Protective drainage wraps

Abstract

A protective drainage wrap comprises a polymeric spunbonded portion being adapted to allow water vapor to flow therethrough and a plurality of fibers, filaments, tapes or yarn being attached to the polymeric spunbonded portion. The plurality of fibers, filaments, tapes or yarn forms a plurality of channels to assist in forming a drainage path for draining liquid moisture from the protective drainage wrap.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 11/415,925 filed on May 2, 2006, which is a continuation-in-part of application Ser. No. 10/869,333 filed on Jun. 16, 2004, which is entitled “Method for Producing Protective Drainage Wraps”; application Ser. No. 10/869,333 is a division of application Ser. No. 10/255,273 filed on Sep. 26, 2002 and issued as U.S. Pat. No. 6,869,901; application Ser. No. 10/255,273 is a continuation-in-part of U.S. application Ser. No. 09/788,776 filed on Feb. 20, 2001, and issued as U.S. Pat. No. 6,550,212. application Ser. Nos. 11/415,925; 10/869,333; 10/255,273; and 09/788,776 are all incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to protective wraps that are used to protect against air infiltration and moisture build-up in buildings. Specifically, the protective wraps of the present invention include a polymeric spunbonded portion being attached to a plurality of fibers, filaments, tapes or yarn.

BACKGROUND OF THE INVENTION

There have been many different protective wraps used in the construction of buildings, such as residential and commercial construction. Protective wraps are used to protect against air infiltration and damaging moisture build-up. Air infiltration may occur in typical construction through, among other places, sheathing seams and cracks around windows and doors. Moisture build-up can occur externally in the wall cavity from, for example, leaking exterior finishes or coverings, and cracks around windows and doors. The exterior of the protective wraps should not trap the water, but rather allow it to flow downward so as to exit the wall system.

Protective wraps are typically used as secondary weather barriers in buildings behind exterior finishes or coverings such as siding, brick, stone, masonry, stucco and concrete veneers. Examples of siding include wood siding, aluminum siding, vinyl siding, cementitious siding, wood compositions boards and lapboard. Stucco may be synthetic based (e.g., a polymer-based stucco) or cementitious (a mixture of Portland cement, lime and sand). One type of stucco system, exterior insulation finish system (drainage EIFS), that is used in buildings typically involves using a drainage plane, an insulation board, and a wire or synthetic mesh that accepts a cementitious coating. In stucco systems, protective wraps are not typically installed directly in contact with the cementitious coatings. In some instances, multiple layers of protective wrap are installed with one layer contacting the cementitious coatings. These multiple layers may be house wrap, building paper or both.

Both woven and non-woven protective wraps are commonly used in the construction of buildings. The strength properties of woven wraps are typically much higher than the strength properties of non-woven wraps. Some woven wraps are translucent, which assist in locating studs, as well as window and door openings. Non-woven wraps, however, may have higher permeabilities than woven wraps.

Protective wraps, such as non-woven wraps, woven wraps and cross-laminated wraps, also may be micro-perforated so as to allow moisture vapor to pass therethrough. Most non-woven commercial protective wraps (such as spun bonded polyolefin wraps) are not perforated because the processes used in forming the wraps result in a structure that inherently allows the moisture vapor to pass through the wrap.

Accordingly, a need exists for a protective wrap that enhances drainage of damaging moisture build-up, while still protecting against air infiltration.

SUMMARY OF THE INVENTION

According to one embodiment, a protective drainage wrap comprises a polymeric spunbonded portion being adapted to allow water vapor to flow therethrough. The drainage wrap further includes a plurality of fibers, filaments, tapes or yarn being attached to the polymeric spunbonded portion. The plurality of fibers, filaments, tapes or yarn forms a plurality of channels to assist in forming a liquid drainage path for draining moisture from the protective drainage wrap.

According to one method, a protective wrap to be used in a building is provided. The protective wrap includes a polymeric spunbonded portion and a plurality of fibers, filaments, tapes or yarn. The polymeric spunbonded portion is adapted to allow water vapor to flow therethrough. The plurality of fibers, filaments, tapes or yarn is attached to the polymeric spunbonded portion and forms a plurality of channels to assist in facilitating a drainage path for draining liquid moisture from the protective drainage wrap. At least one framing member is provided. The protective wrap is installed over at least one of the framing members.

According to another method, a protective wrap to be used in a building is provided. The protective wrap includes a polymeric spunbonded portion and a plurality of fibers, filaments, tapes or yarn. The polymeric spunbonded portion is adapted to allow water vapor to flow therethrough. The plurality of fibers, filaments, tapes or yarn is attached to the polymeric spunbonded portion and forms a plurality of channels to assist in facilitating a drainage path for draining liquid moisture from the protective drainage wrap. A sheathing is provided and the protective wrap is installed over the sheathing.

According to one method of forming a protective drainage wrap, the method comprises providing a polymeric spunbonded portion being adapted to allow water vapor to flow therethrough. A plurality of fibers, filaments, tapes or yarn is attached to the polymeric spunbonded portion and forms a plurality of channels to assist in facilitating a drainage path for draining liquid moisture from the protective drainage wrap.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a protective wrap according to one embodiment of the present invention.

FIG. 2 is a cross-sectional view taken generally along line II-II of FIG. 1.

FIG. 3a is a cut-away perspective view of the protective wrap of FIG. 1 fastened to sheathing and a framing member according to another embodiment of the present invention.

FIG. 3b a side view taken generally along line 3b-3b of FIG. 3a depicting the relative locations of the various layers.

FIG. 4a is a cut-away perspective view of the protective wrap of FIG. 1 fastened to a framing member according to another embodiment of the present invention.

FIG. 4b a side view taken generally along line 4b-4b of FIG. 4a depicting the relative locations of the various layers.

While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed but, on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

DESCRIPTION OF SPECIFIC EMBODIMENTS

Turning now to the drawings and referring initially to FIGS. 1 and 2, a protective drainage wrap 110 according to one embodiment is shown. The protective wraps of the present invention, including protective wrap 110, are adapted to be attached over sheathing or framing members. The protective wraps are typically covered by an exterior covering such as siding, brick, stone, masonry, stucco (e.g., synthetic or cementitious) or concrete veneer.

The protective wrap 110 of FIGS. 1 and 2 comprises a plurality of fibers, filaments, tapes or yarn 112 and a polymeric spunbonded portion 116. The plurality of fibers, filaments, tapes or yarn of the protective wrap assists in providing an improved traverse direction (TD) strength. A desirable TD strength and machine direction (MD) strength assists in inhibiting or preventing tears and/or fraying that may be caused during installation. These tears and/or fraying may be caused by, for example, nails or staples during the installation of the protective wraps. These tears and/or fraying may also be caused after installation by environmental conditions such as wind, UV degradation or by vandalism before the protective wrap is covered with an exterior covering. The polymeric spunbonded portion of the protective wrap assists in providing MD and TD strength to the protective wrap.

The plurality of fibers, filaments, tapes or yarn 112 may be made of materials such as polyolefins, polyesters, nylons or combinations thereof. Polyolefins that may be used in forming the plurality of fibers, filaments, tapes or yarn 112 include polypropylenes or polyethylenes. The term “polypropylene” as used herein includes polymers of propylene or polymerizing propylene with other aliphatic polyolefins, such as ethylene, 1-butene, 1-pentene, 3-methyl-1-butene, 4-methyl-1-pentene, 4-methyl-1-hexene, 5-methyl-1-hexene and mixtures thereof. Polypropylene not only includes homopolymers of propylene, but also propylene copolymers comprised of at least 50 mole percent of a propylene unit and a minor proportion of a monomer copolymerizable with propylene and blends of at least 50 percent by weight of the propylene homopolymer with another polymer.

The term “polyethylene” as used herein includes low density polyethylene (LDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), very low density polyethylene (VLDPE), linear low density polyethylene (LLDPE), metallocene-catalyzed linear low density polyethylene (mLLDPE) and combinations thereof.

An example of a “polyester” includes a polyester resin, which is a polycondensation product of a dicarboxylic acid with a dihydroxy alcohol. An example of a “polyethylene terephthalate” includes a polyester resin made from ethylene glycol and terephthalic acid. An example of a “nylon” is a polyamide polymer that is characterized by the presence of the amide group (—CONH).

Each of the plurality of fibers, filaments, tapes or yarn 112 may be made of a single fiber or filament, or a plurality of fibers, filaments, tapes or yarn aligned with each other. It is contemplated that the plurality of fibers, filaments, tapes or yarn 112 may be made of a mixture of single fibers or filaments, and a plurality of fibers, filaments, tapes or yarn aligned with each other. For example, the single fibers or filaments may be alternated with the plurality of filaments aligned with each other such that the thicknesses of the plurality of fibers, filaments, tapes or yarn 112 vary.

As best shown in FIG. 2, each of the plurality of fibers, filaments, tapes or yarn 112 is shaped in a generally oval manner. The plurality of fibers, filaments, tapes or yarn 112 is desirably substantially circular or circular in shape. The plurality of fibers, filaments, tapes or yarn 112 is shaped in a manner that will allow liquid water to flow down the channels formed between the plurality of fibers, filaments, tapes or yarn 112 via gravity. It is contemplated that the plurality of fibers, filaments, tapes or yarn 112 may be shaped in a different manner.

The thicknesses of the plurality of fibers, filaments, tapes or yarn 112 of the present invention provide unique vertical channels, when installed, that enhance liquid moisture drainage external to the protective wrap (i.e., between the protective wrap and the exterior finish). The installed plurality of fibers, filaments, tapes or yarn 112 allows liquid water to readily exit a wall system.

The plurality of fibers, filaments, tapes or yarn 112 is shown in FIGS. 3a,b after being installed. The plurality of fibers, filaments, tapes or yarn 112 is installed in a general vertical manner (in direction of arrow A) so as to enhance liquid moisture drainage. The plurality of fibers, filaments, tapes or yarn 112 of FIG. 3a may also be referred to as extending across the width of the protective wrap.

It is contemplated that the plurality of fibers, filaments, tapes or yarn 112 may be located in a generally diagonal manner when installed such that the liquid water is allowed to drain and readily exit a wall system.

The plurality of fibers, filaments, tapes or yarn 112 may be made by a variety of processes. In one process, the plurality of fibers, filaments, tapes or yarn 112 is made from an extrusion process.

According to one embodiment, the plurality of fibers, filaments, tapes or yarn 112 is yarn. The yarn portion is capable of absorbing moisture such as water. Additionally, the yarn portion may be capable of wicking the liquid moisture that may provide further enhancement to the hydration properties. To assist in moving the liquid water downwardly via gravity, the yarn portion is desirably installed in a generally vertical position. In addition, the yarn portion provides a channeling effect between the plurality of yarn strands to assist in moving the liquid water downwardly. If the channel formed between adjacent yarn strands is blocked by, for example, stucco, then the water may be absorbed by the yarn. This absorbed liquid water may flow downwardly via the yarn strand or may be transported to another channel for moving the liquid water downwardly.

Types of yarn that may be used in the present invention include spun yarn, bulk continuous process (bcp) yarn and natural yarn (e.g., jute). Spun yarn may be formed by a two step process in which very small filaments are extruded and chopped to a selected length. These filaments are then spun into a continuous yarn using, for example, a spinning frame. Bulk continuous process yarns may be formed by extruding 70 or 80 very small fibers into continuous filaments that are spaced in close proximity to each other. The close proximity of the continuous filaments allows for the filaments to be intertwined by air entanglement or twisting to create a single yarn. It is contemplated that the yarn may be made in a larger diameter monofilament to assist in providing strength to the protective wrap. The larger diameter monofilaments may be used on a portion of the protective wrap such as in: an alternating technique with bulk continuous process yarns.

It is contemplated that a bulk continuous filament may be used. The process for forming a bulk continuous filament includes providing a number of monofilaments that are wound or twisted together to form a larger diameter filament. One commercial example of a bulk continuous filament is manufactured by Hercules Incorporation of Wilmington, Del.

The yarn portion may be made of polymeric materials such as polyolefins, polyesters, nylons or combinations thereof. Some contemplated polyolefins to be used in forming the yarn portion include polypropylenes or polyethylenes. Each of the plurality of strands of the yarn portion may be made of a plurality of fibers or filaments twisted with each other. It is contemplated that the strands of yarn portion may have varying numbers of fibers or filaments twisted with each other such that the thicknesses of the strands differ. For example, the strands of yarn portion may alternate the number of fibers or filaments twisted with each other to provide strands of varying thicknesses. One type of yarn that is contemplated is a spun polypropylene yarn that is manufactured by Propex Fabrics of Austell, Ga.

To assist in natural vapor transmission, the protective wraps of the present invention includes the polymeric spunbonded portion 116. The polymeric spunbonded portion 116 allows water vapor to exit while preventing or inhibiting water flow therethrough. Natural vapor transmission is desirable because of moisture build-up occurring from internal moist air present in the wall cavity. Moisture build-up may occur from materials, such as green lumber, used in framing or structural sheathing. Moisture build-up may also occur from environmental elements, such as rain, during construction before an exterior finish has been installed or water that enters the installed wall system. In addition to moisture, some air will pass through the polymeric spunbonded portion 116. It is desirable that the polymeric spunbonded portion 116 has a permeability of from about 5 to about 50 perms. The most desired permeability is dependent on the application and environmental conditions where the protective wrap is used.

The polymeric spunbonded portion 116 is a breathable polymeric film. The spunbonded polymeric film may be a polyolefin film such as, for example, polyethylene, polypropylene or the combination thereof. It is contemplated that other spunbonded polymeric films may be used including polyester, nylon and the combination thereof. Spunbonded polymeric film that may be used include film marketed as DuPont's TYVEK® spunbonded olefin, which is a continuous fiber form of high density polyethylene that includes carbon and hydrogen. It is contemplated that other spunbonded polymeric films may be used.

The polymeric spunbonded portion 116 generally has a thickness of from about 0.5 mil to about 2 mils, and desirably from about 0.8 to about 1.2 mil.

The plurality of fibers, filaments, tapes or yarn 112 and the polymeric spunbonded portion 116 may be attached to each other via a suitable adhesive, heat bonding, laminating, UV-cured material or attaching method. If an adhesive is used, the adhesive is selected based on the materials used to form the plurality of fibers, filaments, tapes or yarn 112 and polymeric spunbonded portion 116. It is desirable for the adhesive to be located initially on the plurality of fibers, filaments, tapes or yarn 112 before being attached to the polymeric spunbonded portion 116. It is contemplated that the adhesive may be selectively located on the polymeric spunbonded portion 116. The adhesive in these embodiments is not typically placed in such a manner that the water vapor would be hindered in traveling through the polymeric spunbonded portion 116. In another embodiment, the adhesive may be a breathable adhesive such that water vapor is adapted to travel therethrough. A breathable adhesive is desirable in that it will not inhibit or prevent water vapor from exiting through the polymeric spunbonded portion 116.

In another method, the polymeric spunbonded portion is applied to the plurality of fibers, filaments, tapes or yarn by laminating, thermobonding, or ultrasonically bonding or welding. The thermobonding should not be performed at temperatures where the polymeric spunbonded portion film loses the ability to allow the water vapor to travel therethrough.

Additives to the protective wraps are contemplated in the present invention. For example, the protective wraps may include colorant additives to resist the glare of the sun or identification of manufacturer. The addition of colorant assists workers in installing the protective wrap. The protective wraps may also include chemical additives such as ultraviolet inhibitors and antioxidants to withstand deterioration from prolonged exposure to sunlight. In addition, the protective wraps of the present invention may be translucent. Translucent protective wraps assist in locating studs, as well as window and door openings. The protective wraps of the present invention may also include printing thereon.

The protective wraps of the present invention provide improved drainage characteristics. The protective wraps of the present invention also provide for water vapor transmission rates (WVTR) as measured by ASTM E 96, Procedure A.

The tensile strength of the protective wraps as measured by ASTM D 882 is generally greater than about 15 lbs./in, and desirably greater than about 20 or 25 lbs./in. It is beneficial that the protective wraps of the present invention are strong so as to inhibit or prevent tearing and/or fraying during or after installation. Tearing and/or fraying may, and typically will, result in unwanted air infiltration and/or moisture penetration. The TD tear strength of the protective wraps as measured by ASTM D 1117 is generally greater than 10 lbs., and desirably greater than about 15 or 20 lbs.

The protective wraps of the present invention may be formed into a number of shapes. The protective wraps, however, are generally stored in a roll on a circular cardboard core. The protective wraps of the present invention may be manufactured in a variety of sizes. Popular sizes used in residential and commercial construction include, but are not limited to, 3 foot by 100 foot (3′×100′), 4.5′×100′, 4.5′×150′, 4.5′×195′, 9′×100′, 9′×150′, 9′×195′ and 10′×150′. For example, the 3′ length extends in the transverse direction, while the 100′ length extends in the machine direction.

The thickness of the protective wraps may also vary, but is generally from about 8 to about 12 mils as measured by ASTM D 751. The thickness of the protective wraps is typically from about 9 to about 11 mils. Popular thickness of protective wraps includes about 10 mils.

The protective wraps of the present invention may be used as wraps in residential and commercial buildings. The protective wrap is typically covered by an exterior covering like siding, brick, stone, masonry or concrete veneer. Alternatively, the protective wraps of the present invention may be used as stucco drainage wraps in which the protective wraps are covered by a cementitious exterior covering (stucco or EIFS). The protective wrap may also assist in controlling the drying/curing process of the cementitious exterior covering so that the hydration of the exterior covering will not occur too fast or too slow.

According to one process of the present invention, a protective drainage wrap is attached directly to sheathing which is attached to framing members. The sheathing may be made from various materials. Some examples of materials used as sheathing include thin composite laminations, fiberboard, oriented-strand board (OSB), plywood, polyisocyanurate foam, extruded polystyrene (XPS) foam, and molded expanded polystyrene (EPS) foam. Some examples of framing members include plywood and OSB. The protective wraps may be attached mechanically to the sheathing by using fasteners such as nails or staples.

Referring back to FIG. 3a, a protective wrap 110 (plurality of fibers, filaments, tapes or yarn 112 and polymeric spunbonded portion 116) is installed over the sheathing 30. The sheathing 30 is attached to a plurality of framing members 35. Types of framing members that may be used include southern yellow pine (SYP) and spruce pine fur (SPF). Some framing members, however, may be made of metal. In another embodiment, the framing members may be structural insulated panels. The protective wrap 110 of FIG. 3a has been cut-away to depict the plurality of fibers, filaments, tapes or yarn 112 and the polymeric spunbonded portion 116. FIG. 3a also shows an exterior covering (siding 40) that is located on an exterior surface of the protective wrap 110. The polymeric spunbonded portion 116 of FIG. 3a is located adjacent to the sheathing 30. The relative locations of the layers after installation are depicted in FIG. 3b.

According to another process of the present invention, the protective wrap 110 of FIG. 4a is installed directly over the plurality of framing members 35. The protective wrap may be attached to the plurality of framing members in a similar manner as discussed above with respect to attaching the protective wrap to the sheathing. The relative locations of the layers after installation are depicted in FIG. 4b.

While the present invention has been described with reference to one or more particular embodiments, those skilled in the art will recognize that many changes may be made thereto without departing from the spirit and scope of the present invention. Each of these embodiments and obvious variations thereof is contemplated as falling within the spirit and scope of the claimed invention, which is set forth in the following claims.

Claims

1-6. (canceled)

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

providing a protective wrap including a polymeric spunbonded portion and a plurality of fibers, filaments, tapes or yarn, the polymeric spunbonded portion being adapted to allow water vapor to flow therethrough, the plurality of fibers, filaments, tapes or yarn being attached to the polymeric spunbonded portion and forming a plurality of channels to assist in facilitating a drainage path for draining liquid moisture from the protective drainage wrap;

providing at least one framing member; and

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

8. The method of claim 7 further comprising providing an exterior covering selected from siding, brick, masonry, stucco or concrete veneer and installing the exterior covering over the protective wrap.

9. The method of claim 7 wherein the at least one framing member is plywood or oriented-strand board.

10. The method of claim 7 further including providing a sheathing, the sheathing being located between the protective wrap and the at least one framing member.

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

providing a protective wrap including a polymeric spunbonded portion and a plurality of fibers, filaments, tapes or yarn, the polymeric spunbonded portion being adapted to allow water vapor to flow therethrough, the plurality of fibers, filaments, tapes or yarn being attached to the polymeric spunbonded portion and forming a plurality of channels to assist in facilitating a drainage path for draining liquid moisture from the protective drainage wrap;

providing a sheathing; and

installing the protective wrap over the sheathing.

12. The method of claim 11 further comprising providing an exterior covering selected from siding, brick, masonry, stucco or concrete veneer and installing the exterior covering over the protective wrap.

13-16. (canceled)

17. The method of claim 7 wherein the polymeric spunbonded portion is a polyolefin spunbonded portion.

18. The method of claim 17 wherein the polyolefin spunbonded portion is polyethylene, polypropylene or the combination thereof.

19. The method of claim 7 wherein the polymeric spunbonded portion includes polyester, nylon or the combination thereof.

20. The method of claim 7 wherein the plurality of fibers, filaments, tapes or yarn comprises polypropylene, polyethylene or combinations thereof.

21. The method of claim 7 wherein the plurality of fibers, filaments, tapes or yarn is fibers.

21. The method of claim 7 wherein the plurality of fibers, filaments, tapes or yarn is yarn.

22. The method of claim 11 wherein the polymeric spunbonded portion is a polyolefin spunbonded portion.

23. The method of claim 22 wherein the polyolefin spunbonded portion is polyethylene, polypropylene or the combination thereof.

24. The method of claim 11 wherein the polymeric spunbonded portion includes polyester, nylon or the combination thereof.

25. The method of claim 11 wherein the plurality of fibers, filaments, tapes or yarn comprises polypropylene, polyethylene or combinations thereof.

26. The method of claim 11 wherein the plurality of fibers, filaments, tapes or yarn is fibers.

27. The method of claim 11 wherein the plurality of fibers, filaments, tapes or yarn is yarn.