Masonry insulated board with integral drainage

• US 5,860,259 A
• Filed: 07/17/1997
• Issued: 01/19/1999
• Est. Priority Date: 05/15/1995
• Status: Expired due to Term

• Current Assignee: Walter A. Laska
• Original Assignee: Walter A. Laska
• Inventors: Laska, Walter A.
• Primary Examiner(s): Aubrey, Beth
• Application Number:
  US08/895,646
• Time in Patent Office: 551 Days
• Field of Search: 52/169.5, 52/302.3
• US Class Current: 52/302.3
• CPC Class Codes: E04B 1/7612 in combination with an air space
• CPC Class Codes: E04B 1/7675 Insulating linings for the interior face of exterior walls
• CPC Class Codes: E04C 2/326 with corrugations, incisions or reliefs in more than one direction of the element

Abstract

An insulated drainage panel for use in cavity wall or veneer wall construction. The insulated panel includes a generally planar insulating board; and a porous structure disposed on one side of the board.

Claims

1. A laminated insulated drainage panel, for installation between a backing wall and an exterior masonry wall of a masonry drainage wall system, the panel comprising:

a generally planar insulating layer; and

a porous layer disposed on one side of the insulating layer;

the panel having mitered edges;

wherein the panel may be installed in the wall system with the insulating layer adjacent the backing wall, and with the porous layer between the insulating layer and the exterior masonry wall for providing a vertical drainage path within the drainage wall system.

2. The insulated panel as in claim 1 wherein the porous layer further comprises a waffle structure.

3. The insulated panel as in claim 1 wherein the porous layer is further comprised of a woven mesh of high density polyethylene strands.

4. The insulated panel as in claim 1 wherein the porous layer is further comprised of one of the group including high density polyethylene, cellulose acetate, polyester, nylon and polyethylene terephthalate.

5. The insulated panel as in claim 1 wherein the porous layer is further comprised of a cross-hatched pattern of slots formed in a surface of the generally planar insulating layer.

6. The insulated panel as in claim 1 further comprising a woven porous material, corrosion resistant screen or mesh cloth disposed over the porous layer.

7. The insulated panel as in claim 1 wherein the insulating layer further comprises polystyrene.

8. The insulated panel as in claim 1 wherein the insulating board further comprises polyisosyanurate.

9. The insulating panel as in claim 1 further comprising a strip of the porous layer disposed along an edge of the laminated drainage panel.

10. An above-ground drainage wall system comprising:

an outer masonry wythe;

an interior back-up system separated from the outer wythe by an air space or cavity; and

an insulated drainage panel disposed substantially throughout the air space between the interior back-up system and the outer wythe for excluding mortar from entering the space between the interior back-up system and the outer wythe during construction of the drainage wall system and for providing a continuous vertical drainage path after construction;

wherein the insulated drainage panel comprises a plurality of insulated drainage boards, each board having horizontal and vertical edges, the edges of adjacent boards aligned so that the panel is disposed substantially throughout the air space; and

wherein the horizontal adjacent edges of the boards are beveled sloping towards the outer wythe.

11. The wall system as in claim 10 wherein the drainage panel further comprises polyethylene matting.

12. The wall system as in claim 10 further comprising a woven cloth disposed between the drainage panel and the outer wythe of masonry.

13. The wall system as in claim 10 wherein the insulated drainage panel further comprises:

a planar sheet of insulation with a first side of the planar sheet of insulation disposed adjacent the interior back-up system; and

a planar drain section disposed adjacent the outer wythe on a second side of the planar sheet of insulation.

14. The wall system as in claim 10 wherein each of the boards further comprises:

a planar sheet of insulation with a first side of the planar sheet of insulation disposed adjacent the interior back-up system; and

a planar drain section disposed adjacent the outer wythe on a second side of the planar sheet of insulation; and

wherein the panel further comprises a layer of the planar drain section disposed between the horizontal adjacent edges of the boards.

15. The wall system as in claim 10 wherein the vertical adjacent edges of the boards are beveled.

16. In a masonry drainage wall system including a backing wall, an exterior masonry wall, and a cavity formed between the backing wall and the exterior masonry wall, the improvement comprising:

a laminated insulated drainage panel, with a generally planar insulating layer and a porous layer disposed on one side of the insulating layer, wherein the panel may be installed in the cavity with the insulating layer adjacent the backing wall, and with the porous layer between the insulating layer and the exterior masonry wall for providing a vertical drainage path within the drainage wall system;

wherein the insulated drainage panel comprises a plurality of insulated drainage boards, each board having horizontal and vertical edges, the edges of adjacent boards aligned so that the panel is disposed substantially throughout the cavity; and

wherein the adjacent edges of the boards are beveled and the horizontal edges slope down towards the exterior masonry wall.