Note: Descriptions are shown in the official language in which they were submitted.
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1
PROTECTIVE DRAINAGE WRAPS
CROSS-REFERENCE To IZELATED APPLICATION
100011 This application is a continuation-in-part of Application No.
10/869,333
filed on June 16, 2004, which is entitled "Method for Producing Protective
Drainage Wraps";
Application No. 10/869,333 is a division of Application No. 10/255,273 filed
on September
26, 2002, which is entitled "Protective Drainage Wraps"; Application No.
10/255,273 is a
continuation-in-part of U.S. Application No. 09/788,776 filed on February 20,
2001, which is
entitled "Protective Drainage Wraps". Application Nos. 10/869,333; 10/255,273;
and
09/788,776 are all incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] 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 cross-woven material, cross-laminate
material or mesh
material.
BACKGROUND OF THE INVENTION
[0003] 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.
[0004] 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),
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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.
[0005] 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.
[0006] 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.
[0007] 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
100081 According to one embodiment, a protective drainage wrap comprises a
cross-woven material portion, cross-laminate material portion or mesh material
portion in a
first direction and in a second direction, and a breathable solid layer
portion. The material in
the first direction comprises a polyolefin, polyester, nylon or combinations
thereof. The
material in the second direction comprises a polyolefin, polyester, nylon or
combinations
thereof The first direction is roughly perpendicular to the second direction.
The cross-
woven material portion, cross-laminate material portion or mesh material
portion is adapted
to facilitate a drainage path. The breathable solid layer portion is attached
to the cross-woven
material portion, cross-laminate material portion or mesh material portion.
The breathable
solid layer portion is adapted to allow water vapor to flow therethrough.
[0009] According to another embodiment, a protective drainage wrap comprises a
cross-woven material portion, cross-laminate material portion or mesh material
portion in a
first direction and in a second direction, and a breathable solid layer
portion. The material in
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the first direction comprises a polyolefin, polyester, nylon, yarn or
combinations thereof. The
material in the second direction comprises a polyolefin, polyester, nylon,
yarn or
combinations thereof. The first direction is roughly perpendicular to the
second direction.
The cross-woven material portion, cross-laminate material portion or mesh
material portion is
adapted to facilitate a drainage path. At least one of the materials in the
first direction and the
second direction is yarn. The breathable solid layer portion is attached to
the cross-woven
material portion, cross-laminate material portion or mesh material portion.
The breathable
solid layer portion is adapted to allow water vapor to flow therethrough.
[0010] According to one method, a protective wrap is provided to be used in a
building. The protective wrap is provided and includes a cross-woven material
portion, cross-
laminate material portion or mesh material portion in a first direction and in
a second
direction, and a breathable solid laver portion. The material in the first
direction comprises a
polyolefin, polyester, nylon, yam or combinations thereof. The material in the
second
direction comprises a polyolefin, polyester, nylon, yarn or combinations
thereof. The first
direction is roughly perpendicular to the second direction. The cross-woven
material portion,
cross-laminate material portion or mesh material portion is adapted to
facilitate a drainage
path. The breathable solid layer portion is attached to the cross-woven
material portion,
cross-laminate material portion or mesh material portion. The breathable solid
layer portion
is adapted to allow water vapor to flow therethrough. At least one framing
member is
provided. The protective wrap is installed over at least one of the framing
members.
[0011] According to another method, a protective wrap is provided to be used
in a
building. The protective wrap is provided and includes a cross-woven material
portion, cross-
laminate material portion or mesh material portion in a first direction and in
a second
direction, and a breathable solid layer portion. The material in the first
direction comprises a
polyolefin, polyester, nylon, yarn or combinations thereof. The material in
the second
direction comprises a polyolefin, polyester, nylon, yarn or combinations
thereof. The first
direction is roughly perpendicular to the second direction. The cross-woven
material portion,
cross-laminate material portion or mesh material portion is adapted to
facilitate a drainage
path. The breathable solid layer portion is attached to the cross-woven
material portion,
cross-laminate material portion or mesh material portion. The breathable solid
layer portion
is adapted to allow water vapor to flow therethrough. Sheathing is provided
and the
protective wrap is installed over the sheathing.
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[0012] According to one method of forming a protective drainage wrap, a cross-
woven material portion, cross-laminate material portion or mesh material
portion is provided
in a first direction and in a second direction. The material in the first
direction comprises a
polyolefin, polyester, nylon, yarn or combinations thereof. The material in
the second
direction comprises a polyolefin, polyester, nylon, yarn or combinations
thereof. The first
direction is roughly perpendicular to the second direction. The cross-woven
material portion,
cross-laminate material portion or mesh material portion is adapted to
facilitate a drainage
path. A breathable solid layer portion is applied to the cross-woven material
portion, cross-
laminate material portion or mesh material portion. The breathable solid layer
portion is
attached to the cross-woven material portion, cross-laminate material portion
or mesh
material portion. The breathable solid layer portion is adapted to allow water
vapor to flow
therethrough.
BRIEF DESCRIPTION OF THE DRAWINGS
100131 FIG. 1 is a top perspective view of a cross-woven protective wrap
according to one embodiment.
[0014] FIG. 2a is a cross-sectional view taken generally along line II-II of
FIG. 1
using a breathable film.
[0015] FIG. 2b is a cross-sectional view taken generally along line II-II of
FIG. 1
using a breathable coating.
[0016] FIG. 3 is a top perspective view of a cross-laminated protective wrap
according to one embodiment of the present invention.
[0017] FIG. 4 is a cross-sectional view taken generally along line IV-IV of
FIG. 3.
100181 FIG. 5 is a top perspective view of a mesh protective wrap according to
one embodiment.
[0019] FIG. 6 is a cross-sectional view taken generally along line VI-VI of
FIG. 5.
[0020] FIG. 7a 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.
[0021] FIG. 7b is a cut-away perspective view of the protective wrap of FIG. 3
fastened to sheathing and a framing member according to another embodiment of
the present
invention.
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[0022] FIG. 8 is a cut-away perspective view of the protective wrap of FIG. 5
fastened to sheathing and a framing member according to a further embodiment
of the present
invention.
100231 FIG. 9 is a top perspective view of a yarn cross-woven protective wrap
according to yet another embodiment of the present invention.
[0024] FIG. 10 is a cross-sectional view taken generally along line X-X of
FIG. 9.
[0025] FIG. I 1 is a cut-away perspective view of the protective wrap of FIG.
9
fastened to sheathing and a framing member according to yet another embodiment
of the
present invention.
[0026] 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
[0027] 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.
[0028] According to one embodiment, the protective wrap 110 of FIGs. 1 and 2
comprises a cross-woven material portion 112 and a breathable solid layer
portion 116. In
another embodiment, the protective drainage wrap may includes a cross-laminate
material
portion, such as shown in FIGs. 3 and 4 with a cross-laminated protective
drainage wrap 120.
In a further embodiment, the protective drainage wrap may include a mesh
material portion,
such as shown in FIGs. 5 and 6 with a mesh protective drainage wrap 130.
[0029] The cross-woven material portion, cross-laminate material portion or
mesh
material portion of the protective wrap provides a desirable strength that
assists in inhibiting
or preventing tears and/or fraying that may be caused during installation.
These tears and/or
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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.
[0030] The cross-woven material portion is located in a first direction and a
second direction, in which the first direction is roughly perpendicularly to
the second
direction. It is desirable for the first direction to be substantially
perpendicular or
perpendicular to the second direction of the cross-woven material. For
example, referring
back to FIG. 1, the cross-woven material portion 112 comprises a plurality of
machine
direction (MD) tapes or strands 112a and a plurality of transverse direction
(TD) tapes or
strands 112b. The machine direction is also referred to as "warp", while the
transverse
direction is also referred to as "fill" or "weft".
[0031] The scrim shown in FIG. 1 is a 10 x 4 count scrim (MD number per inch x
TD number per inch) that has been enlarged. It is also contemplated that
various other scrim
counts may be used, including a 7 x 3 count, a 10 x 5 count and a 16 x 5
count, in forming the
cross-woven material portion of the present invention. The scrim count is
typically a greater
number in the machine direction than the transverse direction. The MD scrim
count is
generally from about 6 to about 24 tapes per inch, while the TD scrim count is
generally from
about 3 to about 12 tapes per inch. The MD and TD scrim counts are generally
lesser in
number per inch as the respective widths of the MD and TD tapes are increased.
[0032] The plurality of machine direction tapes 112a may be made of materials
such as polyolefins, polyesters, nylons or combinations thereof. Polyolefins
that may be used
in forming the machine direction tapes 112a 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-l-
butene, 4-methyl-l-pentene, 4-methyl-l-hexene, 5-methyl-l-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.
[0033] The term "polyethylene" as used herein includes low density
polyethylene
(LDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE),
very low
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7
density polyethylene (VLDPE), linear low density polyethylene (LLDPE),
metallocene-
catalyzed linear low density polyethylene (mLLDPE) and combinations thereof.
[0034] 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).
[0035] Each of the plurality of machine direction tapes 112a may be made of a
single fiber or filament, or a plurality of fibers or filaments aligned with
each other. It is
contemplated that the plurality of machine direction tapes 112a may be made of
a mixture of
single fibers or filaments, and a plurality of fibers or filaments 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 machine
direction tapes
112a vary. The machine direction tapes 112a may also be referred to as cords.
As shown in
FIG. 1, the plurality of machine direction tapes 112a is substantially flat.
[0036] The plurality of transverse direction tapes 112b may be made of
materials
such as polyolefins, polyesters, nylons or combinations thereof as described
above with
respect to the machine direction tapes 112a. Polyolefins that may be used in
forming the
transverse direction tapes 112b include polypropylenes and polyethylenes. Each
of the
plurality of transverse direction tapes 112b may be made of single fibers or
filaments, or a
plurality of fibers or filaments aligned with each other. It is contemplated
that the plurality of
transverse direction tapes 112b may be made of a mixture of single fibers or
filaments, and a
plurality of fibers or filaments 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 transverse direction tapes 112b vary. The
transverse
direction tapes 112b may also be referred to as cords. As best shown in FIG.
2, each of the
transverse direction tapes 112b is shaped in a generally oval manner. The
plurality of
transverse direction tapes 112b is desirably substantially circular or
circular in shape. The
transverse direction tapes 11 2b are shaped in a manner that will allow water
to flow down the
channels formed between the transverse direction tapes 112b via gravity.
[0037] The thicknesses of transverse direction tapes 112b of the present
invention
provide unique vertical channels, when installed, that enhance moisture
drainage external to
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the protective wrap (i.e., between the protective wrap and the exterior
finish). The installed
transverse direction tapes 112b allow water to readily exit a wall system. To
enhance
moisture drainage, the thickness of the transverse direction tapes 112b is
generally at least
about 2 times greater than the thickness of the machine direction tapes 112a.
This is more
desirable in cross-woven protective wraps as opposed to cross-laminated
protective wraps.
The thickness of the transverse direction tapes 112b is generally at least
about 3 or about 4
times greater than the thickness of the machine direction tapes 112a. The
thickness of the
transverse direction tapes 112b may be from about 6 to about 8 times greater
than the
thickness of the machine direction tapes 112a.
[0038] The plurality of transverse direction tapes 112b according to one
embodiment is shown in FIG. 7a after being installed. The transverse direction
tapes 112b
are generally perpendicular to the machine direction tapes 112a so as to
enhance moisture
drainage. It is contemplated that the tapes 112b may be located roughly
perpendicular (e.g.,
generally diagonally) with respect to the tapes 112a as long as the tapes 112b
are in a
generally downward position when installed.
[0039] The cross-woven material portion 112 comprising the plurality of MD and
TD tapes 112a and 112b may be made from an extrusion process. After being
formed, the
tapes 112a and 112b may be cross-woven by different processes. One
contemplated process
for weaving the tapes 112a and 112b together is through the use of a loom.
[0040] Alternatively, the MD and TD tapes 112a and 112b may be cross-
laminated to each other by attaching the tapes 112a and 112b together via the
use of a suitable
adhesive, heat bonding, UV-cured material or other attaching method (see FIGs.
3 and 4). The
adhesive is selected based on the materials used to form the tapes 112a and
112b. The cross-
laminated protective wrap 130 of FIGs. 3 and 4 form natural channels without
increased
thickness because the tapes 112b form a natural channel over the tapes 112a.
[0041] Referring to FIGs. 5 and 6, the protective wrap 130 is shown that
includes
a mesh material portion 132 and the breathable solid layer portion 116. The
mesh material
portion 132 includes a pattern that has a plurality of tape or strand portions
extending in a first
direction and in a second direction. Specifically, the mesh material portion
132 includes a
plurality of machine direction tape or strand portion 132a and a plurality of
transverse
direction tape or strand portion 132b. The mesh material portion is an
integral structure and
may be formed using a mold.
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[0042] The mesh material may have unequal number of tape or strand portions
going in the first and second directions. These may be similar to the scrim
counts described
above in connection with the machine and transverse direction tapes 112a,
112b. The mesh
material portion 132 may be made of materials such as polyolefins, polyesters,
nylons or
combinations thereof. Polyolefins that may be used in forming the tape
portions 132a, 132b
include polypropylenes or polyethylenes. The mesh material portion 132 is
shaped in a
manner that will allow water to flow down the channels formed between the
transverse
direction tape portions 132b via gravity. It is desirable for the thickness of
the transverse
direction tape portion 132b to be at least about 2 times greater than the
thickness of the
machine direction tape portion 132a so as to provide a channel to enhance the
drainage of the
water from the wall system. The thickness of the transverse direction tape
portion 132b may
be at least about 3 to 4 times greater than the thickness of the machine
direction tape portion
132a.
[0043] To assist in natural vapor transmission, the protective wraps of the
present
invention includes a breathable solid layer portion (see, e.g., FIGs. I and 2
with breathable
solid layer portion 116). The breathable solid layer portion 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
breathable solid
layer portion. It is desirable that the breathable solid layer portion 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.
[0044] The breathable solid layer portion of the protective wrap is applied to
the
cross-woven material portion, cross-laminate material portion or the mesh
material portion.
The breathable solid layer portion 116 may be a breathable coating or may be a
breathable
film. For example, FIG. 2a shows the breathable solid layer portion 116 as a
breathable film
116a, while FIG. 2b shows the breathable solid layer portion 116 as a
breathable coating
116b. The breathable solid layer portion includes materials that are
inherently breathable or
materials that are processed in such a manner that the material becomes
breathable.
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[0045) The breathable solid layer portion may be made of materials that are
inherently breathable such as polyurethane, nylon or spun-bonded polyolefins.
It is
contemplated that other materials may be used in forming the breathable solid
layer portion.
The breathable solid layer portion made of inherently breathable material may
be a breathable
coating or a breathable film.
[0046] The breathable coating may be applied by various processes to the cross-
woven material portion, cross-laminate material portion or the mesh material
portion.
According to one process of the present invention, pellets of a resin(s) for
forming the
breathable coating are added in their solid form into an extrusion hopper.
These pellets are
heated to a sufficient temperature in an extruder to form a molten material.
The molten
material that will form the breathable coating exits the extruder through a
die. The extruder
typically has a horizontal die in which the molten material exits and falls
vertically by gravity
onto a surface of the cross-woven material portion, cross-laminate material
portion or the
mesh material portion. At the same time the molten material is exited from the
extrt.ider, the
cross-woven material portion, cross-laminate material portion or the mesh
material portion
proceeds in a direction transverse to the extruder.
[0047] The cross-woven material portion, cross-laminate material portion or
the
mesh material portion may proceed on a transport mechanism involving rollers
that pull the
cross-woven, cross-laminated material or mesh material portion along a
threaded path. The
transport mechanism is located below the extruder die that extrudates the
coating. The
amount of breathable coating applied to the cross-woven material portion,
cross-laminate
material portion or the mesh material portion depends on factors such as the
speed of the
transport mechanism, size of the extruder die opening, and speed of the
coating exiting the
die. The amount of breathable coating used should be sufficient to form a
breathable solid
layer portion that covers the cross-woven material portion, cross-laminate
material portion or
the mesh material portion without leaving pin holes or interstices.
[0048] The breathable coating or film of the present invention is generally
applied
to obtain a thickness of from about 0.5 mil to about 2 mils, and desirably
from about 0.8 to
about 1.2 mil.
[0049] In another embodiment, the breathable solid layer portion may be made
of
materials that are further processed to become a breathable film or breathable
coating. In one
process, material is extruded or blown to form a film. The resulting extruded
or blown film is
CA 02578488 2007-02-14
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then further processed (e.g., stretched) to form a breathable film or
breathable coating that
provides air and moisture breathability. It is contemplated that other
processing may be used
to form the breathable film or breathable coating.
100501 In one process, material is extruded to form a coating. The coating is
applied to the cross-woven material portion, cross-laminate material portion
or the mesh
material portion, and then further processing (e.g., stretching) occurs to
form a breathable
coating.
[0051] Materials that may be further processed to form the breathable solid
layer
portion include polyolefins, polyurethanes, polyesters and nylons. Polyolefins
that may be
used in forming the breathable film include polyethylene, polypropylene or the
combination
thereof. It is contemplated that other materials may be used and further
processed to form the
breathable solid layer portion.
[0052] It is contemplated that the material to be used in forming the
breathable
film or coating may include additional components such as a mineral or
inorganic filler. Non-
limiting examples of fillers that may be used include calcium carbonate, talc,
clay, titanium
dioxide, barium sulfate, fungible fillers, polystyrenes, and zeolites. It is
contemplated that
other materials may be used including other finely powdered inorganic
materials. The
average size of the mineral or inorganic filler may vary, but is generally
from about 0.1 to
about 5 microns. The average particle size and size distribution is typically
optimized for the
desired properties and end uses.
[0053] For example, the breathable film or coating may include at least one
polyolefin and a mineral or inorganic filler in one embodiment. In this
embodiment, the
breathable film or coating typically includes at least about 40 wt.% of the
filler with the
balance being the polyolefin. The breathable film or coating generally
comprises from about
40 to about 60 wt.% filler.
100541 In one embodiment, the breathable film comprises polyetheylene or
polypropylene in combination with calcium carbonate. The polyethylene or
polypropylene is
mixed with the calcium carbonate and melted. The composition is extruded into
a film by,
for example, a blown or cast process. In one embodiment, the film including a
polyolefin
(e.g., polyethylene or polypropylene) and a filler (e.g., calcium carbonate)
is stretched,
resulting in the bonds of the film breaking slightly around the location of
the mineral filler.
By slightly breaking the bonds of the film, the film becomes a breathable
film. The stretching
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of the film is typically performed prior to attachment with the cross-woven
material portion,
cross-laminate material portion or the mesh material portion, but may be
performed after
attachment to the cross-woven material portion, cross-laminate material
portion or the mesh
material portion.
[0055] The stretching may be performed by a machine direction orientation,
cross,
machine direction tentering, intermeshing stretching or a combination thereof.
Machine
direction orientation typically involves running the film between two pairs of
rollers in which
the second pair of rollers is running faster than the first pair. Because of
the difference in
speeds between the pair of rollers, the film is stretched. Cross machine
direction tentering
typically includes grasping the sides of the film and stretching it sideways.
Intermeshing
stretching, which may also be referred to as incremental or interdigitating
stretching typically
involves the film traveling between two grooved or toothed rollers. One
example of an
intermeshing process technology is disclosed in U.S. Patent No. 5,865,926 to
Clopay Plastic
Products Company of Cincinnati, Ohio. It is contemplated that other stretching
techniques
may be used to form the breathable film. This type of breathable film may be
referred to as a
voided polymeric coating.
[0056] Breathable films that may be used include those made by 3M Company
(SCOTCHO microporous films), Exxon (Exxaire porous films) and AssiDoman
Bellcoat in
Belgium. It is contemplated that other breathable films may be used in the
present invention.
[0057] In one method, the breathable film is applied to the cross-woven
material
portion, cross-laminate material portion or mesh material portion using an
adhesive. It is
desirable for the adhesive to be located initially on the cross-woven material
portion, cross-
laminate material portion or mesh material portion before being attached to
the breathable
film. It is contemplated that the adhesive may be selectively located on the
breathable film.
The adhesive in these embodiments are not typically placed in such a manner
that the water
vapor would be hindered in traveling through the breathable film. 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 breathable film.
[0058] In another method, the breathable film is applied to the cross-woven
material portion, cross-laminate material portion or mesh material portion by
lamination or
thermobonding. The thermobonding should not be performed at temperatures where
the
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breathable film loses the ability to allow the water vapor to travel
therethrough.
[0059] According to another embodiment, a protective drainage wrap 160 is
shown in FIGs. 9 and 10. As discussed above with respect to the protective
wrap 110, the
protective wrap 160 is adapted to be attached to sheathing or framing members.
The
protective wrap 160 comprises a tape or strand portion 162, a yam portion 164
and a
breathable solid layer portion 116. The tape portion 162 of FIGs. 9 and 10
comprises a
plurality of tapes in a first direction (e.g., the machine direction), while
the yarn portion 164
comprises a plurality of yarn strands in a second direction (e.g., the
transverse direction).
[0060] The yarn portion 164 is capable of absorbing moisture such as water.
Additionally, the yarn portion 164 may be capable of wicking the moisture that
may provide
further enhancement to the hydration properties. To assist in moving the water
downwardly
via gravity, the yarn portion 164 is preferably installed in a generally
vertical position. In
addition, the yarn portion 164 provides a channeling effect between the
plurality of yarn
strands to assist in moving the water downwardly. If the channel formed
between adjacent
yam strands is blocked by, for example, stucco, then the water may be absorbed
by the yarn.
This absorbed water may flow downwardly via the yarn strand or may be
transported to
another channel for moving the water downwardly.
[0061] Types of yam 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 such
as in an
alternating technique with bulk continuous process yarns.
[0062] The yam portion 164 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 164 include polypropylenes or polyethylenes.
Each of the
plurality of strands of the yarn portion 164 shown in FIG. 9 is made of a
plurality of fibers or
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filaments twisted with each other. It is contemplated that the strands of yarn
portion 164 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 164 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. The tape portion 162 and the yarn portion 164 may be both made from
polypropylenes.
[0063] The tape portion 162 may be made of materials such as polyolefins,
polyesters, nylons or combinations thereof. Examples of such materials include
polypropylenes or polyethylenes. The tape portion 162 may be made in a similar
manner as
described above with respect to the machine direction tape 112a.
[0064] The yarn portion 164 and the tape portion 162 are preferably located in
directions that are generally perpendicular to each other. This location of
the yarn portion
164 with respect to the tape portion 162 is depicted in FIG. 9. It is
contemplated, however,
that the yarn portion 164 may be located roughly perpendicular (e.g.,
generally diagonally)
from the tape portion 162 as long as the yarn portion 164 is in a generally
downward position
when installed.
[00651 As depicted in FIG. 9, each of the plurality of yarn strands of the
yarn
portion 164 is woven between the plurality of tapes/strands of the tape
portion 162. When
cross-woven, the combination of the yarn portion 164 and the tape portion 162
may be
referred to as a cross-woven scrim. The yarn portion 164 and the tape portion
162 may be
woven by various techniques. One such example is with the use of a loom that
weaves the
yarn portion 164 and the tape portion 162.
[0066] Alternatively, the tape portion 162 and the yarn portion 164 may be
cross-
laminated (not shown) by adhering the plurality of tapes and plurality of yarn
strands together
via the use of a suitable adhesive.
[0067] 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. 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
CA 02578488 2007-02-14
assist in locating studs, as well as window and door openings. The protective
wraps of the
present invention may also include printing thereon.
[0068] 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.
[0069] The tensile strength of woven protective wraps as measured by ASTM D
882 is generally greater than about 25 lbs./in. The tensile strength of woven
protective wraps
is preferably greater than about 30 lbs./in. and more preferably greater than
about 35 lbs./in.
as measured by ASTM D 882. 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.
[0070] The TD tear strength of woven protective wraps as measured by ASTM D
1117 is generally greater than 25 lbs. The TD tear strength of woven
protective wraps is
preferably greater than about 30 lbs. and more preferably greater than about
35 lbs. as
measured by ASTM D 1117.
[0071] The tensile strength of non-woven protective wraps as measured by ASTM
D 882 is generally greater than about 15 lbs./in, and preferably greater than
about 20 or 25
lbs./in. The TD tear strength of non-woven protective wraps as measured by
ASTM D 1117
is generally greater than 10 lbs., and preferably greater than about 15 or
201bs.
[0072] 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' x 100'), 4.5' x 100', 4.5' x 150',
4.5' x 195', 9' x
100', 9' x 150', 9' x 195' and 10' x 150'. For example, the 3' length extends
in the
transverse direction, while the 100' length extends in the machine direction.
[0073] 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.
[0074] The protective wraps of the present invention may be used as wraps in
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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.
[0075] 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.
[00761 One example of a protective wrap attached to a sheathing is shown in
FIG. 7a where the protective wrap 110 (cross-woven material 112 and breathable
solid layer
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. 7a has been cut-away to depict the cross-woven
portion 112 and
the breathable solid layer portion 116. FIG. 7a also shows an exterior
covering (siding 40)
that is located on an exterior surface of the protective wrap 110. The
breathable solid layer
portion 116 of FIG. 7a is located adjacent to the sheathing 30.
[0077] The protective wrap 120 may be attached in a similar fashion as
described
above with respect to protective drainage wraps 110. The protective wrap 120
is shown in
FIG. 7b as being installed over the sheathing 30. The sheathing 30 is attached
to the plurality
of framing members 35.
[0078] Referring to FIG. 8, another example of a protective wrap attached to a
sheathing is shown where the protective wrap 130 (mesh material portion 132
and breathable
solid layer portion 116) is installed over the sheathing 30. The sheathing 30
is attached to a
plurality of framing members 35. The protective wrap 130 of FIG. 8 has been
cut-away to
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=
17
depict the mesh portion 132 and the breathable solid layer portion 116. FIG. 8
also shows an
exterior covering (siding 40) that is located on an exterior surface of the
protective wrap 130.
The breathable solid layer portion 116 of FIG. 8 is located adjacent to the
sheathing 30.
100791 The protective drainage wrap 160 (tape portion 162, yarn portion 164
and
the breathable solid layer portion 116) is shown in FIG. 11 over sheathing 70.
The sheathing
is attached to a plurality of framing members 75. The protective wrap 160 of
FIG. 11 has
been cut-away to depict the tape portion 162, the yarn portion 164 and
breathable solid layer
portion 116. FIG. 11 also shows an exterior covering (siding 80) that is
located on an exterior
surface of the protective wrap 160. The breathable solid layer portion 116 of
FIG. 11 is
located adjacent to the sheathing 70.
[0080] According to another process of the present invention (not shown), the
protective wrap is installed directly over a plurality of framing members. 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.
[0081] 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.
