Vapor & moisture resistant carrier apparatus

Abstract

The carrier apparatus used for suspending an object within the periphery of a concrete slab comprises an elongate member and a moisture membrane sheet; the elongate member comprises a first distal end, and a second distal end, the elongate member is oriented such that the second distal end is pointed in a downwardly direction and the first distal end is pointed in an upwardly direction; the moisture membrane sheet is comprised of a flexible material disposed around the elongate member; the moisture membrane sheet comprises a first surface and a second surface; the first surface is facing the first distal end of the elongate member and the second surface is facing the second distal end of the elongate member.

Description

CROSS REFERENCE TO PATENT APPLICATIONS

The present invention incorporates and refers to pending patent application: “A VAPOR & MOISTURE RESISTANT CONDUIT”.

FIELD OF THE INVENTION

The present invention relates to the construction industry and more particularly relates with a system and apparatus for use in the construction of buildings, homes and other structures.

BACKGROUND OF THE INVENTION

Per current Building Codes and ASTM (American Society for Testing Materials) strict rules are in place which promulgate the use of vapor membranes to be used in construction projects. The aim of these codes, specifications and laws is to reduce the amount of moisture and radon migration into buildings, dwellings and other structures. By observing these codes one can eliminate many drastic problems frequented in the construction industry.

One of the foremost challenges with building a solid foundation for a home or a building is how to prevent moisture from permeating through the concrete foundation. The main source of moisture migration is from the groundwater underneath the structure (the other main source is through roofing). Studies show that 80% of the moisture in a building originates from building site groundwater. If groundwater or other moisture permeates through the concrete serious damage may ensue. Each year in the United States over $1.8 Billion dollars worth of damage results from moisture migration and its effects on floor coverings, adhesives, and coatings systems. What's more, many of these effects may not manifest themselves for months or years.

Moisture migration occurs through two ways: capillary action and vapor from underneath the slab. Capillary action occurs through surface tension and the general dynamic of diffusion. Vapor migration occurs due to the humidity of the soil. Oftentimes, soil tested near the slabs can exhibit a humidity approximating 100%.

In addition, moisture migration is problematic because of its effect on the air quality inside the structures such as buildings and homes. When excess moisture is able to permeate through the ground threshold, the excess moisture facilitates the rapid propagation of mold, mildew, spores, bacteria and other pathogens.

An additional negative effect associated with moisture migration is the relative acidity or alkalinity of the moisture itself. Many tests performed in moisture migrations have found pH levels in the range of 11-12 (7 being neutral such as water and 14 being maximum alkalinity. This heightened alkalinity can lead to failure or dis-bondment of the flooring system, especially when the adhesives is coupled with a re-emulsification of the adhesive.

Another undesirable effect often associated with poor vapor barrier is radon permeation through the ground threshold. Without an effective membrane under a concrete foundation, excess radon may also permeate the ground threshold causing various health maladies. Excess radon permeation has been linked with cancer.

Unfortunately, the marketplace has yet to adequately provide a means of completely stopping moisture migration and/or radon migration. Currently, materials known as vapor membrane or retarder are used to prevent sub-slab moisture migration. These materials are typically made from low-permeance polyethylene or polyolefin membranes. Although these materials are effective in preventing moisture migration, problems develop when conduits must be made through the slab and vapor membrane or retarder. When vapor membrane must be compromised in order to receive conduit for pipes or electrical wires it is difficult to completely repair the vapor membrane such that moisture migration will not inexorably ensue around the compromised seams.

According to ASTM E 1643 it is required that all damaged areas of vapor barrier be lapped with a minimum of 6″ of vapor barrier and sealant materials. Or, in the alternative ASTM E 1745-97 promulgates that the producer shall provide instructions for lap sealing, including minimum width of lap, method of sealing, and either supply or specify suitable products for lap sealing.

Unfortunately, it is difficult to comply with these requirements at points of compromise where structures must traverse a vapor barrier, specifically the requirement for a 6″ overlap. Typically the vapor barrier is used to boot around all penetrations and seal with tape to create a continuous vapor barrier. However, it may not always be possible to create a seal which accords with general codes and standards where a pipe must traverse a vapor barrier from underneath a slab. The reason for this is because of the awkward processes used to make this pipe boot due to the procedures which include several cuts of membranes overlapping, taping, and mastic

Construction builders are faced with yet another problem in the industry which is the process of leveling off the concrete after wet concrete has been placed into a frame. Typically, the screeding process is used in the industry for the purpose of leveling off the concrete such that there is a smooth and uniform level to the surface of the concrete. The screeding process incorporates several stakes positioned in a grid throughout the concrete frame. These stakes support a railing which is then leveled off with a 2″×4″ wooden member used to move back and forth over the wet concrete.

Due to the issues related above, construction builders find the screeding process challenging due to the fact that they cannot place screed stakes throughout the inside of a concrete frame prior to the concrete pouring process. This is because the stakes must be pulled out after concrete placement. By pulling the stakes out, the vapor membrane will be torn apart. As a result, this tear renders the vapor membrane to become non-compliant with most building codes. The reason why the stakes must be removed is because typically the stakes are made of wood, steel or similar materials.

Finally, those in the construction industry are frequently challenged by the placement and routing of electrical wires and other conduits throughout the structure. Currently, electrical wiring and their attendant conduits must be trenched and routed in such a way that it is very labor intensive because the wiring must be placed underground rather than above ground. It would be a lot easier and more cost effective if one were able to bypass the trenching and route the electrical wiring through the concrete slab. However, since one cannot suspend structures within the periphery of a concrete slab while abiding by standard building codes this option is not available.

Therefore, what is clearly needed in the art is an apparatus for use in suspending objects through a concrete slab while preventing moisture migration through a concrete slab. Furthermore, the apparatus should suspend objects through the concrete slab in accordance with building codes and other regulations requiring the use of vapor membranes (sometimes known as vapor barrier or vapor membrane or membranes). Moreover, the system and apparatus should enable one to leave screed stakes inside the concrete thereby preserving the integrity of the vapor barrier or membrane.

SUMMARY OF THE INVENTION

It is an object of the present invention to prevent moisture migration and radon migration by repairing the compromise of sub-slab membranes such as vapor membrane or retarder. Such system possesses a water-tight seal and enables one to suspend objects through a concrete slab without compromising the moisture vapor underneath a concrete slab. This suspension system should be in accordance with building codes and regulations requiring the use of vapor membrane or membrane.

Another object of the present invention is to provide a system and/or apparatus wherein the stakes may be left in place thereby avoiding the consequences associated with their removal.

Another object of the present invention to provide an apparatus for the purpose of positioning anchor bolts within the periphery of a concrete framework before the pouring of concrete while being in compliance with building codes and other regulations requiring the use of vapor membrane or membrane.

The final object of the present invention is to provide for an apparatus for the purpose of enabling electrical wiring and other conduits through a concrete slab while maintaining the integrity of the membrane. This apparatus will be in accordance with building codes requiring the use of vapor membrane or membrane

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 is a perspective view of a preferred embodiment of the present invention.

FIG. 2 is an exploded view of a preferred embodiment of the present invention.

FIG. 3 is a perspective view of a preferred embodiment of the present invention

FIG. 4 is an exploded view of a preferred embodiment of the present invention.

FIG. 5 is a perspective view of a preferred embodiment of the present invention.

FIG. 6 is an exploded view of a preferred embodiment of the present invention.

FIG. 7 is a perspective view of a preferred embodiment of the present invention

DESCRIPTION OF PREFERRED EMBODIMENTS

According to a preferred embodiment of the present invention, a unique apparatus is used to repair the compromise of membrane sheets used for the purpose of preventing moisture migration and/or radon migration. The following apparatus enables positioning and placement of anchor bolts, rebars, electrical gang boxes, and other objects through concrete slabs without “wet-setting”. The present invention also enables the support of electrical wires and other conduits with their attendant structures to be supported through the concrete slab without trenching and “wet-setting”. And the present invention also enables a more efficient screeding system which enables the placement and positioning of screed assemblies in concrete while being in compliance with building codes and other regulations. Moreover, the improved screed posts may be left in the concrete slab after the concrete has been poured. The present invention is described in enabling detail below.

First, it will be pointed out here that the present invention incorporates patent application “A VAPOR & MOISTURE RESISTANT CONDUIT”. This foregoing patent application incorporates many of the concepts to be discussed in the present application.

For the purposes of the present invention the term “moisture membrane sheet” shall hereafter refer to any material which is designed to prevent moisture, vapor, radon, or other fluid migration. Examples include vapor barrier or vapor retarder. These materials are commonly utilized in building envelopes, under concrete slabs, and other areas where preventing moisture migration is critical to the longevity of a building structure.

For the purposes of the present invention the term “periphery” shall mean the outer edges of a structure to which the present invention is intended to be used. For instance, the periphery of a concrete slab refers to any area within the concrete slab whether on the edges or anywhere within the slab.

For the purposes of the present invention the term “screed assembly” shall refer to the assemblage comprising a screed hook and a screed post. Both parts are well known in the art. This apparatus is used for the purpose of suspending a member (usually a 2″×4: wooden member).

For the purposes of the present invention the term “wet-setting” is the practice of placing an object within concrete soon after the concrete has been poured and before the concrete has congealed or hardened. This practice should be contrasted with the appropriate practice of placing an object within the periphery of a concrete framing before the concrete has been poured into the concrete framing.

FIG. 1 illustrates a preferred embodiment of the present invention. The carrier apparatus 100 used for suspending an object within the periphery of a concrete slab comprises an elongate member 101 and a moisture membrane sheet 102. The elongate member comprises a first distal end 103, a second distal end 104, and a membrane lip 105.

The elongate member is oriented such that the second distal end is pointed in a downwardly direction and the first distal end is pointed in an upwardly direction. The membrane lip is disposed around the circumference of the elongate member and abuts with the moisture membrane sheet nearest the first distal end. In various preferred embodiments the elongate member may be comprised of either plastic, metal, wood, ceramic, or other suitable materials.

In some preferred embodiments the elongate member is a stake 110. The reason a stake is suitable for the present invention is that the pointed tip on the second distal end facilitates easier placement of the elongate member into the ground. However, other shapes and apparatus may also comprise the elongate member. In other preferred embodiments the elongate member may be a long wire. In others, it may be a PVC pipe. For this reason, the scope of the present invention is not limited to just stakes for the use of the elongate member.

In some preferred embodiments first distal end further comprises an orifice to receive an object to be suspended. Additionally, this receiving orifice may be threaded in order to affix with an object to be suspended. And alternatively, the orifice of the first distal end may be affixed to the object through sizing to create an interference fit.

Moreover, the first distal end may be fashioned to be a male adapter for the purpose of affixing the elongate member with the object to be suspended. In turn, the object would provide a female adapter for receiving the first distal end.

In some preferred embodiments the first distal end is fashioned to mate with another object. The first distal end in some preferred embodiments may be tapped, threaded, sized to fit, etc. with another object to be suspended thereto. Or, in some other preferred embodiments, the first distal end may be affixed with a connecting apparatus 108. The connecting apparatus has a first mating end 109 and a second mating end 110. The first mating end is affixed to the first distal end of the elongate member. The connecting apparatus, in turn, is designed to affix to the object which will be suspended.

In some preferred embodiments either the connecting apparatus or the first distal end will connect with a screed assembly 112, an electrical gang box 113, or an anchor bolt 114. In some preferred embodiments, these objects will be incorporated into the invention. Each of these structures may have a mating member 115 which will mate with either the first distal end of the elongate member or the connecting apparatus.

The moisture membrane sheet is comprised of a flexible material disposed around the elongate member. In some preferred embodiments the flexible material is comprised of vapor barrier or vapor retarder. These vapor barriers or retarders are typically comprised of polyethylene or similar materials.

In other preferred embodiments, the moisture membrane sheet is comprised of ethylene propylene diene monomer rubber (epdm). The reason epdm is used is because it is moisture resistant, tough, and has the ability to create a moisture tight interference fit with the elongate member. By sliding the elongate member into the orifice of the sheet of epdm the resulting assemblage of the elongate member and the epdm sheet is seemingly seamless and resembles a unitary apparatus.

The moisture membrane sheet comprises a first surface 111 and a second surface 112. The first surface is facing the first distal end of the elongate member and the second surface is facing the second distal end of the elongate member. On either surface there may be a plurality of adhesive layers 106 with attendant liners 107. These adhesive layers are used for the orderly placement of the moisture membrane sheet upon the surface it is intended to interface.

FIG. 5 illustrates another preferred embodiment of the present invention. Universal carrier apparatus 200 comprises a stake member 201, a membrane sheet 202, washers 203, 204 and a universal adapter 205. The universal carrier apparatus is thrusted into the ground before concrete placement. Thereafter, concrete pouring takes place. The concrete pouring will envelop and cover the membrane sheet as well as portions of the coupling and in some cases portions or all of the universal adapter 204. In some preferred embodiments, the membrane sheet may also incorporate adhesive materials such as the preceding embodiments. A layer of adhesive may be covered with a removable strip on the surface of the membrane sheet.

The membrane sheet 202 is comprised of material well known in the art as vapor membrane or vapor retarder. Other types of membranes which may also be used for the purpose of preventing moisture migration and/or radon migration are: acetone membrane, moisture membrane, Stego Wrap (a Trademarked material), Visqueen (a Trademarked material) Pandex (a Trademarked material, Vaporblock (a Trademarked material), Moistop (a Trademarked material) and others.

Most membrane sheets 201 are comprised of either polyethylene or polyolefin materials. Another material suitable for preventing moisture migration is EPDM (ethylene propylene diene monomer rubber) (These materials are used because they may possess the requisite tensile strength along with the low permeance in order to prevent moisture migration and/or radon migration.

Since there abound a panoply of different membrane sheets which are designed for different uses and purposes (some may be designed for certain types of grade, construction, alkalinity levels, radon retardants, etc.) the specific type of membrane sheet is of no consequence insofar as it meets minimum standards set forth by the governing construction laws and regulations and that of their respective manufacturers.

FIG. 6 illustrates an exploded view of the universal carrier apparatus 200. Both the universal adapter and the stake member sandwiches the membrane sheet. The membrane sheet has an orifice 210 in the center in order to allow for insertion of the coupling. In some preferred embodiments, the membrane sheet may also incorporate adhesive materials such as the preceding embodiments. A layer of adhesive may be covered with a removable strip on the surface of the membrane sheet.

Washers 203, 204 are used in order to sandwich the membrane and further enable a water tight seal. In some preferred embodiments the washers are comprised of rubber because of its particular water-proof properties and its pliability. Or in some other preferred embodiments the washers may be made of either metal or plastic. The particular type of washers used will depend upon the type of object which the present invention will suspend as well as climate conditions. For these reasons, the scope of the present invention should not be construed as requiring one particular washer over another. Just about any washer may be used and adapted for use with the present invention. Furthermore, in some preferred embodiments, the present invention may not require the use of washers. Again, the scope of the present invention should not be construed as requiring the use of washers or the equivalent means of washers.

Stake member 201 in a preferred embodiment possesses a narrow and concentrated point on one distal end hereafter referred to as tip 206. This tip makes it easier for the universal carrier to be placed into the ground. The stake member also possesses a central portion which is comprised of a plurality of planar surfaces 108 which meet in the middle. FIG. 7 illustrates this cross-sectional view of the stake member. The purpose of these planar surfaces is for added stability such that there will be less lateral movement of the universal carrier. In preferred embodiments where screeding is used stability becomes an overriding factor because precise leveling is crucial. In the event the universal carrier is displaced only a few degrees, the concrete slab may be seriously compromised. In addition, the distal end of the state member opposite the tip is the mating end 207.

In some preferred embodiments the mating end is threaded. Consequently, the universal adapter is complimentarily tapped and sized to fit with the mating end. And in some other preferred embodiments the mating end is tapped. When the mating end is tapped, the corresponding universal adapter is threaded and sized to fit and mate with the mating end. Moreover, other methods may also be used to connect and affix the mating end with the universal adapter. For example, the mating end may be affixed with the universal adapter through an orifice on either the mating end or the universal adapter. And consequently, the corresponding mating end or universal adapter would possess a spring loaded button. As the button is pressed downwards, the mating end or the universal adapter is placed over the corresponding piece until the button reaches the orifice and snaps upwards thereby retaining the two corresponding pieces.

Whereas, in other embodiments the stake member may be comprised of a single PVC pipe. The disadvantage of using a pipe is that the blunt surface of the walls will push the sand or other ground material further outwards than the stake member. The pipe is round and may spin in the ground. This is because the stake member is less concentrated at the distal end and will result in less ground displacement.

It should be noted here that the stake member may embody many different shapes, forms, apparatuses, sizes, and materials. The various characteristics will depend upon the nature of the object to be suspended above the concrete slab as well as the relative functions of the objects to be suspended over the concrete slab. For instance, as in the screeding processes, stability and precision of positioning is paramount. For this reason, the size, shape, or material used to comprise the stake member or to shape the stake member is not intended to limit the scope of the present invention.

The universal adapter is for use in securing an instrument. (Instrument shall be explained with more detail below.) In some preferred embodiments the universal adapter is comprised of a receiving orifice 301, a base, instrument adapter and instrument orifice. The receiving orifice is sized to fit the mating end of the stake. In some preferred embodiments both the mating end of the stake and the receiving orifice are complimentarily threaded to affix to one another. And in some preferred embodiments the receiving orifice and the coupling are tapped to create an interference fit. Glue may also be added to secure this fitting.

In other preferred embodiments the receiving orifice may be replaced with a male connecting piece. This male piece may be either tapped, threaded, glued, etc. The same holds true for the instrument orifice. In short, the means of affixing the universal adapter with the instrument and with the coupling is of no consequence. For this reason, the means of affixing any part of the present invention should not be construed to be limiting the scope of the present invention.

It should also be noted that in some preferred embodiments there may not be a universal adapter. In this embodiment, the mating end of the stake will be connected or affixed directly with the object to be suspended above the concrete. For this reason, the scope of the present invention does not necessarily require use of the universal adapter.

It will be apparent to the skilled artisan that there are numerous changes that may be made in embodiments described herein without departing from the spirit and scope of the invention. For example, various types of materials such as copper, aluminum, etc. may comprise some of the elements of the present invention. Or, in some other preferred embodiments, mating members may be alternatively, tapped, threaded, glued, compressed, etc. in order to create the interference fit. Also, various different types of washers are available which may also be used in accordance with the present invention. The possibilities are endless. As such, the invention taught herein by specific examples is limited only by the scope of the claims that follow.

Claims

1. A carrier apparatus used for suspending an object within the periphery of a concrete slab comprising:

an elongate member and a moisture membrane sheet;

the elongate member comprises a first distal end, a second distal end, and a membrane lip;

the elongate member is oriented such that the second distal end is pointed in a downwardly direction and the first distal end is pointed in an upwardly direction;

the membrane lip is disposed around the circumference of the elongate member and abuts with the moisture membrane sheet nearest the first distal end;

the moisture membrane sheet is comprised of a flexible material disposed around the elongate member; the moisture membrane sheet comprises a first surface and a second surface; the first surface is facing the first distal end of the elongate member and the second surface is facing the second distal end of the elongate member.

2. (canceled)

3. (canceled)

4. (canceled)

5. (canceled)

6. (canceled)

7. The carrier apparatus for suspending an object within the periphery of a concrete slab of claim 1 wherein the moisture membrane sheet is comprised of ethylene propylene diene monomer rubber (epdm).

8. The carrier apparatus for suspending an object within the periphery of a concrete slab of claim 1 wherein the moisture membrane sheet is comprised of polyethylene.

9. (canceled)

10. (canceled)

11. (canceled)

12. (canceled)

13. (canceled)

14. The carrier apparatus for suspending an object within the periphery of a concrete slab of claim 13 wherein the first end of the adapter is affixed to either the first distal end of the elongate member or the connecting apparatus; and the second end is mated with an object to be suspended within the periphery of a concrete slab.

15. (canceled)

16. (canceled)

17. (canceled)

18. A carrier apparatus for suspending an object and for preventing moisture migration comprising: an elongate member and a moisture membrane sheet;

the elongate member comprises a first distal end, a second distal end, and a membrane lip;

the elongate member is oriented such that the second distal end is pointed in a downwardly direction and the first distal end is pointed in an upwardly direction;

the second distal end of the elongate member is a pointed tip;

the membrane lip is disposed around the circumference of the elongate member and abuts with the moisture membrane sheet nearest the first distal end;

the moisture membrane sheet is comprised of a flexible material disposed around the elongate member; the moisture membrane sheet comprises at least one adhesive layer, at least one liner disposed upon the adhesive layer, a first surface and a second surface; the first surface is facing the first distal end of the elongate member and the second surface is facing the second distal end of the elongate member.

19. The carrier apparatus of claim 18 further comprising a screed apparatus assembly.

20. The carrier apparatus of claim 19 further comprising an electrical gang box.