacent to the water channel material; and

the drainage channel according to claim 1, wherein the first end of the drainage panel is positioned outboard of the water channel material such that any water from the primary drainage plane is directed inboard toward the weather resistive barrier.

21. The drainage system of claim 20, wherein a rear panel is coupled to the exterior sheathing and inboard of a portion of the weather resistive barrier such that any water in the secondary drainage plane is directed to a drainage well of the drainage channel, and wherein a front panel is positioned outboard of the water channel material such that any water in the primary drainage plane is directed to the drainage well via the drainage panel.

22. The drainage system of claim 20, wherein the drainage system is coupled to the exterior sheathing via a plurality of fasteners, each fastener in the plurality of fasteners extending through the lath member, the water channel material, the insulating material, and the weather resistive barrier.

23. The drainage system of claim 20, wherein the lath member is positioned outboard of the front panel, and wherein the lath member is coupled to the front panel by one or more fasteners via a plurality of apertures in the front panel.

24. The drainage system of claim 20, wherein the insulating material comprises a front side and a back side defining a thickness therebetween, and wherein the thickness of the insulating material is a least 1 inch.

25. A building wall comprising:

an exterior sheathing;

the drainage system according to claim 20 coupled to the exterior sheathing via a plurality of fasteners;

a corner bead comprising a first flange and a second flange, wherein the first flange is coupled to the lath member, and wherein the second flange is positioned adjacent to a bottom surface of the drainage panel and perpendicular to the first flange; and

a cementitious material applied to the lath member and the corner bead.

26. The building wall of claim 25, wherein an end of the second flange of the corner bead is positioned atop a shelf of the drainage channel.

27. The building wall of claim 26, wherein the end of the second flange is coupled to the shelf via the plurality of apertures in the shelf.

28. A method of installing a drainage channel within a building wall, the method comprising:

positioning the drainage system according to claim 20 such that a rear panel is positioned inboard of a portion of the weather resistive barrier, such that water in the secondary drainage plane is directed to the drainage well, and wherein the front panel is positioned outboard of the water channel material, such that any water in the primary drainage plane is directed to the drainage well via the drainage panel; and

coupling the rear panel of the drainage channel to the exterior sheathing via a plurality of fasteners.

29. The method of claim 28, further comprising:

coupling the lath member to a front panel of the drainage channel.

30. The method of claim 29, wherein coupling the lath member to the front panel of the drainage channel comprises wiring the lath member, via a plurality of openings in the lath member, to the front panel of the drainage channel via the plurality of apertures in the front panel.

31. The method of claim 28, further comprising:

folding a respective portion of the drainage panel about one of the scored lines of the drainage panel to position the respective portion of the drainage panel parallel to the rear panel; and

folding the front panel about the connection of the front panel and the drainage panel to position the front panel coplanar with the respective portion of the drainage panel.

32. The method of claim 28, further comprising:

fastening a first flange of a corner bead to the lath member; and

positioning a second flange of the corner bead adjacent to a bottom surface of the drainage panel and perpendicular to the first flange.

33. The method of claim 32, further comprising:

positioning an end of the second flange of the corner bead atop the shelf of the drainage channel.

34. The method of claim 33, further comprising:

fastening the second flange of the corner bead to the shelf via the plurality of apertures in the shelf.

35. The method of claim 34, wherein fastening the second flange of the corner bead to the shelf comprises wiring the second flange of the corner bead, via a plurality of openings in the second flange of the corner bead, to the shelf via the plurality of apertures in the shelf.

36. The method of claim 28, further comprising:

applying a cementitious material to the lath member and the corner bead.