BACKGROUND 1. Field of the Invention
The exemplary embodiment described herein relates to foundation wall systems and particularly to a novel and efficient system for closing foundation walls and wall blocks and preventing the entry of outside air and undesired gases into interiors of buildings such as homes.
2. Brief Description of Related Developments
Many buildings and homes are supported on foundation systems, with foundation walls, that for example may define basements, crawlspaces or other such partially subterranean chambers, made of open hollow core concrete blocks. FIG. 1 shows one example of a conventional foundation system of hollow core block construction. As will be described further below, in many cases the crawlspace or basement formed by the building foundation system, extends at least partially down to a level below the level of the surrounding soil. Accordingly, the foundation walls extend down below the level of the surrounding soil, and possibly below the level of saturated soils in wet weather. The hollow core concrete blocks are porous so that water vapor may enter into and is absorbed up through the concrete blocks of the crawlspace or basement walls, from adjacent ground areas of higher elevation and up from the sub-soil. FIG. 1 illustrates a conventional foundation system FDN for a building (either commercial or residential which is not shown in FIG. 1 for clarity). The conventional foundation system FDN may have footings FT, extending for example around a periphery of the foundation system to distribute the building loads to the supporting soil. As seen in FIG. 1, the footings FT may be positioned well below the ground surface of the surrounding soil S, and as noted before for example, below the level of saturated soil in wet weather (this ensures that footings rest on stable undersoil). As seen in FIG. 1, the foundation system FDN may have walls W that carry and distribute the building loads onto the footings FT. In this example a sill plate SP located well above the ground surface to avoid the deleterious effects from being in contact with the ground and which may form an interface between the building structure (not shown) and foundation system FDN, is shown seated on the foundation walls. The foundation walls W hence, may extend through surrounding soil that is saturated with moisture in wet weather. As may be realized, the foundation walls W may form a basement or crawlspace B for the building. Many earlier construction techniques employed open hollow core blocks HB in erecting foundation walls as shown in FIG. 1. In conventional systems, a solid cap block may be used as a top course to cap the open cores of the open core blocks of the foundation wall W, to prevent moisture and outside air from the exterior E of the building/foundation system from entering the basement/crawlspace through the sill plate foundation interface. This nevertheless is not enough to prevent uncontrolled entry of water vapor (as noted above), along with possibly radon gas, and outside air (e.g. hot humid air in the summer, cold air in the winter) through the foundation. FIG. 1 shows the infiltration routes IR (in phantom) for some of these undesired vapors and gases from the exterior air E or soil S through the conventional foundation system into the basement/crawlspace B. The openings of open hollow cores HC of the wall blocks HB (which as may be realized from FIG. 1 are oriented vertically) extend inwards from and remain uncovered, at least in part, by the sill plate SP. Also, the openings of the hollow cores of stacked blocks HB may overlap to form substantially vertical channels or passages extending in the foundation wall. The porous nature of the foundation blocks HB allows the water vapor or radon gas (from soil S, see FIG. 1) and undesired unconditioned outside air (cold in winter, hot in summer; from exterior E) to infiltrate through the block walls into the open hollow cores and from there flow into the basement/crawlspace B. By way of example, buildings have low air pressure in the basements and crawlspaces (lower levels) as air escapes the upper levels of structures as heat rises which then creates a suction on the ground, drawing make-up air in from places such as the open cores of the top of block foundation walls. The escape of dangerous radon gas from the ground into the crawlspace and into the building is highly undesired. The water or water vapor drawn into the basement/crawlspace penetrates the wooden structural members of the building, possibly causing wood rot, mold, odors, attraction of ants and other insects, rodents etc. Also, unconditioned air causes an energy penalty for the building and its occupants, as on entry it is either heated, or cooled and/or dehumidified by interior ambient air with converse effects on the ambient conditions inside the building ultimately compensated for with the building air conditioning systems that consume energy.
Mold spores exist in air and grow into destructive mold in the presence of organic material, such as moist wood. Humidity levels of from 50% to 90% are common in crawlspaces, even those that have never flooded. Mold can grow on dirt, insulation, wood framing and even under carpeting on the floor within the home. Mold digests and destroys organic materials as it feeds on them. Damp environments also provide an inviting environment for insects such as termites, ants and similar critters which feed on moist organic material such as structural support wood and can contribute to the destruction and collapse thereof.
In an effort to prevent the penetration of water vapors and other undesired air into building basement(s) and crawlspace(s), through the open cavities at the top of the block foundation wall, a number of conventional techniques have been employed. For example, such conventional techniques include inserting fiberglass insulation, injecting foam insulation, putting a 2×4 or 1×3 board on top of the wall alongside the 2×6 sill plate and trying to caulk it, or trying to slide a piece of metal flashing on top of the wall and caulking it. This is difficult as after the building is built with the joists just 1½″ above the top of the foundation wall making access to work difficult. Then there may be pipes and or wires on top of the wall making access more difficult.
The conventional techniques for preventing the entry of undesired vapors and air into basements crawlspaces through open hollow core block foundation walls have proven unsuccessful. The exemplary embodiments of the present invention disclosed herein overcome the problems of conventional systems as described further below.
SUMMARY OF THE EXEMPLARY EMBODIMENTS In accordance with one exemplary embodiment of the present invention a wall sealing system for sealing a foundation against infiltrating vapors is provided. The system comprises a wall cap adapted for capping at least a portion of the foundation wall and for closing at least one open hollow in the foundation wall communicating with a source of infiltrating vapors. The wall cap has a recess formed therein for admitting the cap portion of the foundation wall. At least one surface of the recess forms a closure substantially sealing the at least one open hollow.
In accordance with another exemplary embodiment a sealing system for at least a partially subterranean chamber of a building is provided. The system comprises a foundation wall cap for capping a hollow block foundation wall, and a continuous sealed liner barrier layer. The barrier layer covers a floor of the chamber to provide a barrier against the penetration of ground water and water vapor through the floor. The barrier layer has extensions which extend up against the foundation wall to seal with the foundation wall cap.
BRIEF DESCRIPTION OF THE DRAWINGS The foregoing aspects and other features of the present invention are explained in the following description, taken in connection with the accompanying drawings, wherein:
FIG. 1 is a partial perspective view of a conventional foundation system;
FIG. 2 is a side elevational view of a building having a foundation system incorporating features in accordance with one exemplary embodiment of the present invention,
FIG. 3 is an enlarged cross-sectional view of the foundation system in FIG. 1, showing a wall cap in installed and uninstalled positions.
FIG. 4 is an enlarged cross-sectional view of the foundation system according to another exemplary embodiment;
FIG. 5 is another magnified partial cross sectional view of a foundation system in accordance with still another embodiment;
FIG. 6 is another magnified partial cross-sectional view of a foundation system in accordance with yet another embodiment;
FIG. 7 is another magnified partial cross-sectional view of a foundation system in accordance with yet another embodiment;
FIG. 8 is another magnified partial cross-sectional view of a foundation system in accordance with yet another embodiment;
FIG. 9 is another magnified partial cross-sectional view of a foundation system in accordance with yet another embodiment; and
FIGS. 10-12 are other magnified partial cross-sectional views of foundation systems in accordance with yet other embodiments.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENT(S) Referring to FIG. 2, there is shown a building 10 such as a house is illustrated supported upon foundation system 11 incorporating features according to one exemplary embodiment of the present invention. Although the embodiments disclosed will be described with reference to the embodiments shown in the drawings, it should be understood that the embodiments disclosed can be embodied in many alternate forms of embodiments. In addition, any suitable size, shape or type of elements or materials could be used.
The foundation system 11 generally has footings 11FT and foundation walls 11W. The foundation system shown in FIG. 2 is a representative foundation system, and in alternate embodiments the foundation system may have any other desired configuration. The footings 11FT and walls 11W of the foundation system 11 are arranged generally similar to the footings and walls of conventional foundation systems. The footings 11FT may be arranged around the perimeter of the foundation system. The wall 11W may be formed of open hollow core foundation blocks 11HB and may rest on the footings 11FT as shown. The foundation footings 11FT and wall 11W may be buried, at least in part, in soil. The foundation wall open hollow core blocks 11HB are generally similar to conventional open hollow core foundation blocks HB, shown in FIG. 1 and described before. Similar to the conventional foundation system (see also FIG. 1) the open hollow core blocks may be stacked, with the hollow core openings of each block located to bottom, to form the foundation wall 11W. As seen in FIG. 2, sill plate 12SP, such as for example a 2×6 strip, may be seated atop the foundation wall 11W, providing an interface between the building structure and foundation system 11 (as may be realized, floor beams (not shown) of the building may be seated on the sill plate and may be joined by a tie member 12T also seated on the sill plate). The sill plate 12SP may only partially cover the topmost openings in the hollow core blocks 11HB, similar to sill plate SP partially covering openings HC shown in FIG. 1. In this exemplary embodiment, the foundation system 11 includes a block capping system 16. The block capping system 16 closes and seals the exposed openings in the open hollow core blocks 11W (similar to openings HC shown in FIG. 1) as will be described in greater detail below.
Referring now also to FIG. 3, there is shown a magnified partial cross-sectional view of foundation system 11 and sill plate shown in FIG. 2. FIG. 3 shows the capping system 16 in an installed position, and in a displaced position for clarity. In the displaced position, the capping system is identified as 16′.
In this exemplary embodiment, the capping system 16 includes wall cap element(s) 18. The wall cap element(s) 18 may be formed for example of extruded or molded plastic material including for example clear plastic, that is water-impervious or may be made from suitable metal such as aluminum. In alternate embodiments may be formed of any suitable material in any suitable manner. The wall cap element(s) 18 may be formed in any desired length and may be cut to suit at installation or may have various different predetermined lengths selected at installation to suit the given configuration. As seen in FIG. 3, the wall cap element(s) 18 has a general angle configuration with a generally horizontal flange 22 and a generally vertical or inner flange 20 extending at an angle of about 90° from each other. As shown in FIG. 3, the shape of the wall cap element(s) 18 is generally conformal to the wall 11W so that when the cap element 18 is mounted over the inside upper corner of the foundation walls 11, the horizontal flange 22 overlaps the uncovered portion of the top surface 11WS of the walls 11W, from the inner edge 11WE thereof into the interior side of the sill plate 12SP mounted on top of the walls 11W. Thus flange 22 operates to cover the exposed portion of the top of the walls 11W and close the open hollow cores (similar to cores HC in FIG. 1) in the wall as will be described further below.
The terms generally vertical and generally horizontal are used for example purposes when referring to flanges 20, 22 and are meant to cover any flange orientation of flanges 20, 22 that are generally aligned with inside and upper wall 11W surfaces. In the embodiment shown in FIG. 3, the vertical flange 20 may be seated against the inner wall surface 11WE when the wall cap element(s) is placed into its installed/mounted position on the wall. In alternate embodiments, a gap may remain or be formed between the vertical flange, or at least part thereof, and the inner wall surface. The gap may be filled or closed by a suitable substantially impermeable seal, gasket or liner that may be positioned at installation of the wall cap element(s), or may be introduced into the gap after the wall cap element(s) is installed on the wall. In the embodiment shown in FIG. 3, the generally horizontal flange 22 may rest on the upper surface 11WS of the wall when the wall cap element(s) 18 is installed. The outer edge 22E of the flange 22 may engage the sill plate 12SP. In the embodiment shown in FIG. 3, the flange 22 may engage the sill plate 12SP. In the embodiment shown in FIG. 3, the flange 22 may have an outer portion terminating in outer edge 22E that is tapered or ramped to allow the outer edge of the flange to be interposed (or otherwise tucked in) between the bottom of the sill plate 12SP and the top surface 11WS of the wall. This allows the flange 22 of the wall cap element(s) 18 to form a seal 24 between wall cap element(s) and sill plate 12SP that is sufficiently tight so that undesired water vapor, water, and other gases and airs (from within the hollows in the wall) are substantially prevented from infiltrating past the cap element(s) to sill plate seal and entering the basement/crawlspace interior. In alternate embodiments, a seal or gasket made of a suitable elastomer material may be attached to the outer edge of the top flange to generally seal against the sill plate. In other alternate embodiments, a caulk material may be placed at the interface between flange edge and sill plate. As may be realized the configuration of the wall cap element(s) 18 allows formation of a cap or cover of the wall hollows by merely inserting or placing the wall cap element(s) 18, as indicated by the arrow in FIG. 3, without demanding direct access to the top of the wall for the installer. The clearance provided by the sill plate thickness is more than sufficient to allow the flange 22 to slide over the top of wall 11W to engagement with the sill plate. Moreover, the top flange 22 of the wall cap element(s) 18 is sufficiently thin to pass readily under any pipes, conduits or wires (II, shown in phantom in FIG. 3) that may be installed above the wall when the cap element(s) 18 is installed. As noted before, placement of the wall cap element(s) 18 to its installed position, with the outer edge 22E of flange 22 engaging (e.g. tucked under) the sill plate 12SP, forms seal 24 thereby sealing the wall upper surface without using or depositing caulk materials at the interface between sill plate and wall cap element(s) 18. As also noted before, in alternate embodiments caulking material (e.g. a caulk bead) may be deposited if desired at the juncture between the top flange wall cap element and sill plate. As may be realized, the outer surface of the wall cap element top flange provides an appropriate contact surface for any caulking material that may be deposited at the interface with the sill plate. As may be realized, the caulking material may be placed onto the interface using suitable caulking material deposition dispenser, or in other alternate embodiments, the caulk material may be deposited in a desired amount onto the outer edge of the cap element top flange prior to placement into its installed position, so as to automatically contact the sill plate upon placement of the cap element to the installed position.
Referring still to FIG. 3, in the exemplary embodiment the inner flange 20 forms a seal 26, when the wall cap element(s) 18 is installed, with the inner upper surface 11WE. As noted before, in the exemplary embodiment shown in FIG. 3, the inner flange 20 is seated against the inner wall surface 11WE. An adhesive layer (not shown) may be deposited between the flange 20 and wall surface 11WE to secure the wall cap element(s) 18 in its installed position to the wall. The adhesive layer may be provided by a sealing caulk that forms seal 26. In alternate embodiments, an adhesive to hold the cap element onto the wall may be used in addition to the sealing caulk sealing the inner flange to the wall. In other alternate embodiments, the seal between inner flange may be formed by impermeable gaskets, seals or liners that may be attached to the inner flange of the wall cap pre-mounting to the wall. In such alternate embodiments, caulking seal material may not be used, the gasket/seal on the wall cap flange providing the cap to wall seal (similar to seal 26 in FIG. 3) alone. In the exemplary embodiment, the adhesive/caulking material may be pressure sensitive applied to either the wall cap element(s) inner flange, or if desired the wall surface 11WE, prior to placement of the wall cap element(s) against the wall. As also shown in FIG. 3, in this exemplary embodiment the wall cap element(s) 18 may be held to the wall 11 by mechanical fasteners 28. The fasteners 28 may be used in combination with an adhesive/caulk to secure the wall cap element(s) to the wall, or the fasteners may be used in place of an adhesive. Fasteners 28 (only one is shown for example purposes) may be of any suitable type, for example wall anchors and screws, and may be used in any desired size and number suitable to secure each of the wall cap element(s) 18 to the wall 11. Holes may be drilled in the wall surface 11WE and flange 20 for fasteners 28 at any time including before or after placement of the wall cap element(s) in the installed position (e.g. the wall cap element(s) flange may have pre-formed fastener holes, or they may be drilled in place). As may be realized, the general angle configuration of the wall cap element(s) 18 enable the wall cap element(s) 18 to serve not only as a cap for the open hollow cores of the wall 11, but also overcome problems of conventional systems with the in place sealing of the cap to the sill plate or other structure resting on the top of the wall. By effectively automatically sealing the cap to structure interface on top of the wall on placement, and presenting an easy to access inner flange on the inside of the wall, the wall cap element(s) 18 transforms the problem of sealing the hard to access top of the open hollow core wall 11W to an easy to seal flange to wall interface. It may be further realized that the inner flange also serves as a user handling feature for holding and handling the cap element(s) 18 during installation, which upon installation becomes substantially flush with the surface of the wall (thereby avoiding further work to remove or position out of the way).
Referring now to FIG. 4, there is shown a cross-sectional view of a foundation sealing or capping system 11C in accordance with another exemplary embodiment, Capping system 116 is substantially similar, except as otherwise noted below, to capping system 16 described before and shown in FIG. 3. Similar features are similarly numbered. In this embodiment, the capping system′' element(s) 118 may be used in conjunction with an impermeable continuous sealed plastic film barrier 13 sealing the basement/crawlspace. FIG. 2 illustrates film barrier 13 placed to seal the interior of the basement/crawlspace. One example of a suitable sealing film barrier is disclosed in U.S. Pat. No. 6,575,666, the disclosure of which is hereby incorporated by reference. U.S. Pat. No. 6,525,666 discloses a system for waterproofing a basement crawlspace against the entry of sub-soil water vapor and also against the entry of external ground water through the crawlspace walls and further completely isolates the building from water vapor from the earth or subterranean gases. The system of U.S. Pat. No. 6,575,666 comprises a applying over the floor of the basement crawlspace, for example a dirt floor but sometimes a poured concrete floor, a continuous sealed plastic film barrier layer similar to barrier 13 in FIG. 2, and extending the barrier film vertically-upwardly to cover and seal the interior peripheral walls similar to walls 11W enclosing the crawlspace to a desired elevation. The film barrier 13, such as of plastic film, which may be a monofilm but preferably is a 16 mil thick durable heavy duty, fiber-reinforced multi-ply plastic film or rubber sheeting. This encapsulates the inner surface of the entire crawlspace against the penetration of external ground water or flood water and also sub-soil water and water vapor onto the surface of the plastic barrier film and into the basement/crawlspace atmosphere. In the embodiment shown in FIG. 2, the film barrier 13 is extended along the walls 11W to a region proximate the tops of walls 11W so that the barrier 13 may be interface with and sealed to the capping system 116 as will be described below. The wall cap element(s) 118 of capping system 116, are shaped, as shown In FIG. 4, substantially similar to element(s) 18 described before. Thus cap element(s) 118 have a general angle shape complementing the top inner corner of wall 11W, with a top flange 122 which is designed to extend along the top surface (similar to surface 11WS in FIG. 2) of the block wall substantially into contact with the inside edge of the sill plate supported on the cement block wall, to seal the top surface of the cement block wall from the edge of the sill plate inwardly to the inside surface of the wall. The cap element(s) 118 may also have inner flange 120 which is designed to extend downwardly at least a slight distance along the inner surface of wall 11W to provide a continuous bonding surface for the top edge of a plastic film barrier 13.
As seen in FIG. 4, the inner flange 120 of the cap element(s) 18 may be bonded to the inside surface of the water-impervious film barrier 13, around the inner periphery of the foundation walls 11W to provide a continuous sealing system or barrier around the basement/crawlspace to foundation system interface.
The inner peripheral flange 120 of the cap element(s) 118 extends and is supported against the inner surfaces of the foundation walls 11 and bonded thereto at an elevation which may be above the exterior ground level, to the top inner wall 11W of the foundation walls 11. The continuous film barrier 13 may be sealed or bonded to the inner flange 20 around the entire inner periphery of the foundation wall 11 by means of an adhesive tape or a continuous bead of suitable adhesive or caulk composition 126 such as a polyurethane composition. Nylon fasteners may be used to support the barrier film 13 vertically over the foundation 11 during installation and prior to attachment to cap element(s) 18.
In the embodiment shown in FIG. 4, the barrier film 13 may be sealed adjacent barrier film 13 of the walls 11 peripherally, adjacent the uppermost edges 13T of the liner 13 by a continuous sealing bead 21b, as illustrated. Any exterior ground water or condensation or water vapor which might penetrate the foundation 11, such as through a concrete block wall, is trapped beneath the barrier film 13 and flows down to the floor of the crawl space and/or into a perimeter drain and sump, if present (see FIG. 2). The inner flange 120 of the capping element(s) 118 may be also secured to the wall 11W by a fastener system similar to system 28 shown in FIG. 3. The fasteners and fastener holes of the fastener system may be located in a suitable location such as above the sealing area 21b between barrier film 13 and inner wall surface. In alternate embodiments, a fastener system may not be used. As noted before, cap element(s) 118 may be clear plastic thereby allowing an installer to visually inspect the interface between barrier film 13 and inner flange 120 to ensure sufficient overlap is present and desired seal is provided. Furthermore, the clear element(s) may enable inspection of the underlying region to detect or identify undesired activity such as termite or insect activity.
Referring now to FIG. 5, there is shown a partial cross-sectional view of a wall cap system 216 in accordance with another exemplary embodiment, and a portion of a foundation wall 11W. Except as otherwise noted below, wall cap system 216 is substantially similar to cap systems 16, 116 described before. Similar features are similarly numbered. In this exemplary embodiment the wall cap system 216 has cap element(s) 218 having a general angle shape with top and inner flange 222, 220 (similar to flanges 22, 20 of the cap element(s) 18 shown in FIG. 3) but sized to include insulation panels 213 as shown. The insulation panels may be of any suitable type, such as hard foam insulation panel 213. The insulation panels 213 may have the foam core enclosed in suitable facia material (not shown) of suitable metal or plastic. The insulation panels 213 may be of any desired thickness. In alternate embodiments the panels may be any desired type of panel. As seen in FIG. 5, the panels 213 may be positioned against the foundation wall(s) 11W. For example, the panels 213 may be placed so that a space or air gap 218G is formed between the panel face and inner wall surface. The gap may allow water penetrating the wall or condensation to run to the floor for collection and discharge. A suitable panel mounting or positioning system (not shown) may be used to locate and mount the panels 213 in the desired position relative to the foundation wall. If desired, the panel mounting system may depend from or engage the foundation wall. A caulking bead or caulk panel may be placed between the top of panels 213 and foundation wall if desired. In alternate embodiments, a barrier film, similar to barrier film 13 in FIG. 4, or other desired seal material may be interposed between panel and inner wall surface. In other alternate embodiments, the panel outer facia may be formed from a seal material, and the panel positioned with the seal material against the wall. As seen in FIG. 5, in this embodiment the top 213T of the wall panels(s) 213 is located within the angle of the cap element(s) 218 when the cap element(s) 218 is in the installed position. The top flange 222 of the cap element(s) 218 extends over the panel 213 and covers the open top of the walls 11w to engage and seal against the sill plate 12SP as previously described. As may be realized the panel 213 may have any desired height so that when the cap element(s) 218 is installed inner flange 220 overlaps an upper portion of the panel sufficiently to form a seal 226 therewith. A suitable caulking material or layer may be deposited or installed to seal the interface between the inner flange 220 and inner face of panel(s) 213. The cap element(s) 218 may otherwise be mounted in a manner similar to cap element(s) 18, 118 described before.
Referring now to FIG. 6 there is shown a partial cross-sectional view of a wall cap system 316 in accordance with another exemplary embodiment and foundation wall 11W′. In this embodiment, the foundation wall 11W′ may represent foundation walls such as during new construction or other such state of construction in which the top surface 11WS′ of the foundation wall 11W′ may be generally entirely accessible. Otherwise foundation walls(s) 11W′ is substantially similar to foundation wall(s) 11W (formed of open hollow core construction in blocks) described before. The foundation wall(s) 11W′ is shown in FIG. 6 at a stage of construction before placement of a sill plate or other building support structure onto the top of the foundation wall(s). The wall cap system 316 has wall cap element(s) 318 which though generally similar to cap element(s) 18, 118, 218 described before, cap over substantially the entire top surface 11WS′ of the foundation wall 11W′ as will be described below. In this exemplary embodiment, the cap element(s) 318 has a general channel shape defining a recess substantially conformal to the top of the foundation wall(s) 11W′. The cap element(s) 318 may have inner and outer flanges 320I, 320O, oriented to extend respectively along inner and outer wall surfaces 11WE′, 11WO′, and connected by spanning member 322, extending over the top wall surface 11WS′ as shown in FIG. 6. The wall cap element(s) 318 may be of unitary construction. In alternate embodiments, each wall cap element(s) may be formed from multiple independent wall cap element sections, such as two or more angle shaped cap element sections that may be positioned on the wall in an opposing relationship to each other (i.e. one angle section capping the inner top wall corner and the opposing angle section capping the outer top wall corner) with an overlap of the top flange. In still other alternate embodiments, the wall cap element(s) may have a general angle shape (e.g. inner flange, or upper flange and top flange) with the top flange extending sufficiently to cover substantially the entire top surface (similar to surface 11WS″) of the wall. Seal or caulk material may be placed between the outer flange 322O and outer wall surface 11WO′ to form outer seal 326O between cap element(s) 318 and wall 11W′ on the exterior of the building A foam seal strip 340 may be positioned between span member 322 of cap element(s) 318 and top wall surface 11WS′. The foam seal strip 340 may be pliant, helping to close off any opening or gaps between the top wall surface 11WS′ and span member 322 of the wall cap element(s) 318. The foam seal strip 340 may thus form an insulating space (i.e. dead space) to prevent infiltration of outside air between cap element(s) and top of wall. In this embodiment the span member 322 defines a seating surface for building structure members such as sill plate 12SP.
As seen in FIG. 6, in this embodiment the cap element(s) 318 may have an intermediate flange 320B positioned between inner and outer flanges 320I, 320O. The intermediate flange 320B is positioned to be located immediately adjacent and interface with the inner wall surface 11WS′ when the cap element(s) 318 is mounted on the wall 11W′. The intermediate and inner flanges 320B, 320I define a secondary channel or recess 320R in the cap element(s) 318. The secondary channel 320R may be sized to admit the top of a foam panel 313 (which may be substantially similar to foam panel 213 described before). Hence, the secondary channel 320R may provide the cap element(s) 318 with a panel holding or locating system capable of holding or locating panel(s) 313. In alternate embodiments, the cap element(s) 318 may have any other desired type of panel holding/locating system. In other alternate embodiments, the cap element(s) may be without the intermediate flange, the panel (similar to panel 313) being held by the inner cap element flange against the wall in a manner similar to that shown in FIG. 5. Caulk material may be placed between the panel 313 and inner and intermediate flange 320I, 320B to form a seal 326 between panel and cap element(s) 310. As may be realized from FIG. 6, the open access over the top of foundation wall 11W′ allows the cap element(s) 318 to be placed over the wall top surface 11WS′ and top of panel 313, by lowering the cap element(s) 318 (in the direction indicated by arrow Z) until seated on the wall 11W′ as shown. Once seated caulking material may be applied if desired. The cap element(s) 318 may be secured to the wall 11W′ in a similar manner to cap element(s) 18 shown in FIG. 3.
Referring now to FIG. 7, there is shown a cross-sectional view of a wall capping system 416 in accordance with yet another exemplary embodiment. The exemplary embodiment shown in FIG. 7 may be used/installed during new construction and seals either open cavities of blocks before installation of a sill plate, or may stop water vapor infiltration, by capillary action, from a block wall with a solid course of cap blocks on top or even with a poured concrete wall. The capping system in this embodiment may further serve for example in a termite, or other insect, barrier protecting the sill plate. Capping system 416 is substantially similar to capping system 316 except as otherwise noted. The cap element(s) 418 of the capping system 416 does to have an intermediate flange (similar to flange 320B) for locating a wall panel. In this embodiment, the cap element(s) 418 has inner and outer flanges 420I, 420O and span member 422 extending therebetween. The inner and outer flanges 320I, 320O are respectively sealed to inner and outer faces of wall 11W′ by seals 426, 426O. The top span member 422 may have a suitable flexible or elastomeric foam seal strip 440 on the surface facing the top of the wall. The seal strip 440 may be secured to the span member with suitable adhesive (e.g. pressure sensitive adhesive or tape) or with mechanical fasteners (such as clamps, flex tabs, screws) to allow installation of the cap element(s) 418 onto the wall 11W′ with the seal strip already secured thereto.
FIG. 8 shows a wall cap system 516 in accordance with yet another embodiment. The exemplary embodiment shown in FIG. 8 may be used/installed during new construction and seals either open cavities of blocks before installation of a sill plate, or may stop water vapor infiltration, by capillary action, from a block wall with a solid course of cap blocks on top or even with a poured concrete wall. The capping system in this embodiment may further serve for example in a termite, or other insect, barrier protecting the sill plate. The cap element(s) 518 of the wall cap system in this embodiment is similar to cap element(s) 418, but with the opening to the channel formed by the cap element(s) 518 flared outwards. As seen in FIG. 8, the lower portion 520L of both inner and outer flanges 520I 520O is angled with respect to the rest of the flange, and hence also with respect to the adjacent wall surface. The angled portion 520L are angled away from the wall thereby providing the channel an outward flare. The angled portions 520L of the flanges may serve as placement guide surfaces aiding in the positioning of the cap element(s) 518 when the cap element(s) 518 is lowered over the top of the wall, the guiding/angled surface 520L allow the inner and outer flanges 520I, 520O to be positioned closer together, thereby forming a smaller clearance gap with the wall 11W′ (which is more readily sealed), without impairing the ease of installation of the cap element(s) 518 onto the wall. In alternate embodiments, the cap element(s) may have one flange (e.g. either inner or outer) that has an angled portion and one flange which has no angled portion.
FIG. 9 shows a wall cap system 616 in accordance with yet another exemplary embodiment. The cap system 616 has wall cap element(s) 618 substantially similar to cap element(s) 418. In this embodiment the cap element has seal strips 440L, 440V on both the inside and outside of the span member 622 (spanning between inner and outer flanges 620O, 620I) seal strips 640L, 640V may be similar to each other and to seal strip 440 described before. The seal strips 640L, 640V may be of any desired thickness and may be secured to the span member 622 or other portions of the cap element(s) by any suitable adhesive or fastening system. As seen in FIG. 9, the seal strip 640L on the inside of span 622 is sandwiched between span member 622 and top of wall 111W′. The seal strip 640O on the outside of span member 622 (opposite seal strip 640L) provides a pliant sealing surface for building support structure member, for example sill plate, 12SP, that may be seated onto the cap element(s) 618 of capping system 616.
In FIG. 10, another wall cap system 716 is shown in accordance with another exemplary embodiment. Wall cap system 716, is similar to cap system 616 shown in FIG. 9, having a cap element(s) 718 (similar to element 618) and a seal strip 740V (similar to seal strip 640V). The seal strip 740V is affixed to outside of span member 722. In this embodiment there may be no seal strip between span member 722 and top of wall 11W′. The cap element(s) 718 may be sealed to wall by seals 726, 726O respectively between inner and outer flanges 720I, 720O of the element(s) and inner and outer surface of wall 11W′.
Referring now to FIG. 11, there is shown another wall cap system 816 in accordance with yet another exemplary embodiment. Wall cap system 816 is generally similar to cap systems 16, 216, (see FIGS. 3, 5) as well as cap system 316 (see FIG. 6) described before. Similar features are similarly numbered. In the exemplary embodiment, the cap system 816 may have cap element(s) 818 having a general angle shape with top and inner flanges 822, 820 (similar to flanges 22, 20 of cap element(s) 18 shown in FIG. 3). The flanges are shed and shaped to seat substantially flush against top and inner surfaces of wall 11W, and seal the exposed top of the hollow core block wall as previously described. Cap element(s) may be clear plastic, or may include a clear plastic portion for example in flange 820, enabling visual inspection of the underlying wall section. This may allow inspection of the adequacy of the fit up at installation between cap and wall, as well as post installation inspections for detection of undesired insect activity proximate the sill plate (similar to sill plate 12SP). As seen in FIG. 11, in this embodiment cap 318 has a recess or channel 820R formed on the vertical flange 800. The recess 820R is generally similar to channel 320R of cap element(s) 318 shown in FIG. 6, and is sized and shaped to stably hold the top of a foam panel (similar to panel 313 described before). The location of the channel 820K shown in FIG. 11 is merely exemplary, and in alternate embodiments the channel may be positioned as desired. The cap element(s) 818 may be a one piece member, with flanges 820I, 820T forming channel 820R being integrally formed with flange 820. In alternate embodiments, the flanges defining the panel retaining channel being fastened, or attached otherwise to the inner flange of the cap element(s). As may be realized, the cap element(s) 818 of capping system 816, may be retrofit to existing structure, though if desired capping system 816 may be installed also during new construction. Retrofit installation may be accomplished in a manner generally similar to installation to cap element(s) 18, 216 described before. For example, in crowded conditions, where multiple interferences (similar to conduit, wiring, pining I) are located in close proximity to the top of the wall, the cap element(s) 818 may be mounted by sliding the cap elements outward to the seated position shown. The panel(s) (similar to panels 313) may be installed into channels 820R and the cap element(s) may be sealed to sill plate and wall as previously described. The cap element(s) may be allowed to float (i.e. remain unsealed) to facilitate panel fit up into the channel(s) 820R. In alternate embodiments any other desired method of installation may be employed.
FIG. 12 shows another wall cap system 916 in accordance with yet another exemplary embodiment. Wall cap system 916 is generally similar to cap system 816 described before and shown in FIG. 12 (Similar features are similarly numbered). In the exemplary embodiments, cap system 916 may have cap element(s) 918. As seen in FIG. 12, in this embodiment the cap element(s) 918 may have vertical 920 and horizontal flanges 922 that form a general angle configuration. Vertical flange 920 has a general stepped configuration, formed by flange portions 920I, 920T, providing the cap element(s) with a first wall receiving recess, and a second recess 920R. The wall receiving recess is shaped to conform to the exposed corner of the block wall 11W as seen in FIG. 12. Accordingly, when the cap element(s) 918 is installed on the wall, the flanges 920, 922 may be seated against the wall, as shown closing off the exposed top of the wall. The second recess 920R is sized and shaped to receive the top of an insulation panel 913 (similar to panels 213, 313) and stably secure the panel top when the cap element(s) 918 is mounted on the wall as shown as will be described below. In the exemplary embodiment, the cap element(s) 918 may be of unitary construction, though in alternate embodiments the cap element(s) may be formed from sections (e.g. flange sections) that are assembled and joined together to form the cap element(s). The cap element(s) 918 may be made from clear plastic, alternatively or the upper portion 920U of the vertical flange 920 may be clear plastic, or any other suitable transparent material. This, as noted before facilitates visual inspection of the wall portion behind the flange for installation fit up and post installation conditions. Installation of the cap element(s) 918 may be similar to installation of cap element(s) 818. In this exemplary embodiment, the size of the second recess 920R may be such that the lower portion of the inner flange 920I contacts the insulation panel 913 and biases the insulation panel against the wall. As may be realized, the flange portion 920I, or vertical flange 920 may be resiliently flexible, or may have any suitable biasing elements (e.g. adjustable clamps) mounted thereon to enable flange portion 920I in contact with insulating panel to bias the panel against the wall. As may also be realized, the bias generated by flange portion 920I also allows a liner or vapor barrier 13 to be captured and held at the top of the insulation panel(s) 913 as shown in FIG. 12. In alternate embodiments, the vapor barrier may be exterior to the panels (i.e. between panel and wall). Thus, installation of the cap element(s) 918 of cap system 916 seals the exposed portion of the top of the block wall 11W, and facilitates securing insulation panels with or without a vapor barrier to the wall.
It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.
