Note: Descriptions are shown in the official language in which they were submitted.
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PROTECTIVE DRAINAGE WRAPS
FIELD OF THE INVENTION
100011 The present invention relates generally to protective wraps
that are used to
protect against air infiltration and moisture build-up in buildings.
Specifically, the protective
wraps of the present invention include a porous layer and a breathable solid
layer portion.
BACKGROUND OF THE INVENTION
100021 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.
100031 Protective wraps are typically used as secondary weather
barriers in
buildings behind exterior coverings such as stucco. Stucco may be synthetic
based (e.g., a
polymer-based stucco) or cementitious (a mixture of Portland cement, lime and
sand). One
type of stucco system, exterior insulation finish system (drainage EIFS), that
is used in
buildings typically involves using a drainage plane, an insulation board, and
a wire or
synthetic mesh that accepts a cementitious coating. In existing stucco
applications, at least
one protective wrap is not typically installed directly in contact with the
cementitious
coatings. In some instances, multiple layers of protective wrap are installed
with one of the
layers contacting the cementitious coatings. These multiple layers may be
house wrap,
building paper or both and are installed in two separate applications.
100041 The protective wraps to be used in stucco applications
desirably (a)
prevents or inhibits liquid water from passing through the protective wrap
into the sheathing
or interior wall cavity when a large water head builds up on its surface; (b)
attaches to the
stucco; and (c) allows water to partially enter into the protective wrap so as
to potentially
assist the hydration process of the stucco curing.
100051 Accordingly, a need exists for a protective wrap that is
adapted to be used
in stucco applications that addresses at least some, if not all, of these
desirable attributes.
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SUMMARY OF THE INVENTION
100061
According to one embodiment, a protective drainage wrap comprises a
porous layer, a breathable solid layer portion, and a plurality of fibers,
filaments, tapes or
yarn. The porous layer is adapted to allow liquid water to pass therethrough.
The breathable
solid layer portion is adapted to allow water vapor to pass therethrough while
preventing or
inhibiting liquid water from passing therethrough. The plurality of fibers,
filaments, tapes or
yarn is located between the porous layer and the breathable solid layer
portion and is attached
to the porous layer and the breathable solid layer portion. The plurality of
fibers, filaments,
tapes or yarn forms a plurality of channels to assist in forming a drainage
path for draining
liquid water from the protective drainage wrap.
10007]
According to one method, a protective drainage wrap is used in a building.
A protective drainage wrap is provided that comprises a porous layer, a
breathable solid layer
portion and a plurality of fibers, filaments, tapes or yarn. The porous layer
is adapted to allow
liquid water to pass therethrough. The breathable solid layer portion is
adapted to allow water
vapor to pass therethrough while preventing or inhibiting liquid water from
passing
therethrough. The plurality of fibers, filaments, tapes or yarn is located
between and attached
to the porous layer and the breathable solid layer portion. The plurality of
fibers, filaments,
tapes or yam forms a plurality of channels to assist in forming a drainage
path for draining
liquid water from the protective drainage wrap. At least one framing member is
provided.
The protective drainage wrap is installed over at least one of the framing
members.
100081
According to another method, a protective drainage wrap is used in a
building. A protective drainage wrap is provided that comprises a porous
layer, a breathable
solid layer portion and a plurality of fibers, filaments, tapes or yarn. The
porous layer is
adapted to allow liquid water to pass therethrough. The breathable solid layer
portion is
adapted to allow water vapor to pass therethrough while preventing or
inhibiting liquid water
from passing therethrough. The plurality of fibers, filaments, tapes or yarn
is located between
and attached to the porous layer and the breathable solid layer portion. The
plurality of fibers,
filaments, tapes or yarn forms a plurality of channels to assist in forming a
drainage path for
draining liquid water from the protective drainage wrap. A sheathing is
provided. The
protective drainage wrap is installed over the sheathing.
100091
According to one method of forming a protective drainage wrap, a porous
layer is provided that is adapted to allow liquid water to pass therethrough.
A breathable
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solid layer portion being adapted to allow water vapor to pass therethrough
while
preventing or inhibiting liquid water from passing therethrough is provided. A
plurality of fibers, filaments, tapes or yarn is attached to the porous layer
and the
breathable solid layer portion. The plurality of fibers, filaments, tapes or
yarn is
located between the porous layer and the breathable solid layer portion. The
plurality
of fibers, filaments, tapes or yarn forms a plurality of channels to assist in
forming a
drainage path for draining liquid water from the protective drainage wrap.
In another aspect, there is provided a protective drainage wrap in combination
with a stucco exterior covering, the combination comprising:
the protective drainage wrap comprising a porous layer, a breathable solid
layer portion and a plurality of fibers, filaments, tapes or yarn, the porous
layer being
adapted to allow liquid water to pass therethrough, the breathable solid layer
portion
being adapted to allow water vapor to pass therethrough while preventing or
inhibiting liquid water from passing therethrough, the plurality of fibers,
filaments,
tapes or yarn being located between the porous layer and the breathable solid
layer
portion and being attached to the porous layer and the breathable solid layer
portion,
the plurality of fibers, filaments, tapes or yarn forming a plurality of
channels to assist
in forming a drainage path for draining liquid water from the protective
drainage
wrap; and,
the stucco exterior covering,
wherein the porous layer of the protective drainage wrap is attached to the
stucco exterior covering.
In a further aspect, there is provided a method of using a protective drainage
wrap in a building, the method comprising the acts of:
providing a protective drainage wrap comprising a porous layer, a breathable
solid layer portion and a plurality of fibers, filaments, tapes or yarn, the
porous layer
being adapted to allow liquid water to pass therethrough, the breathable solid
layer
portion being adapted to allow water vapor to pass therethrough while
preventing or
inhibiting liquid water from passing therethrough, the plurality of fibers,
filaments,
tapes or yarn being located between the porous layer and the breathable solid
layer
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3a
portion and being attached to the porous layer and the breathable solid layer
portion,
the plurality of fibers, filaments, tapes or yarn forming a plurality of
channels to assist
in forming a drainage path for draining liquid water from the protective
drainage
wrap;
providing a stucco exterior covering;
providing at least one framing member;
installing the protective drainage wrap over at least one of the framing
members; and
installing the stucco exterior covering to the porous layer of the protective
drainage wrap.
In another aspect, there is provided a method of using a protective drainage
wrap in a building, the method comprising the acts of:
providing a protective drainage wrap comprising a porous layer, a breathable
solid layer portion and a plurality of fibers, filaments, tapes or yarn, the
porous layer
being adapted to allow liquid water to pass therethrough, the breathable solid
layer
portion being adapted to allow water vapor to pass therethrough while
preventing or
inhibiting liquid water from passing therethrough, the plurality of fibers,
filaments,
tapes or yarn being located between the porous layer and the breathable solid
layer
portion and being attached to the porous layer and the breathable solid layer
portion,
the plurality of fibers, filaments, tapes or yarn forming a plurality of
channels to assist
in forming a drainage path for draining liquid water from the protective
drainage
wrap;
providing a stucco exterior covering;
providing a sheathing;
installing the protective drainage wrap over the sheathing; and
installing the stucco exterior covering to the porous layer of the protective
drainage
wrap.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a top perspective view of a protective drainage wrap
according to one embodiment of the present invention.
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[0011] FIG. 2 is a cross-sectional view taken generally along line II-II of
FIG.
1.
[0012] FIG. 3a is a cut-away perspective view of the protective drainage wrap
of FIG. 1 fastened to sheathing and a framing member according to one
embodiment
of the present invention.
[0013] FIG. 3b is a side view taken generally along line 3b-3b of FIG. 3a.
[0014] FIG. 4a is a cut-away perspective view of the protective drainage wrap
of FIG. 1 fastened to a framing member according to one embodiment of the
present
invention.
[0015] FIG. 4b is a side view taken generally along line 4b-4b of FIG. 4a.
[0016] 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
[0017] 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 of the
present
invention are adapted to be used in stucco (e.g., synthetic or cementitious)
applications. It is contemplated that the
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protective wraps may be used in other applications.
100181 The protective drainage wrap 110 of FIGs. 1 and 2 comprises
a porous
layer 112, a plurality of fibers, filaments, tapes or yarn 114 and a
breathable solid layer
portion 116. The plurality of fibers, filaments, tapes or yarn 114 is located
between the
porous layer 112 and the breathable solid layer portion 116. The plurality of
fibers, filaments,
tapes or yarn 114 is attached to the porous layer 112 and the breathable solid
layer portion
116. Thus, the protective wrap 110 is an integral structure.
[00191 The porous layer 112 of the protective drainage wrap 110 is
adapted to
allow liquid water to pass therethrough. In a stucco application, a large
water head may tend
to build up on the surface closest to the stucco (i.e., the porous layer 112).
By having the
. porous layer being adapted to allow liquid water to pass therethrough, a
large water head
tends not to form. The porous layer 112 may be made of several different types
of materials.
Non-limiting examples of materials that may be used to form the porous layer
112 include
building paper, housewrap, non-woven porous material and felt. Non-limiting
commercial
examples of building paper and housewrap may be available from several sources
including
Fortifiber Building Systems Group of Reno, Nevada. The strength of the non-
woven porous
material should hold the stucco in place. Non-limiting examples of non-woven
porous
material that may be used include polymeric materials such as, for example,
polyester,
polyethylene, polypropylene, nylon and combinations thereof. It is
contemplated that other
materials may be used in forming the porous layer of the protective drainage
wrap that is
adapted to allow water to pass therethrough.
100201 The plurality of fibers, filaments, tapes or yarn 114 forms
a plurality of
channels to assist in forming a drainage path for draining liquid moisture
from the protective
drainage wrap. The plurality of fibers, filaments, tapes or yarn of the
protective wrap assists
in providing an improved traverse direction (TD) strength. A desirable TD
strength and
machine direction (MD) strength assists in inhibiting or preventing tears
and/or fraying that
may be caused during installation. These tears and/or fraying may be caused
by, for example,
nails or staples during the installation of the protective wraps. These tears
and/or fraying may
also be caused after installation by environmental conditions such as wind, UV
degradation or
by vandalism before the protective wrap is covered with an exterior covering.
Depending on
the material selected for the porous material and the breathable solid layer
portion, they may
provide MD and TD strength to the protective wrap.
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100211 The plurality of fibers, filaments, tapes or yarn 114 may be
made of
materials such as polyolefins, polyesters, nylons or combinations thereof.
Polyolefins that
may be used in forming the plurality of fibers, filaments, tapes or yam 114
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.
[0022] The term "polyethylene" as used herein includes low density
polyethylene
(L1)PE), medium density polyethylene (MDPE), high density polyethylene (HDPE),
very low
density polyethylene (VLDPE),. linear low density polyethylene (LLDPE),
metallocene-
catalyzed linear low density polyethylene (mLLDPE) and combinations thereof.
[0023] 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).
[0024] Each of the plurality of fibers, filaments, tapes or yarn 114
may be made of
a single fiber or filament, or a plurality of fibers, filaments, tapes or yarn
aligned with each
other. It is contemplated that the plurality of fibers, filaments, tapes or
yam 114 may be made
of a mixture of single fibers or filaments, and a plurality of fibers,
filaments, tapes or yarn
aligned with each other. For example, the single fibers or filaments may be
alternated with
the plurality of filaments aligned with each other such that the thicknesses
of the plurality of
fibers. filaments, tapes or yarn 114 vary.
[0025] As best shown in FIG. 2, each of the plurality of fibers,
filaments, tapes or
yarn 114 is shaped in a generally oval manner. The plurality of fibers,
filaments, tapes or
yarn 114 is desirably substantially circular or circular in shape. The
plurality of fibers,
filaments, tapes or yam 114 is shaped in a manner that will allow water to
flow down the
channels formed between the plurality of fibers, filaments, tapes or yarn 114
via gravity. It is
contemplated that the plurality of fibers, filaments, tapes or yarn 114 may be
shaped in a
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different manner.
100261 The thicknesses of the plurality of fibers, filaments, tapes or
yarn 114 of
the present invention provide unique vertical channels, when installed, that
enhance liquid
water drainage within the protective wrap. The installed plurality of fibers,
filaments, tapes
or yarn 114 allows liquid water to readily exit a wall system.
100271 The plurality of fibers, filaments, tapes or yarn 114 is shown
in FIGs. 3a,3b
after being installed. The plurality of fibers, filaments, tapes or yarn 114
is installed in a
general vertical manner (in direction of arrow A) so as to enhance moisture
drainage. The
plurality of fibers, filaments, tapes or yarn 114 of FIG. 3a may also be
referred to as extending
across the width of the protective wrap.
100281 It is contemplated that the plurality of fibers, filaments,
tapes or yarn 114
may be located in a generally diagonal manner when installed such that the
water is allowed
to drain and readily exit a wall system.
100291 The plurality of fibers, filaments, tapes or yarn 114 may be
made by a
variety of processes. In one process, the plurality of fibers, filaments,
tapes or yarn 114 is
made from an extrusion process.
100301 According to one embodiment, the plurality of fibers,
filaments, tapes or
yarn 114 is yarn. The yarn portion is capable of absorbing moisture such as
liquid water.
Additionally, the yarn portion may be capable of wicking the liquid water that
may provide
further enhancement to the hydration properties. To assist in moving the
liquid water
downwardly via gravity, the yarn portion is desirably installed in a generally
vertical position.
In addition, the yarn portion provides a channeling effect between the
plurality of yarn strands
to assist in moving the liquid water downwardly. lf the channel formed between
adjacent
yarn strands is blocked within the protective drainage wrap, then the liquid
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.
[00311 Types of yarn that may be used in the present invention include
spun yarn,
bulk continuous process (bcp) yarn and natural yarn (e.g., jute). Spun yarn
may be formed by
a two step process in which very small filaments are extruded and chopped to a
selected
length. These filaments are then spun into a continuous yarn using, for
example, a spinning
frame. Bulk continuous process yarns may be formed by extruding 70 or 80 very
small fibers
into continuous filaments that are spaced in close proximity to each other.
The close
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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 drainage
wrap. The larger diameter monofilaments may be used on a portion of the
protective drainage
wrap such as in an alternating technique with bulk continuous process yarns.
[0032] It is contemplated that a bulk continuous filament may be used. The
process for forming a bulk continuous filament includes providing a number of
mono filaments that are wound or twisted together to form a larger diameter
filament. One
commercial example of a bulk continuous filament is manufactured by Hercules
Incorporation of Wilmington, Delaware.
100331 The yarn portion may be made of polymeric materials such as
polyolefins,
polyesters, nylons or combinations thereof. Some contemplated polyolefins to
be used in
forming the yarn portion include polypropylenes or polyethylenes. Each of the
plurality of
strands of the yarn portion may be made of a plurality of fibers or filaments
twisted with each
other. It is contemplated that the strands of yarn portion may have varying
numbers of fibers
or filaments twisted with each other such that the thicknesses of the strands
differ. For
example, the strands of yarn portion may alternate the number of fibers or
filaments twisted
with each other to provide strands of varying thicknesses. One type of yarn
that is
contemplated is a spun polypropylene yarn that is manufactured by Propex
Fabrics of Austell,
Georgia.
100341 To assist in natural vapor transmission, the protective wraps of the
present
invention includes the breathable solid layer portion 116. The breathable
solid layer portion
116 allows water vapor to exit while preventing or inhibiting liquid water
from passing
therethrough. The liquid water desirably runs down the plurality of fibers,
filaments, tapes or
yarn 114 as discussed above. By preventing or inhibiting liquid water from
passing
therethrough, such liquid water does not contact the sheathing or interior
building wall cavity.
100351 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 coating 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 116. It is
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desirable that the breathable solid layer portion 116 has a permeability of
from about 5 to
about 50 perms. The most desired permeability is dependent on the application
and
environmental conditions where the protective wrap is used.
[0036i In one embodiment, the breathable solid layer portion is a
spunbonded
polymeric film. The spunbonded polymeric film may be a polyolefin film such
as, for
example, polyethylene, polypropylene or the combination thereof. It is
contemplated that
other spunbonded polymeric films may be used including polyester, nylon and
the
combination thereof. Spunbonded polymeric film that may be used include film
marketed as
DuPont's TYVEX spunbonded olefin, which is a continuous fiber form of high
density
polyethylene that includes carbon and hydrogen. It is contemplated that other
spunbonded
polymeric films may be used.
100371 In another embodiment, the breathable solid layer portion is a
woven
material with a breathable coating. The woven material may be a polymeric
material such as
polyester, polyethylene, polypropylene, nylon and combinations thereof. The
breathable
coating may be may from different materials including polymeric materials. One
type of
breathable coating is a polyurethane coating. One non-limiting example of a
commercial type
of polyurethane coating is marketed by Noveon Inc. It is contemplated that
other breathable
coatings may be used.
100381 The breathable coating may be applied by various processes to
the woven
material. 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
arc 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 whieh the molten material exits and falls
vertically by gravity
onto a surface of the woven material. At the same time the molten material is
exited from the
extruder, the woven material proceeds in a direction transverse to the
extruder.
100391 The woven material may proceed on a transport mechanism
involving
rollers that pull the woven material 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 woven material 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 cover the woven
material without
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leaving pin holes or interstices.
100401 -- In a further embodiment, the breathable solid layer portion is a
breathable
film. The breathable film may be made of materials that are inherently
breathable or
materials that are processed in such a manner that the material becomes
breathable. The
breathable film may be made of materials that are inherently breathable such
as polyurethane
or nylon. Some materials such as nylon become more breathable as the humidity
increases. It
is contemplated that other materials may be used in forming an inherently
breathable film.
100411 -- In one process of further processing material to become a breathable
film,
material is extruded or blown to form a film. The resulting extruded or blown
film is then
further processed (e.g., stretched) to form a breathable film that provides
air and moisture
breathability. It is contemplated that other processing may be used to form
the breathable
film. Materials that may be further processed to form the breathable film
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 film.
100421 -- It is contemplated that the material to be used in forming the
breathable
film 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.
[0043] -- For example, the breathable film may include at least one polyolefin
and a
mineral or inorganic filler in one embodiment. In this embodiment, the
breathable film
typically includes at least about 40 wt.% of the filler with the balance being
the polyolefin.
The breathable film generally comprises from about 40 to about 60 wt.% filler.
[0044] -- In one embodiment, the breathable film comprises polyethylene 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,
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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
of the breathable film is typically performed prior to attachment with the
plurality of fibers,
filaments, tapes or yarn 114. =
100451 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 wit% 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
ref - to as a
voided polymeric coating.
100461 Breathable films that may be used include those made by 3M
Company
TM
(SCOTCH 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.
100471 The breathable solid layer portion 116 generally has a
thickness of from
about 0.5 mil to about 2 mils, and desirably from about 0.8 to about 1.2 mil.
[00481 The plurality of fibers, filaments, tapes or yam 114 may be
attached to the
porous layer 112 and the breathable solid layer portion 116 via a suitable
adhesive, heat
bonding, laminating, UV-cured material or attaching method. If an adhesive is
used, the
adhesive is selected based on the materials used to fim-rn the porous layer
112, the plurality of
fibers, filaments, tapes or yarn 114, and breathable solid layer portion 116.
The adhesive may
be located initially on the plurality of fibers, filaments, tapes or yarn 114
before being
attached to the porous layer 112, breathable solid layer portion 116. It is
contemplated that
the adhesive may be selectively located on the porous layer 112 and the
breathable solid layer
portion 116. The adhesive in these embodiments is not typically placed in such
a manner that
the water vapor would be hindered in traveling through the breathable solid
layer portion 116.
In another embodiment, the adhesive may be a breathable adhesive such that
water vapor is
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adapted to pass therethrough. A breathable adhesive is desirable in that it
will not inhibit or
prevent water vapor from passing through the breathable solid layer portion
116.
[0049] In another
method, the porous layer and the breathable solid layer portion
are applied to the plurality of fibers, filaments, tapes or yam by laminating,
thermobonding, or
ultrasonically bonding or welding. The thermobonding should not be performed
at
temperatures where the breathable solid layer portion loses the ability to
allow the water
vapor to travel therethrough.
100501 Additives to
the protective wraps are contemplated in the present
invention. For example, the protective wraps may include colorant additives to
resist the
glare of the sun or identification of manufacturer. The addition of colorant
assists workers in
installing the protective wrap. The protective wraps may also include chemical
additives such
as ultraviolet inhibitors and antioxidants to withstand deterioration from
prolonged exposure
to sunlight. In addition, the protective wraps of the present invention may be
translucent.
Translucent protective wraps assist in locating studs, as well as window and
door openings.
The protective wraps of the present invention may also include printing
thereon.
100511 The tensile
strength of the protective drainage wraps as measured by
ASTM D 882 is generally greater than about 15 lbs./in, and desirably greater
than about 20 or
25 lbs./in. It is beneficial that the protective drainage wraps of the present
invention are
strong so as to inhibit or prevent tearing and/or fraying during or after
installation. Tearing =
and/or fraying may, and typically will, result in unwanted air infiltration
and/or moisture
penetration. The TD tear strength of the protective drainage wraps as measured
by ASTM D
1117 is generally greater than 10 lbs., and desirably greater than about 15 or
20 lbs.
100521 The
protective drainage wraps of the present invention may be formed into
a number of shapes. The protective drainage wraps, however, are generally
stored in a roll on
a circular cardboard core. The protective drainage 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.
100531 The
thickness of the protective drainage 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 drainage wraps is typically from about 9 to about 11 mils. Popular
thickness of
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protective drainage wraps includes about 10 mils.
100541 The protective drainage wraps of the present invention may be
used as
wraps in residential and commercial buildings. The protective drainage wrap is
typically
covered by a cementitious exterior covering (stucco or EIFS). The protective
drainage 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.
100551 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.
100561 Referring back to FIG. 3a, the protective wrap 110 (porous
layer 112,
plurality of fibers, filaments, tapes or yarn 114 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. 3a has been cut-away to depict the porous layer
112, the plurality
of fibers, filaments, tapes or yam 114 and the breathable solid layer portion
116. FIG. 3a also
shows an exterior covering (stucco 40) that is located on an exterior surface
of the protective
wrap 110. More specifically, the stucco is attached to the porous layer 112.
The breathable
solid layer portion 116 of FIG. 3a is located adjacent to the sheathing 30.
The relative
locations of the layers after installation are depicted in FIG. 3b.
100571 According to another process of the present invention (FIG.
4a), the
protective wrap 110 is installed directly over a plurality of framing members
35. The
protective wrap is attached to the plurality of framing members in a similar
manner as
discussed above with respect to attaching the protective wrap to the
sheathing. The relative
locations of the layers after installation are depicted in FIG. 4b.
10058] While the present invention has been described with reference
to one or
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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 et forth in the following claims.
