Static structures (e.g. – buildings) – Bridger strip hiding juncture of panels – Interfitted with surfacing section
Reexamination Certificate
1999-06-07
2001-07-03
Stephan, Beth A. (Department: 3635)
Static structures (e.g., buildings)
Bridger strip hiding juncture of panels
Interfitted with surfacing section
C052S062000, C052S586200, C052S395000, C052S417000
Reexamination Certificate
active
06253514
ABSTRACT:
FIELD OF THE INVENTION
1. Field of the Invention
The present invention relates generally to caulking, and in particular to systems for forming proper caulk joints.
2. Background of the Invention
Water damage to buildings is an old and recurring problem. The damage frequently arises from improper caulk joints. Buildings are formed from many different components or sections. Where two components or sections meet one another, there is a seam or joint at the interface. If the joint is subject to water exposure, caulk is applied along the joint for preventing water from penetrating through the joint.
Prior to application, the caulk is stored in a tube in the form of a thick, sticky substance. In applying the caulk, it is extruded to form a bead along the length of the joint. The bead should extend continuously from one edge of the joint to the other, along the joint's entire length. The caulk thereafter dries or cures, ideally forming a durable, resilient barrier that prevents water from penetrating through the joint.
Unfortunately, caulk joints usually fall short of ideal. Often joints are in the form of a channel or trough. In such joints, the caulk should extend from edge of the joint to the other, along the length of the joint. The caulk, though, should not extend to the bottom of the joint. Space between the bottom of the caulk and the joint allows for building movement due to wind, settling, and etc. If the caulk extends to the bottom of a joint, it adheres in place and tends to tear during building movement. In contrast, if the caulk adheres only to the sides of the joint, the caulk tends to stretch and compress with building movement, rather than tearing.
Construction personnel often do not realize this, and overfill joints with caulk. Overfilling caulk joints often creates other problems as well. Overfilling can result in caulk being forced behind building components in locations that cause damage. Further, overfilling may prevent building components from having sufficient ability to flex relative to each other, thus damaging these and/or other building components.
To prevent overfilling, sometimes a backer rod is inserted into a joint. The backer rod is made of an inexpensive, highly flexible material, such as foam rubber. Caulk is then applied over the backer rod. During building movement, the backer rod flexes with building movement so that the caulk does not tear.
Use of backer rods, however, does not make for trouble-free caulk joints. Personnel often do not insert the backer rod deep enough into the joint. Consequently, caulk is not applied thick enough to form a durable barrier.
With shallow joints, backer rods should not be used if the joint does not have sufficient depth for an adequate depth of caulk above the rod. In this situation, a tape or special coating may be applied. The caulk does not adhere well to the tape or coating, and thus tends to prevent tears in the caulk during building movement.
A major problem with caulking occurs in building repair. Frequently, a building will have damage caused by improper caulking. The edges of the building components forming the joint, though, have been damaged. The caulk therefore does not have a proper surface to adhere to. Thus, a proper caulk joint cannot be formed for creating a durable barrier against water. Hence, the building components must be repaired or replaced, and the joints caulked.
This is especially true for buildings employing an exterior insulated finish system, often called “EIFS.” Such systems typically have exterior building surfaces that are relatively brittle, with a wire mesh interior. The edges of such surfaces are easily damaged, and absent replacement or repair of the surfaces, proper caulking is effectively prevented.
Lap joints occur where one component extends over another. For example, in the vicinity of a window there is often metal framing overlapping an exterior wall. A corner or lap joint is thus formed between the edge of the framing and the underlying structure. Fasteners generally extend through the framing and into the wall for holding the framing in place. In this situation, caulk is generally only applied along the interface between the framing and the wall. The fasteners, though, create paths for moisture to travel and penetrate into the building. This is especially problematic in buildings that have relatively brittle exterior surfaces, which are more prone to cracking.
In general, proper caulking is a time consuming, laborious, and hence costly process. With large office buildings, there are literally miles of caulking that must be performed. Additionally, the caulking process is frequently misunderstood and performed improperly, often with catastrophic results. The present invention addresses these problems.
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Jobe Mark
Tatley Ronald D.
Glessner Brian E.
Stephan Beth A.
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