Packaged Roll Construction Material

Abstract

A packaged construction material includes a housing, a roll of construction material such as a roll of building wall sheathing fabric located within the housing and a hanging device engaged with the housing for hanging the packaged construction material on the belt or other article of clothing worn by a construction worker or on a scaffolding or other support structure. A kit including the packaged rolled construction material and a sufficient amount of fluid membrane to be used on combination with the rolled construction material to impart a secondary weather barrier to a building wall substrate is also provided.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the filing date under 35 U.S.C. 119(e) from U.S. Provisional Application For Patent Ser. No. 61/334,807 filed on May 14, 2010, which is incorporated herein in its entirety.

TECHNICAL FIELD

The present application relates to packaged materials used in the building and construction industry. The present application more particularly relates to packaged rolls of sheathing fabric used to construct building walls in the commercial and residential construction industry.

BACKGROUND

It is well known in the building and construction industry to construct an exterior wall finish system over a building wall substrate, such as a sheathing material. It is often desirable to include secondary air and water barriers in the exterior wall finish system. In order to impart the secondary air and water barriers to the wall system, a fluid membrane saturated sheathing fabric is used to span joints between adjacent sheathing and compensate to discontinuities in the sheathing material itself.

The fluid membrane saturated sheathing fabric is applied to the building wall sheathing in a multiple step process. A layer of fluid membrane is applied to the either or both sides of the joint between two adjacent sections of building wall sheathing. A bi-directional woven fabric is then at least partially embedded in the layer of fluid applied membrane. A further coat or layer of the fluid membrane is applied over the embedded sheathing fabric.

The fluid membrane saturated sheathing fabric is also used to provide a waterproof seal around windows, doors and other construction openings in the building structure. Typically, 4 inch rolls of membrane saturated sheathing fabric are used for sealing sheathing joints and discontinuities. On the other hand, it is typical to use 9 inch rolls to seal windows and other construction openings in the building structure.

Given the competitive nature of the building and construction industry, the amount of time spent installing the membrane saturated sheathing fabric and the amount of membrane saturated sheathing fabric used on each job are important considerations. Therefore, the efficiency in which the sheathing fabric is transported to the application site and in which the fabric is measured, dispensed and applied to the building wall sheathing should be optimized.

Current industry practice is to supply a large number of rolls of the sheathing fabric in a single box that has been optimized for packaging and shipping. These rolls may be pre-slit into 4 inch and 9 inch rolls of fabric. On demand, construction workers draw a single roll from the box containing a number of rolls of sheathing material. The construction workers can easily drop loose rolls of sheathing fabric, allow lengths of fabric to spool off of the roll, or allow the fabric to become contaminated by liquid or paste-like materials often found at construction sites or by dirt/debris.

Construction workers must apply the membrane saturated fabric while working on scaffolds high above the ground and in high wind conditions. It is thus difficult for the construction worker to measure and cut specific lengths of the sheathing fabric from a loose roll of material. Moreover, the presence of loose rolls of sheathing laying around constructions sites potentially creates a dangerous tripping hazard for construction workers and promote unsafe working conditions.

The problems of diminished worker productivity and material waste in connection with installing secondary weather barriers continues to plague the building industry. The prior art neglects the needs and concerns of the construction worker, not providing for the challenges involved in applying fluid membrane saturated sheathing fabrics to building walls. What is needed is a product and method for making roll sheathing fabric readily accessible to the construction worker and permitting the worker to effectively dispense the sheathing fabric materials from continuous rolls under challenging conditions encountered at a construction site, such as the workers being suspension high in the air on a scaffold or swing stage.

SUMMARY

Provided is a packaged construction material which comprises a housing, a roll of construction material located within said housing, and a hanger engaged to said housing. According to certain illustrative embodiments, the roll of construction material comprises a roll of build wall sheathing fabric that is used in combination with a fluid applied membrane to provide a secondary air and water barrier to the exterior building wall.

Additionally provided is a kit for providing an air and water barrier to a building structure which comprises a housing, a roll of construction material at least partially located within said housing, a hanger engaged to said housing, and a quantity of fluid membrane.

Furthermore provided is a method of applying a secondary weather barrier to a building structure which comprises providing a packaged construction material comprising a housing, a roll of construction material at least partially located within said housing, and a hanger engaged to said housing, engaging said packaged construction material to construction worker or a scaffolding, removing at least a portion of said construction material from said housing, and applying said removed construction material to a surface of said building structure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an illustrative embodiment of the packaged construction material.

FIG. 2 is an exploded perspective view showing the housing and hanger of the illustrative embodiment of the packaged construction material shown in FIG. 1.

FIG. 3 is an exploded perspective view showing the housing, roll construction material, and hanger of the illustrative embodiment of the packaged construction material shown in FIG. 1.

FIG. 4 is a perspective view of another illustrative embodiment of the packaged construction material.

FIG. 5 is an exploded perspective view showing the housing and hanger of the illustrative embodiment of the packaged construction material shown in FIG. 4.

FIG. 6 is an exploded perspective view showing the housing, roll construction material, and hanger of the illustrative embodiment of the packaged construction material shown in FIG. 4.

DETAILED DESCRIPTION

Provided is a packaged construction material for use at a construction site. The packaged construction material broadly comprises a housing having a sufficient size and interior volume for housing a desired quantity of a roll construction material. A desired quantity of roll construction material is at least partially located within the housing. A hanger is attached to, or otherwise engaged to, a portion of the housing. The hanger is adapted for hanging the packaged construction material on the belt or another article of clothing that is worn by a construction worker or on a scaffolding or other structure used to support the body of a construction worker at the work site during installation of the roll construction material.

The housing may comprise any suitable container that is capable of housing a desired roll of construction material. Without limitation, and only by way of illustration, the housing for containing a desired quantity of a rolled construction material comprises a box. According to certain embodiments, the box may be manufactured from paper, plastic, wood, or composite materials. Without limitation, box may be manufactured from paper. The box may be manufactured from a corrugated cardboard material to provide a sturdy housing for the roll material and for accommodating the hanger device.

According to certain illustrative embodiments, the roll of construction material comprises a roll of building wall sheathing fabric that is to be used to provide a secondary weather barrier to the exterior building wall of the structure. The building wall sheathing fabric may comprise a woven or non-woven fabric. Additionally, the building wall sheathing fabric material may comprise a fabric that is made of inorganic or polymeric materials. Without limitation, inorganic materials that may be used to manufacture the sheathing fabric the may comprise inorganic glass fibers. According to other embodiments, the building wall sheathing fabric comprises a polymeric material. Without limitation, a useful polymeric sheathing fabric comprises a non-woven polyester fabric. A suitable non-woven polyester fabric material is commercially available from BASF Corporation—Wall Systems (Jacksonville, Fla., USA) under the trade designations Sheathing Fabric 4 and Sheathing Fabric 9.

The hanger device for the package may comprise any device that may be engaged with the housing and the belt or clothing of a construction worker, or, in the alternative, which may be engaged with the housing and a support structure such as a scaffolding. According to certain embodiments, the hanging device includes elongated portion that is engaged with the housing. The opposite ends of the elongated portion terminate into hooks that are adapted to engage another object, such as a construction worker's belt or a rail of a scaffolding.

The hanger device may be manufactured from a wide variety of materials such as metals, metal alloys, plastics or composite materials. According to certain illustrative embodiments, the hanging device may be manufactured from a metal alloy such as steel. The corrugated cardboard box may sized to house a 4 inch wide roll of the rolled non-woven polyester sheathing fabric. In this particular situation, the housing is provided with a hanging device that has sufficient strength to support the weight of the housing and the 4 inch wide roll of sheathing fabric and which is suitable for engaging the belt or other clothing a construction worker. The 4 inch wide roll of fabric would typically be used to provide a secondary weather barrier to joints between adjacent sheets of sheathing material.

According to other embodiments, the corrugated cardboard box may be sized to house a 9 inch roll of said construction material. In this particular situation, the housing is provided with a hanging device that has sufficient strength to support the weight of the housing and the 9 inch wide roll of sheathing fabric and which is suitable for engaging a rail of a construction worker support structure such as a scaffolding structure typically used at a construction site. The 9 inch wide roll of fabric would typically be used to provide a seal around windows, doors and other construction openings.

The housing for the roll sheathing fabric may be provided with a number of further features. For example, and not in limitation, the corrugated box housing may comprise installation instructions printed thereon or attached thereto for installing the sheathing fabric and fluid applied membrane on a surface of a building wall for the purpose of imparting a secondary weather barrier to the wall. The installation instructions may be provided text form or pictorial form.

The corrugated box housing for the roll sheathing fabric may also include a measuring tool printed thereon for the purpose of assisting the construction worker with making the proper measurements before separating a length of sheathing fabric from the continuous roll. Without limitation, the measuring tool may comprise a ruler printed on wall box. The corrugated box housing may also comprise an cutting means that is integral to the housing.

According to further illustrative embodiments, disclosed is a kit for providing an air and water barrier to a building structure. The kit includes a packaged construction material that comprises a housing, a roll of construction material that is at least partially located within the housing, and a hanger engaged to the housing. Without limitation, the roll construction material comprises a continuous roll of building sheathing fabric for spanning joints between adjacent sheets of sheathing and for sealing around windows, doors and other construction openings. The kit further includes a quantity of fluid membrane that is needed for use in combination with the roll building sheathing fabric providing creating a secondary weather barrier against the intrusion of air and water.

According to further embodiments, disclosed is a method of applying a secondary weather barrier to a building structure to prevent the intrusion of air and water into the building wall. The method comprises providing a packaged construction material which includes a housing, a roll of construction material at least partially located within said housing, and a hanger engaged to the housing. The packaged roll construction material is engaged to the belt or other article of clothing worn by the construction worker or to support structure such as a scaffolding. The construction worker measures and removes an appropriate length of the roll construction material from the housing. The measured length of the roll material is separated from the continuous roll of material by, for example, cutting the length of roll material from the continuous roll of material. The separated length of the roll construction material is applied by the construction worker to the appropriate location on the building structure.

According to certain illustrative embodiments, the roll construction material comprises a non-woven polymeric sheathing material. The construction worker applies a first coat or layer of a fluid membrane to the exterior surface of the building wall sheathing. The construction worker measures and removes an appropriate length of the roll construction material from the housing that is engaged to the belt or other article of clothing worn by the construction worker or to the scaffolding. The sheathing fabric is then at least partially embedded within the layer of the fluid membrane applied to the exterior surface of the building wall sheathing. A second coat or layer of the fluid membrane is then applied over the at least partially embedded building wall sheathing fabric. The fluid membrane is permitted to cure to provide a sealed secondary weather barrier than minimizes or prevent the intrusion of air and water into the building wall.

The packaged construction material will now be described in greater detail with reference to the FIGURES. It should be noted that the packaged roll construction material is not intended to be limited to the illustrative embodiments shown in the FIGURES.

FIG. 1 shows a perspective view of an illustrative embodiment of the packaged roll construction material 10. Packaged roll construction material 10 comprises a cube-like box 20 having four side walls 22, 24, 26, 28, a bottom wall 30, and a top wall 32. The four side walls, bottom wall and top wall define an inner space for housing a roll of sheathing fabric 40. A hanging device 50 is engaged with the housing near the interface of the top edge 29 of side wall 28 and the rear edge 31 of top wall 32. Hanging device 50 include an elongated portion 52 that extends between side walls 22, 26 of housing 20 and just beyond side walls 22, 26. Handing device 50 also includes a pair of legs 54, 56 that extend upwardly from elongation portion 52 and top wall 32 of housing 20. Hanging device 50 also includes a pair of hook portions 58, 60 that extend downwardly and outwardly from upwardly extending legs 54, 56. As shown in FIG. 1, the leading edge 42 of the sheathing fabric 40 is show protruding from under the front edge 33 of top wall 32 of housing 20. The sheathing fabric has a width W. According to the illustrative embodiment shown in FIG. 1, the width W of the sheathing fabric 40 is about 4 inches and is particularly useful for spanning joints between two adjacent sheets of building wall sheathing.

Turning to FIG. 2, the roll of sheathing fabric 40 is shown outside of the housing 20. Packaged roll construction material 10 comprises a cube-like box 20 having four side walls 22, 24, 26, 28, a bottom wall 30, and a top wall 32. The four side walls, bottom wall and top wall define an inner space for housing a roll of sheathing fabric 40. A hanging device 50 is engaged with the housing near the interface of the top edge 29 of side wall 28 and the rear edge 31 of top wall 32. Hanging device 50 include an elongated portion 52 that extends between side walls 22, 26 of housing 20 and just beyond side walls 22, 26. Handing device 50 also includes a pair of legs 54, 56 that extend upwardly from elongation portion 52 and top wall 32 of housing 20. Hanging device 50 also includes a pair of hook portions 58, 60 that extend downwardly and outwardly from upwardly extending legs 54, 56. FIG. 2 shows that the side walls, bottom wall and top wall of the housing define an inner volume for accepting and storing a roll of sheathing material 40 until use at a work site. Front edge 34 of top 32 includes foldable flap 36 depending downwardly therefrom. Once the sheathing fabric 40 is positioned within the inner space of the housing 20, then the top wall is closed by moving the wall 32 closer to the top edges of the side walls 22, 24, 26 and inserting flap 36 inside the housing 20 adjacent the inner surface of side wall 24.

FIG. 3 illustrates the positioning of the hanging device 50 with housing 20. cube-like box 20 having four side walls 22, 24, 26, 28, a bottom wall 30, and a top wall 32. Cube-like housing 20 includes four side walls, bottom wall and top wall define an inner space for housing a roll of sheathing fabric 40. A hanging device 50 is engaged with the housing near the interface of the top edge 29 of side wall 28 and the rear edge 31 of top wall 32. Hanging device 50 include an elongated portion 52 that extends between side walls 22, 26 of housing 20 and just beyond side walls 22, 26. Handing device 50 also includes a pair of legs 54, 56 that extend upwardly from elongation portion 52 and top wall 32 of housing 20. Hanging device 50 also includes a pair of hook portions 58, 60 that extend downwardly and outwardly from upwardly extending legs 54, 56. Hanging device 50 is engaged with housing 20 by lifting top wall 32 away from the top edges of side walls 22, 24, 26 so as to expose the interface of the top edge 29 of side wall 28 and rear edge 31 of top wall 32. The elongated portion 52 of the hanging device is moved along the inner surface of top wall 32 of housing 20 and positioned into adjacent contact at the rear of housing 20 at the interface of top edge 29 of side wall 38 and the rear edge 31 of top wall 32. The terminal portions of the elongated portion 52 extend outwardly from the side walls 22, 26 of the housing 20. The upwardly extending legs 54, 56 and connected downwardly extending hook portions 58, 60 are also positioned outside of the housing 20.

FIG. 4 shows a perspective view of another illustrative embodiment of the packaged roll construction material 100. Packaged roll construction material 100 comprises a rectangular prism box 110 having four side walls 112, 114, 116, 118, a bottom wall 120, and a top wall 122. The four side walls, bottom wall and top wall define an inner space for housing a roll of sheathing fabric 130. A hanging device 140 is engaged with the housing near the interface of the top edge 119 of side wall 118 and the rear edge 121 of top wall 122. Hanging device 140 include an elongated portion 142 that extends between side walls 112, 116 of housing 110 and just beyond side walls 112, 116. Handing device 140 also includes a pair of legs 144, 146 that extend upwardly from elongation portion 142 and top wall 112 of housing 110. Hanging device 140 also includes a pair of hook portions 148, 150 that extend downwardly and outwardly from upwardly extending legs 144, 146. As shown in FIG. 1, the leading edge 132 of the sheathing fabric 130 is show protruding from under the front edge 123 of top wall 122 of housing 110. The sheathing fabric has a width W. According to the illustrative embodiment shown in FIG. 4, the width W of the sheathing fabric 150 is about 9 inches and is particularly useful for sealing around windows, doors and other construction openings in the building structure.

Turning to FIG. 5, the roll of sheathing fabric 130 is shown outside of the housing 110. Packaged roll construction material 100 comprises a rectangular prism box 110 having four side walls 112, 114, 116, 118, a bottom wall 120, and a top wall 122. The four side walls, bottom wall and top wall define an inner space for housing a roll of sheathing fabric 150. A hanging device 140 is engaged with the housing near the interface of the top edge 119 of side wall 118 and the rear edge 121 of top wall 122. Hanging device 140 includes an elongated portion 142 that extends between side walls 112, 116 of housing 110 and just beyond side walls 112, 116. Handing device 140 also includes a pair of legs 144, 146 that extend upwardly from elongation portion 142 and top wall 122 of housing 110. Hanging device 140 also includes a pair of hook portions 148, 150 that extend downwardly and outwardly from upwardly extending legs 144, 146. FIG. 5 shows that the side walls, bottom wall and top wall of the housing define an inner volume for accepting and storing a roll of sheathing material 130 until use at a work site. Front edge 124 of top 122 includes foldable flap 126 depending downwardly therefrom. Once the sheathing fabric 130 is positioned within the inner space of the housing 110, then the top wall is closed by moving the wall 122 closer to the top edges of the side walls 112, 114, 116 and inserting flap 126 inside the housing 110 adjacent the inner surface of side wall 114.

FIG. 6 illustrates the positioning of the hanging device 140 with housing 110. Rectangular prism 110 having four side walls 112, 114, 116, 118, a bottom wall 120, and a top wall 122. Housing 110 includes four side walls, bottom wall and top wall define an inner space for housing a roll of sheathing fabric 130. A hanging device 140 is engaged with the housing near the interface of the top edge 119 of side wall 118 and the rear edge 121 of top wall 122. Hanging device 140 include an elongated portion 142 that extends between side walls 112, 116 of housing 110 and just beyond side walls 112, 116. Handing device 140 also includes a pair of legs 144, 146 that extend upwardly from elongated portion 142 and top wall 122 of housing 110. Hanging device 140 also includes a pair of hook portions 148, 150 that extend downwardly and outwardly from upwardly extending legs 144, 146. Hanging device 140 is engaged with housing 110 by lifting top wall 122 away from the top edges of side walls 112, 114, 116 so as to expose the interface of the top edge 119 of side wall 118 and rear edge 121 of top wall 122. The elongated portion 142 of the hanging device is moved along the inner surface of top wall 122 of housing 110 and positioned into adjacent contact at the rear of housing 110 at the interface of top edge 119 of side wall 118 and the rear edge 121 of top wall 122. The terminal portions of the elongated portion 142 extend outwardly from the side walls 112, 116 of the housing 110. The upwardly extending legs 144, 146 and connected downwardly extending hook portions 148, 150 are also positioned outside of the housing 110.

Packaging of rolls of sheathing fabric in smaller housings improve the efficiency of construction works the use the sheathing fabrics to create composite materials comprises of fluid membrane saturated fabrics that act as air and water resistive secondary weather barriers.

Packaging of rolls of sheathing fabric in smaller housings also improves the efficiency of construction works the use the sheathing fabrics to create composite materials comprises of fluid membrane saturated fabrics that are used to seal windows and other construction openings and penetrations.

Packaging of rolls of sheathing fabric in smaller housings and providing a means by which to attached the housings to worker clothing permits the workers to perform their work with both hands without the fear of a loose roll of sheathing fabric will leave the immediate workspace by rolling.

Packaging of rolls of sheathing fabric in smaller housings and providing a means by which to attached the housings to structures, such as scaffolding or swing stages, that support the workers permits the workers to perform their work with both hands without the fear of a loose roll of sheathing fabric will leave the immediate workspace by rolling.

Packaging of rolls of sheathing fabric in smaller housings and providing a means to engage the housing to the workers or to structures that support the workers minimizes or eliminates the risk that unpackaged rolls of sheathing fabric will spool loose fabric around the construction site, thereby reducing the risk for material waste and unsafe working conditions.

Packaging of rolls of sheathing fabric in smaller housings and providing instructions directly on the housing facilitates the training of unexperienced construction workers in the methods of installing fluid membrane saturated sheathing fabrics to create a composite secondary air and water barrier for the exterior building wall.

While the packaged construction material has been described in connection with various illustrative embodiments, it is to be understood that other similar embodiments may be used or modifications and additions may be made to the described embodiments for performing the same function disclosed herein without deviating therefrom. The embodiments described above are not necessarily in the alternative, as various embodiments may be combined to provide the desired characteristics. Therefore, the putter head and putter should not be limited to any single embodiment, but rather construed in breadth and scope in accordance with the recitation of the appended claims.

Claims

1. A packaged construction material comprising:

a housing;

a roll of construction material at least partially located within said housing; and

a hanger engaged to said housing.

2. The packaged construction material of claim 1, wherein said housing comprises a box.

3. The packaged construction material of claim 2, wherein said box is manufactured from paper, plastic, wood, or composite materials.

4. The packaged construction material of claim 3, wherein said paper material comprises a corrugated cardboard material.

5. The packaged construction material of claim 4, wherein said roll of construction material comprises a roll of building wall sheathing fabric.

6. The packaged construction material of claim 5, wherein said building wall sheathing fabric comprises a woven or non-woven fabric.

7. The packaged construction material of claim 6, wherein said building wall sheathing material comprises a fabric of inorganic or polymeric materials.

8. The packaged construction material of claim 7, wherein said building wall sheathing fabric comprises inorganic glass fibers.

9. The packaged construction material of claim 7, wherein said building wall sheathing fabric comprises a polymeric material.

10. The packaged construction material of claim 9, wherein said building wall sheathing fabric comprises a non-woven polyester fabric.

11. The packaged construction material of claim 4, wherein said corrugated cardboard box is sized to house a 4 inch roll of said construction material.

12. The packaged construction material of claim 4, wherein said corrugated cardboard box is sized to house a 9 inch roll of said construction material.

13. The packaged construction material of claim 1, wherein said hanger comprises an elongated portion engaged with said housing and at least one hook portion adapted for attachment to the belt or clothing of a construction worker or to scaffolding.

14. The packaged construction material of claim 13, wherein said hanger is manufactured from metals, metal alloys, plastics or composite materials.

15. The packaged construction material of claim 4, wherein said corrugated box comprises installation instruction printed thereon or attached thereto.

16. The packaged construction material of claim 4, wherein said corrugated box comprises a measuring tool printed thereon.

17. The packaged construction material of claim 16, wherein said measuring tool comprises a ruler.

18. The packaged construction material of claim 17, wherein said corrugated box comprises an integral cutting means.

19. A kit for providing an air and water barrier to a building structure comprising the packaged construction material of claim 1 and a quantity of fluid membrane.

20. A method of applying a secondary weather barrier to a building structure comprising:

providing a packaged construction material of claim 1;

engaging said packaged construction material to construction worker or a scaffolding;

removing at least a portion of said construction material from said housing; and

applying said removed construction material to a surface of said building structure.