Embedded barrier to fluid flow
A method for implementing a barrier to fluid passage in which the barrier is embedded within, instead of atop, porous material. This retains the durability of the surface of the porous material. In one embodiment, a thin set mortar is applied to a concrete slab. A pleated metal foil is pressed into the wet mortar and a bond is established. The mortar is allowed to set and a top, or finish, section of concrete is then poured over the foil and finished conventionally. Provisions are made for sealing expansion joints in concrete slab floors and at the juncture of floor and wall. The foil may be provided in multiple layers to provide a mechanical bond via the mortar oozing through perforations or along pleats in each of the top and bottoms layers, while providing a solid layer through which a fluid will not pass, at least in one direction.
This application is a continuation of U.S. patent application Ser. No. 10/715,430, Embedded Barrier to Fluid Flow, by McInerney et al., filed Nov. 19, 2003, and is related to allowed U.S. patent application Ser. No. 11/386,473, to McInerney et al., filed Mar. 7, 2006 and published Jul. 13, 2006 with publication No. 2006/0150555, a division of U.S. patent application Ser. No. 10/715,430, and is also related to U.S. patent application No. 11/790,508, by McInerney et al., filed Apr. 26, 2007, a division of U.S. patent application Ser. No. 11/386,473, all of which are commonly owned and incorporated herein by reference.
STATEMENT OF GOVERNMENT INTERESTUnder paragraph 1(a) of Executive Order 10096, the conditions under which this invention was made entitle the Government of the United States, as represented by the Secretary of the Army, to the entire right, title and interest therein of any patent granted thereon by the United States. This patent and related ones are available for licensing. Contact Bea Shahin at 217 373-7234 or Phillip Stewart at 601 634-4113.
FIELD OF THE INVENTIONThe present invention relates generally to fluid barriers, in particular to metal or composite vapor barriers that are embedded within porous material, such as concrete.
BACKGROUNDU.S. Pat. No. 6,286,279, Method for Attaching Fabric and Floor Covering Materials to Concrete, to Bean et al., Sep. 11, 2001, and incorporated herein by reference, teaches bonding a thin metal plate or metal foil to a concrete surface to effect a barrier to water vapor transfer. The configuration of the '279 patent improves the maintenance of the bond between a concrete surface and various types of floor coverings. The '279 patent teaches two systems for implementing the barrier: one uses a single-layered thin metal plate or metal foil that is folded to produce recesses much like corrugated sheet metal. One side of the foil is attached to the concrete surface using a Portland cement-based thin set grout. A second embodiment employs a two-part thin metal plate or foil. A first lower part is perforated (or slit and expanded) and attached to a second solid upper part. The lower perforated part is embedded in a layer of thin set mortar on the concrete to anchor it to the concrete. The thin set mortar that oozes through the perforations also serves as a mechanical bond, a “cementitious rivet,” supplementing the chemical bond made along the contact surface.
A preferred embodiment of the present invention is an improvement on the '279 patent in that it allows the thin metal plate or metal foil to be embedded just below the surface of the underlayment, concrete in the case of a “poured slab,” so that there is a layer, e.g., concrete, both above and below the thin metal plate or metal foil. That is, a robust “finish” surface, e.g., concrete, is placed above the thin metal plate or metal foil, thus presenting a durable surface of conventional appearance. One advantage of this design is the ability of the surface to resist moisture flow from without while accommodating typical use, e.g., that of hard-wheeled vehicles on a concrete floor that would otherwise damage vinyl or carpet floor coverings.
SUMMARYA fluid, or vapor, barrier is encapsulated within a durable structure to preclude passage of fluid in at least one direction while retaining the durability of a surface of a structure that conventionally does not contain such a barrier.
A first preferred embodiment of the present invention employs a two-part folded thin metal (or composite) plate or metal (or composite) solid (un-perforated) foil such as provided in the '279 patent, but embedded just below the top surface of a durable surface such as an underlayment, typically a concrete “slab” or floor.
Alternatively, a second preferred embodiment of the present invention employs a two-part thin metal plate or metal foil differing from that of the '279 patent in that the second or top layer of metal is a perforated thin plate or metal foil. The perforations on the top side of the second (top) layer serve to facilitate the formation of a mechanical bond via the concrete oozing through the perforations and acting as a “cementitious rivet” between the top side of the second layer and the bottom side of the surface of the underlayment above this second (top) layer. This mechanical bond acts in addition to any chemical bond formed between the bottom side of the underlayment surface and the remainder of the upper surface of this second (top) perforated layer. This second preferred embodiment must employ a solid thin metal plate or metal foil as a first (bottom) layer to block passage of moisture through the path provided by the underlayment material, typically concrete, that, upon installation, oozed through the perforations in the second (top) layer of perforated thin metal plate or metal foil. That is, if a perforated second (top) layer of a two-part thin metal plate or metal foil is used to achieve a better bond, then the first (bottom) layer must be solid, and conversely, if a perforated first (bottom) layer is used, then the second (top) layer must be solid.
Alternatively, a third preferred embodiment of the present invention employs a three-part thin metal plate or metal foil differing from that of the '279 patent in that a solid center foil or thin metal plate has an expanded metal foil or thin metal plate, e.g., pleated foil, applied to both sides. Application of the top and bottom pleated foils or thin pleated metal plates may be by way of spot welding in one embodiment. This results in a three-layered system that provides opportunity for the adhesive, e.g., thin-set mortar, to infiltrate slots in the lower foil (or thin metal plate) positioned over the adhesive immediately applied to an existing slab, while the expanded foil (or thin metal plate) attached to the top of this three-layer version establishes a similar mechanical and chemical bond to the overlaid concrete that forms a surface, e.g., concrete flooring. This particular embodiment also aids in resisting “curling” of an overlaid concrete layer that provides a durable surface for use by hard-wheeled vehicles.
A preferred method of applying a first preferred embodiment of the present invention to an existing porous surface, such as cured concrete, comprises:
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- applying a layer of adhesive, such as thin set mortar, to the existing surface;
- placing a folded or pleated thin metal plate or folded or pleated metal foil on the layer of adhesive, e.g., thin set mortar;
- embedding the bottom of the thin metal plate or metal foil into the adhesive, e.g., thin set mortar;
- covering the top of the folded or pleated thin metal plate or folded or pleated metal foil with a thin layer of durable material, such as concrete;
- permitting the adhesive to cure; and
- finishing and curing the thin layer of durable material, e.g., concrete, as needed.
Note that if concrete is used as a finish layer, consolidation of this covering concrete must be done with care to avoid loosening the foil bonded to the adhesive, e.g., thin set mortar.
As an alternative, seams between the pieces (sheets) of the folded or pleated thin metal plate or folded or pleated metal foil may be sealed with flexible commercially available room temperature vulcanizing (RTV) products appropriate for use in alkaline environments. As a further alternative, employing accordion-style pleats at edges of the thin metal plate or metal foil accommodates panel movement while avoiding tearing or breaking the folded thin metal plate or folded metal foil should the installed surface move under load. Of course, this method is not limited to existing installations but may be employed upon initial installation of an underlayment or wall.
In installing a second preferred embodiment, the above method of installation may be applied using a two-part thin metal plate or metal foil having a first (bottom) layer and a second (top) layer, instead of a single folded thin metal plate or folded metal foil.
In another method of installing the second preferred embodiment, a two-part thin metal plate or two-part metal foil is use in which the second (top) layer incorporates perforations and the first (bottom) layer is solid.
In yet another method of installing the second preferred embodiment the immediately above method of installation may be applied using a two-part thin metal plate or two-part metal foil in which the first (bottom) layer incorporates perforations and the second (top) layer is solid.
Finally, the above method of installation may be applied using the third preferred embodiment, a three-layer sandwich comprising top and bottom layers of perforated, folded or pleated foil or thin metal covering a solid middle layer of foil or thin metal. The top and bottom layers may be joined to the solid center layer by any of a number of suitable processes, e.g., tack welding.
Embodiments of the present invention are not limited to underlayments but may be used on vertical or slanted surfaces where protection from fluid intrusion is desired. Further, a “one-way” vapor barrier may be installed to prevent intrusion of fluids while permitting expulsion of the same fluids or vapors. Instead of a metal foil or thin metal plate, a special “breathing” polyester such as those marketed under the trademark GORETEX® (waterproof breathable material) may be used in place of metal. This would have particular application in below grade applications such as basement floors or walls and in environments of high humidity such as kitchens or bathroom floors or walls that otherwise “sweat.” In addition to embedding the GORETEX® (waterproof breathable material) lining in concrete on a slab, it could be embedded just beneath a porous outer stucco or similar coating to achieve the same effect as the metal barrier does in the underlayment while also permitting “out gassing” of vapors from within the room.
Embodiments of the present invention may be used in any application where it is necessary to prevent the movement of fluids (liquid or gas) through porous material, such as concrete. Specifically, it may be used to block the movement of water vapor and will be equally effective in preventing the movement of stable gases, such as radon, through porous material, such as concrete.
The “embedded barrier” of the present invention, in all of its preferred embodiments, is unique in its implementation. For example, conventionally, a concrete slab has been “sealed” by pre-placing a polymer membrane under the slab prior to placing the new concrete. Once the concrete slab had been installed, the slab could be further sealed only at its top surface. This sealing of the top surface has been accomplished conventionally by using epoxy, fiberglass or combinations of fiberglass and epoxy, leaving a surface that was less durable than a concrete surface.
To summarize some of the salient advantages of preferred embodiments of the present invention:
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- it permits modifying existing installations, e.g., addition of concrete above the metal barrier on existing slabs;
- it allows a trafficked surface above a vapor barrier to be made of durable castable material such as concrete or asphalt concrete;
- it provides a continuous sheet of metal foil that also serves to reinforce an underlayment, such as a concrete slab;
- it reduces the opportunity for cracking that occurs on one side of a structure to propagate to the other side;
- it reduces the opportunity for fractures that exist in the lower part of an underlayment, e.g., a concrete slab, to widen or propagate laterally;
- in a preferred embodiment it prevents curling of a top surface of concrete that has been applied to an existing concrete slab; and
- in an alternative embodiment, it accommodates joints between panels of structure, such as an underlayment, by employing a pleated barrier joining section thus permitting movement without compromising the integrity of the barrier.
Further advantages of the present invention will be apparent from the description below with reference to the accompanying drawings, in which like numbers indicate like elements.
BRIEF DESCRIPTION OF THE DRAWINGS
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- at least one layer of adhesive 312 applied to a top surface of the porous material comprising a base 311, e.g., thin set mortar applied to a concrete slab;
- panels 100 of non-porous material having edges 102 suitable for overlapping, e.g., pleated edges, as shown at 701 of
FIG. 7 , affixed to a topmost layer of adhesive 312 so as to completely cover the adhesive 312, a flexible sealant as shown at 702 ofFIG. 7 applied between the overlapping edges as shown at 701 ofFIG. 7 ; and - the topmost section 313 emplaced upon the panels 100 so as to completely cover all the panels 100, said topmost section 313 incorporating the top surface suitable for routine use by wheeled traffic.
In a preferred embodiment of the configuration, the barrier is a vapor barrier embedded, i.e., completely enclosed, in porous material. The non-porous material used for the panels 100 may be selected from: a metal, a metal alloy, a steel alloy, a stainless steel, a composite material, a composite material containing at least some metal, and combinations thereof.
In a preferred embodiment of the configuration, the non-porous material comprises at least one metal and the porous material comprises at least some concrete. Further, the adhesive 312 may be a thin set mortar applied to a thickness of about 6 mm (¼ inch). In a preferred embodiment of the configuration in which the porous material at least partially comprises concrete, the topmost section may comprise concrete applied to a thickness of about 2.5 cm (1 inch) or more.
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A preferred method of implementing an embedded barrier comprises:
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- applying at least one layer 312 of adhesive, such as a thin set mortar, to an entire first surface of the porous material of the base 311, e.g., a concrete slab, prior to emplacing the topmost section 313, e.g., a finish layer of concrete;
- placing panels 100 of non-porous material, such as a metal or composite plate or metal or composite foil, upon a topmost layer 312 of adhesive (if more than one layer of adhesive is used), overlapping edges 102 of each panel 100 with edges of any panels 100 placed adjacent thereto in the same plane along the topmost layer 312 of adhesive such as shown at 701 in
FIG. 7 , and - completely covering the topmost adhesive layer 312 with the overlapping panels 100;
- establishing a seal 702 as shown in
FIG. 7 between all the overlapped panel edges 701; and - emplacing at least one layer of material comprising a topmost section 313 upon the panels 100 such that each panel 100 is confined below the topmost section 313 and above a topmost layer 312 of adhesive.
Employing this method, i.e., providing one or more adhesive layers 312 upon a surface of a base 311 of porous material, placing “barrier” panels 100 of one or more layers such as layers depicted at 210, 220, 600, 610 upon the topmost layer 312 of adhesive, establishing a seal 702 between the overlapped edges 701 of the panels 100 and emplacing a topmost section 313 to encapsulate the panels 100, implements a fluid barrier within porous material, preferably durable porous material such as concrete.
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The method of emplacing a fluid barrier within porous material extends to establishing a vapor barrier in porous material. The vapor barrier may be a one-way barrier such that the configuration is permitted to “breathe” or “outgas” in one direction while establishing and maintaining a fluid barrier in the opposite direction.
In a preferred embodiment of a method of implementation of the present invention, the method employs non-porous material comprising at least one metal and the porous material comprises at least some concrete. Further, the topmost adhesive layer 312 may be a thin set mortar applied to a thickness of about 6 mm (0.25 inch). In a preferred embodiment in which the porous material at least partially comprises concrete, the topmost section may comprise concrete applied to a thickness of about 2.5 cm (1.0 inch) or more.
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While the invention has been described in terms of its preferred embodiments, those skilled in the art will recognize that the invention can be practiced with modifications within the spirit and scope of the appended claims. For example, although the system is described in specific examples related to concrete structure, it may be adapted to other porous construction materials, such as drywall, chipboard, wood, tile, composites, and combinations thereof. Thus, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting, and the invention should be defined only in accordance with the following claims and their equivalents.
Claims
1. A method of creating a barrier to fluid flow at least from below concrete-surfaced flooring placed above a prepared base, comprising:
- placing a first layer of concrete upon said prepared base;
- applying at least one layer of adhesive material to the top surface of said first layer of concrete, said at least one layer of said adhesive material to include a topmost layer of said adhesive material;
- placing multiple reinforcing panels, at least one said panel incorporating at least one layer of non-porous material, upon said topmost layer of said adhesive material, overlapping edges of said panels with edges of any said panels placed adjacent thereto,
- wherein said panels completely cover said topmost layer of said adhesive material, and
- wherein said panels serve to reinforce said first layer of concrete;
- sealing all said overlapped edges; and
- emplacing at least one second layer of concrete upon said panels such that said panels are confined below said second layer of concrete and above said topmost layer of said adhesive material,
- wherein the step of placing said panels, the step of sealing said overlapped edges of said panels and the step of emplacing said second layer of concrete completes said barrier, and
- wherein said barrier prevents said fluid flow from said prepared base upward through said second layer of concrete.
2. The method of claim 1 in which said panels comprise non-porous material selected from a group consisting of: a metal, a metal alloy, a steel alloy, a stainless steel, a composite material, a composite material containing at least some metal, and combinations thereof.
3. The method of claim I said non-porous material comprising at least in part a first metal.
4. The method of claim 1 said adhesive material comprising at least in part a thin set mortar deposited at a thickness of about 6 mm (¼ inch).
5. The method of claim 1 applying said second layer at a thickness of about at least 2.5 cm (1.0 inch).
6. The method of claim 1 sealing said overlapped edges at least in part by applying a continuous bead of at least one sealant along the entire length between each said overlapped edge,
- wherein said sealant remains flexible upon curing.
7. The method of claim 6 employing a RTV sealant as said at least one sealant.
8. The method of claim 1 providing said panels as at least one plate of a total thickness less than about 6 mm (¼ inch).
9. The method of claim 1 providing said panels as at least one foil of a thickness less than about 1 mm (40 mil).
10. The method of claim 1 providing said prepared base as an aggregate.
Type: Application
Filed: Sep 19, 2007
Publication Date: Jan 17, 2008
Inventors: Michael McInerney (Champaign, IL), Sean Morefield (Champaign, IL), Vincent Hock (Mahomet, IL), Philip Malone (Vicksburg, MS), Charles Weiss (Clinton, MS)
Application Number: 11/901,897
International Classification: E04B 1/66 (20060101);