Textured Barrier Substrate

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority of U.S. Provisional Patent Application No. 63/626,961, titled “Sealing Tape Improvement/Joist protectant with airflow inducing structures/Textured Substrate for Placement Between Construction Materials,” filed Jan. 30, 2024, the entirety of which is hereby incorporated by reference.

BACKGROUND

When two or more construction elements are adjoined in an exterior or building shell application an environment for trapped moisture, condensation, and eventual rot development is created. One common example where the destructive forces of moisture and rot can be seen in building materials is with decks; including patios, rooftops, walkways, docks, and porches. Residential and commercial decks have become increasingly popular in both new build construction and renovation projects. Consumers are making larger investments in both the labor and the material components that go into these deck projects in an attempt to increase their homes asset value. Considerations are also made as property owners attempt to create a safe outdoor living space and to limit future labor costs associated with replacing prematurely failed building products. Often these projects contain site conditions where best practices cannot be deployed, such as low ground to deck contact or areas of poor drainage. These poor site conditions can exacerbate the forces working against building materials, creating challenging situations beyond what most conventional products can or have been designed for.

Accordingly, there is a need in the art for improved building materials that reduce or prevent unwanted degradation from environmental elements, such as moisture.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a building structure, according to aspects of this disclosure.

FIG. 2 is a side view of a building structure, such as the building structure of FIG. 1, according to aspects of this disclosure.

FIGS. 3A-3E are perspective views of example texture barrier substrates for use in building structures, in accordance with aspects of this disclosure.

FIGS. 4A-4D are side views of example texture barrier substrates for use in building structures, in accordance with aspects of this disclosure.

FIGS. 5A-5E are perspective end views of example textured barrier substrates for use in building structures, in accordance with aspects of this disclosure.

FIG. 6 is a perspective view of an alterative texture barrier substrate, in accordance with aspects of this disclosure.

FIG. 7 is a side view of an alternative building structure including a textured barrier surface, in accordance with aspects of this disclosure.

FIGS. 8A and 8B are perspective views of alternative building structures including textured barrier substrates, in accordance with aspects of this disclosure.

DETAILED DESCRIPTION

The following detailed description is directed to improved building structures, and, more particularly, to textured substrates and building systems including such textured substrates. In examples described herein, the textured substrates may mitigate or prevent damage caused by abutting building materials.

Some aspects of this disclosure relate to a film or substrate material that can be placed between abutting building materials, such as joists and decking boards, to reduce or prevent degradation of such building materials from moisture (e.g., rain, snow, mist, hose spray, and/or the like). In aspects of this disclosure, the substrate material includes one or more protrusions extending from a surface between the building materials. The protrusions act to space the building materials relative to each other. The protrusions are spaced from each other by gaps or channels that allow for flow of moisture and/or air therethrough. In some examples, the gaps or channels may be referred to herein as an Airflow Water Void. For instance, and airflow water void may refer to a space or an area, which may be defined, at least in part, by a predetermined distance between two or more connected construction materials in which a supportive structure allows for air flow to circulate and or be channeled around a building material (e.g., between “abutting” building materials) to alleviate moisture or other related building product issues. The spacing created contains a supportive but passive bridge to the connected building product in order to allow for the reliable fastening of the components, while encouraging airflow through the device. The spacing structure may be arranged in a manner to allow for any one or more of moisture reduction, reduction of standing water, static electricity reduction, voltage grounding, reduction or induction of heat or cold transfer, attachment mechanics, noise reduction caused by the movement of construction components against each other in service, vibration reduction, galvanic reaction reduction between components, height spacing to overcome protuberances such as screw heads in otherwise flat surfaces, reduction of the time which water in any form or other liquids come in contact with components on either side of the device, an increasing of the longevity of a construction component, a decrease in the mold or fungal formation in on or around a construction component, corrosion prevention, and/or prevention of a chemical reaction between two or more construction components of varying materials.

Aspects of this disclosure relate to building materials and building systems that increase airflow around building material(s), while allowing for the protection of mechanically fastened conjoined units from degradation. Aspects of this disclosure may reduce the inevitable rot, corrosion, or decay of a variety of abutted construction materials such as deck boards, joists, beams, sheet goods, wall panels, siding, wood shingles, flooring, and other residential or commercial construction materials while creating proper airflow spacing between components. In one embodiment aspects of the new invention may seal the deck joist or underlying building material, while creating an airflow water void of a predetermined distance and structure between the adjoined deck board or other building component. The space structure created allows for airflow while preventing and or reducing trapped water, reduces condensation moisture on the component surfaces, and/or can protect adjoined components from soaking up water or freezing ice damage. Thus, in aspects of this disclosure, longevity is increased to the components on both sides of the device. The new device may accomplish these feats while allowing for the use of traditional fasteners to be deployed and/or while maintaining a desired airflow water void between components. Many existing devices either attempt to protect items on just one side of a barrier, do not create a proper moisture barrier at all, and/or actually in practice inadvertently induce degradation to a material on the opposing side of a device by allowing for collection of water or other substances.

Many noble but inadequate attempts to reduce construction product failure exist, but fail to fully overcome a multitude of difficult issues. These products may suffice when site conditions, design considerations, installation methods, climate, product selection, and product performance are ideal; however in practice there are typically shortcomings in one or more of these factors resulting in a less than ideal long term outcome. One preexisting joist protection device also manufactured by the inventor, a product named Deckwise® WiseWrap® Joist Tape™ sealer, attempts to prevent damage to the joist located on the underside of the impervious tape. Several competing devices deploy similar efforts as the methodology has become industry norm, however in some instances the joist's preservation is accomplished at some expense to the opposing board or to other components opposite of the barrier. This is due to the fact that water and moisture are repelled away from the joist by the impervious tape, allowing it to collect on top of the sealed joists, often to be absorbed by the abutted bottom side of the connected deck board. Thus, potentially sacrificing the lifespan of the adjoined deck material in order to preserve the joist longevity.

Aspects of this disclosure solve this issue by allowing a predetermined airflow water void spacing area between the objects in order to provide protection to two or more abutted components on opposing sides of the device at the same time. The predetermined spacing created can be of a multitude of dimensions depending upon the joist and deck material used, the amount of airflow required given the site conditions, and the aesthetic desired when observing the gap from the edge of the deck. The gap spacing between the deck boards and the joists can be minimal to be an aesthetically pleasing joint, or can be spaced at a distance similar to the spacing between deck boards or other adjacent components for a more consistent visual match. In some examples, a gap spacing of 1/32″ or more is provided between adjacent building materials to allow for the passing of rainwater, air flow between the joist to deck board connection, and for the rapid evaporation of condensation. In design instances where the deck to joist gap is not a cosmetic consideration which is easily viewed from the side, a more efficient Airflow Water Void gap of 1/16″ or more may be deployed by utilizing a thicker preinstalled spacer unit embedded in, on, through, or under the substrate. In instances where the substrate is also utilized for clearing or leveling to a predetermined height consideration, such as protruding sheet metal screw heads in the surface of a metal deck frame, the preinstalled protruding spacers can match the thickness of the screw heads which are commonly from ⅛″ to ⅜″ in thickness. This allows for a level surface for the deck boards to be installed upon, without modification of the back side of the opposing deck boards to account for the screw head protuberance height. The dimensions given in these examples can be modified for various predetermined heights depending upon the project design specifications, protuberance heights to overcome, and proper airflow water void spacing.

Deck surfaces are conventionally made from a wide variety of materials such as cedar, pine, pressure treated wood, thermally modified wood, composites of wood/plastic mixtures, aluminum, steel, plastics such as HDPE, PVC, and hardwoods such as Ipe, Teak, Mahogany, Red Balau, Yellow Balau, Garapa, Cumaru, Tigerwood, Massaranduba, and several other species. Each of these materials can have benefits and disadvantages over the other depending upon the application, climate, desired use, project design, span distances, and connected materials. Aspects of this disclosure can be utilized in various embodiments, all within the scope of this invention, to resolve a multitude of issues encountered when constructing with current and future building materials. Some items addressed by the current disclosure include any combination of either reducing the installation time of building components, increasing product longevity, reducing unwanted conflicts between material interaction via a conjoined separation, increasing airflow around a product, reducing rot, reducing mold or fungal formation, reducing delamination, maintaining the structural integrity of a component, yielding a desired aesthetic spacing, allowing airflow while reducing insect intrusion through the barrier, reducing energy transfer such as heat/cold/sound/vibration/static or electrical shock conveyance between either materials or persons or pets, reducing galvanic reaction between dissimilar metals, and/or reducing chemical reactions which can develop between materials when used in different combinations or uses.

Deck boards have predominantly been intended to sit directly upon the deck joist. In the US market, for example, the joists of the supporting deck frames are traditionally made of pressure treated pine. In many other markets more expensive hardwood joists are the norm as they are more readily available and allowed by building codes in selective local markets. With the costs rising for wood products and with the lower quality of rapid growth lumber typically being harvested today, the market has seen the beginning of a shift away from pressure treated pine joists towards alternative joist materials. These alternative supporting joists are often made with materials such as steel, aluminum, plastic, and reinforced composites.

Pressure treated joists are often delivered soaked with harsh preservative chemical agents, and they tend to warp, twist, split, or bow when they dry out in service. Since the 1940s the technology of pressure treating lumber has relied upon toxic chemicals in order to prevent rapid deterioration of the softwood material when exposed to moisture, insects, mold, fungus, algae growth, or the elements. In 2004, the US wood-preserving industry voluntarily stopped selling wood treated with Chromated Copper Arsenate (CCA) to homeowners. The Environmental Protection Agency (EPA) had initially prompted this move due to the concerns about risks to workers in wood-treatment facilities and residues on the skin. Many in the industry also realized concerns about installers cutting the material, handling the material without gloves, and even the exposure to the end consumer and their pets when touching the finished project. Due to health concerns, most building codes even restrict that the material cannot be used indoors unless it is concealed with another product. After 2004, most pressure-treated lumber has been preserved with Alkaline Copper Quaternary (ACQ), and similar chemicals. These chemical treatments are said to have fewer environmental and health risks, although they still may pose some risks to installers, consumers, and the environment. The new chemicals also present the issue of being more corrosive to nails, screws, and any other metal fasteners that come in contact with lumber. This causes safety concerns as decks and other building projects can collapse due to fastener failure. The use of the more toxic CCA has been reduced, but not eliminated as it is still allowed for industrial use.

Although the composition of the chemicals has improved in recent years with supposedly less harmful chemicals, the reality is that the material is still toxic to the installer and the environment. As the severity of the chemical compounds in pressure treated wood has been reduced in the industries latest overhaul, the longevity of the material has been compromised as a tradeoff.

Pressure treated joists can also be problematic for the growing composite surface decking market as composite decking is often very flexible and will follow the twisted contour of the joists. Composite decking requires a deck frame that stays flat, as the joist defects can be seen later on in the finish deck as the joists twist, warp, hump and/or sag from their original flat position. Sealing the top of the joist to reduce degradation has become more important than ever in order to maintain the best possible performance of the pressure treated material. Aspects of this disclosure relate to creating an airflow water void between the joists and the deck material, which functions to preserve the integrity of both materials (e.g., the joist and the deck surface) at the same time. Having a device which does both processes at once may increase the speed of installation and/or control labor costs, for example.

Today's new growth pine is causing issues in the construction market. Old growth pine provided a superior product with a high amount of growth rings per inch, which yielded a more stable and consistent product. Current pressure treated pine joists are harvested from very young plantation grown trees, and the end product often varies in the finished board width which causes issues for installers who must achieve a flat surface for the decking to lay upon. This is much more common in the lower quality trees currently being harvested. Being that the wood density varies greatly from one board to another changes the amount of chemicals to be absorbed, the end product can swell more or less than other boards in the same production. The low amount of growth rings per inch of fast growing new growth pine also contributes to less stable wood, with less consistent expansion/contraction rates as older growth pine. It is typical to encounter joist variances of ⅛″ to ½″ between joists. The joists also can exhibit varying degrees of bow (end to end curvature), exasperated by unstable new growth lumber being harvested today. To counter this in installation many installers are forced to recut the boards straight and to a consistent width on the jobsite. This is done to the top edge of the joist that will connect to the deck boards, as the hump (aka bow) of the board must go up to avoid additional sagging. By doing so, many warranties are void by the manufacturer as the wood preservative often does not penetrate fully into the center of the wood, which is now exposed by the fresh cut. Aspects of this disclosure may seal the joist while providing a simultaneous airflow water void, to allow for the consumer to be given protection to the material even though the installer may have voided warranty of the deck joists. Conventional products may not provide such results.

Even with the shortcomings, pressure treated wood is still forecasted to be used in the majority of deck frames for many more years. Alternative joist solutions are currently more expensive than the pressure treated lumber options and/or do not support the span ratings desired by the installers, engineers, and DIY market.

Aspects of this disclosure address many of the issues with pressure treated joists, and can prolong the life expectancy of both the joists and the attached materials. Aspects of this disclosure provide a textured barrier substrate that can be placed over the pressure treated joist, e.g., to seal the surface of the joist on which the substrate is place. The textured barrier substrate also contains separation spacing elements protruding from the substrate and configured to be position between conjoined items. In some aspects of this disclosure, the space created by the textured barrier substrate between the abutted surface decking, beams, or other elements is of a predetermined dimension, and located away from the pressure treated joists by the thickness of the barrier device upon which the spacing element is pre-affixed. This allows the top surface of the joist to be protected from the elements, with no reduction to the lifespan of the connected surface decking as water and moisture are no longer trapped between the objects. The collected water is allowed to drain away with the new device rather than be absorbed by the abutted board as the current best practice in the construction industry reluctantly allows. In one or more embodiments the new device channels water away from its center line via various predetermined dimensions such as slopes, convex, and/or freeform pathways to induce water drainage. The center line can also be replaced with an offset line in either direction, either parallel, angled, or perpendicular to the device's centerline. The new device thus reduces premature rot of both the pressure treated joists and the connected member(s).

Many of the alternative joist materials solve some issues created by pressure treated joists, but come at an increased cost. They also create additional new challenges to overcome in order to preserve the integrity of the deck or other building system. For example, metal joists are straighter, but in many versions the standard fastening methods leave rather large sheet metal screw heads protruding. These screw heads which protrude are a result of the simplest and most economical version of steel deck joist framing, relying on vertical screws to connect C-channel joists to a U track or channel which the joists intersect at the perimeter. These screw heads can interfere with the deck board installation, and the installer must drill or notch out the back of the decking boards in order to get the board to sit flat on the steel joists. As labor shortages become a larger economic burden, there is a need to reduce labor time in order to obtain affordable housing.

Metal joists also typically are fastened together by a vertical screw through the top of the metal joist. This leaves a large heat treated screw head protruding from the joist surface. Fastening the joist with lower profile screws or rivets is not a viable solution, as it does not satisfy the strength and rigidity requirements of many joists manufacturers testing data. Getting the deck boards to properly sit flat on the metal joist in areas where screw heads are protruding causes an increase in time and labor to notch or carve out the back of the deck boards for the protruding screw heads. An additional concern is that notching the back of a deck board can cause premature rot/failure of the deck board, which can penetrate through the surface ruining the look or structural integrity. Against manufacturer's warnings, some installers even resort to grinding the screw heads flat so that the deck boards sit flat on the metal joists. This leaves the mechanical connection dangerously weak, and creates a connection strength that is untested as it has been compromised.

Metal joist can also rust, causing rust staining which can even travel with water runoff onto other surfaces or penetrate through certain deck board surfaces. Additionally, steel joists can cause a chemical reaction with some deck boards such as Ipe wood, causing a black stain mark to penetrate up through the opposing finished surface of the wood. Triple coating steel joists with a galvanization, then a primer, and then a polyester finish coating is one way in which to limit the rusting and reaction with certain woods. However, these coatings can get scratched and scuffed off during shipping, handling, installation, and the harsh environments that active job sites present. Areas where the coating is thin or has scratched off can still allow for a rusting and or a staining reaction of certain woods. The reaction can be irreversible and can destroy the appearance of the wood material. For example, the staining reaction that can occur when untreated steel comes in contact with Ipe hardwood can penetrate from the contact point, all the way through the thickness of the board to the top surface, and often cannot be sanded out. The new invention solves these issues as the device shields materials from one another while still allowing for airflow and the addition of mechanical fasteners for a firm connection.

Aspects of this disclosure provide an improved textured barrier substrate for use with steel joists. For example, the substrates according to this disclosure may be applied to the steel joist surface, thereby protecting the steel joist by a waterproof barrier, e.g., applied as a tape. The substrate also has protruding spacer elements that provide a predetermined spacing, which may be equal to or greater than the screw head height. This allows for the surface deck board to be rapidly installed without having to drill or notch the back side of the deck board or other abutted element. Thus saving both install time and elevating the abutted board out of the puddled water that collects on top of the protected deck joists. Elevating the deck board allows for proper ventilation on all sides of the deck board, reducing rot and maintaining a flatter deck board installation. Deck boards tend to cup or warp when there is more moisture on one side of the board than the other. In this scenario, the flatness is partially achieved as a result of maintaining a predetermined airspace between the deck board and the joists. Drilling or notching out the back of some deck boards is not ideal as it can void manufacturers warranties and/or lessen the lifespan of the material. This penetration point can allow for water and moisture which sit on top of the joist to be later absorbed into the deck board, thus causing moisture and rot issues. The new invention eliminates these concerns as the spacing protuberances of the device can be fashioned at a height equal to the screw head. The device is simply cut around the screw head, or screws can be installed through the device to fasten the joists, since both protuberances are of the same predetermined height.

Joists often conduct heat more so than their connected surface board counterpart. Deck board manufacturers and consumers desire to have the surface temperature of the deck boards to be low in order to reduce burn injuries to exposed skin which may come in contact with deck boards. This can be of a heightened concern for young children who walk barefoot on the deck boards or for pets whose paws come in contact with the hot surface. Joists of high density such as steel, aluminum, and high density structural composites can conduct heat which is absorbed from sunlight and transfer that heat to the deck surface. Plastic and composite boards can warp when subjected to increased temperatures. These plastic based materials are known to be problematic for conducting heat and causing burns to people and pets. Furthermore, once the joists and deck boards are heated during the day, the joist can act as a heat sink or as an opposing cold plate in cooler temperatures, helping to undesirably hold the surface temperature of the decking abnormally high or low after sunset. Aspects of this disclosure may also mitigate these problems, as the device shields materials from one another while still allowing for airflow and the addition of mechanical fasteners for a firm connection.

Common issues with deck structures can be support posts that prematurely rot wherever they touch a beam, joist, deck board, or other rigid material. Joists and beams that are doubled or tripled together for load span requirements often allow water and moisture to seep between them where it stays for long periods of time due to the restricted airflow in, on, between, or around individual deck components. The area where framing joists come into contact with, or support deck boards and rail structures is another common area for problematic deck rot and deterioration. Deck boards must be firmly secured to the framing joist, however this abutment creates an area for hidden moisture penetration and standing water to collect between the pieces. It also creates an area of limited or absent airflow where the two components touch. Limiting airflow while the area is subjected to rain and moisture is problematic for most building materials. Wood for example will cup when moisture is rapidly applied to one face and not the other. Metal can rust when moisture is routinely collected upon the surface and proper airflow cannot dissipate the water. Aluminum can corrode when ocean salt mist is allowed to collect in these connection areas and cannot be isolated from the building material or rapidly dissipated by proper airflow and rainwater.

Another growing segment of alternative joists are those made in various fashions from aluminum. Aluminum joists are straighter than traditional wood joists, but are expensive and the pricing can be volatile as the global price fluctuates for aluminum commodities. Galvanic corrosion can damage aluminum when used near saltwater, and aluminum can react when it is abutted to pressure treated wood containing the new ACQ chemical applications. Despite some drawbacks, many sites are indeed suited for aluminum, if the budget allows. The aluminum joists stay straight and do not degrade the look of composite decking as the joists do not warp like pressure treated. Use of the textured barrier substrates described herein to separate the joists from the decking can be helpful in aluminum joist applications. For example, aspects of this disclosure may reduce galvanic reaction between steel surface decking and aluminum joists, allow for a smooth surface over screw head protuberances in the aluminum frame for the decking to sit flat, thermally isolate the conductive aluminum joists from the surface decking, and reduce noise transfer between the materials. The barrier structure may also reduce moisture from puddling on top of the joists and absorbing into the back side of the deck board.

An additional option in the alternative joists market are Composite Joists. These are often made from plastic reinforced with a rigid material. More specifically, the material combinations are typically High-Density Polyethylene (HDPE) reinforced with fiberglass. Composite joists are rot resistant, but can sag or bounce easily when a standard weight load is applied as they do not have the span capabilities of wood or metal. Composite joists can be submerged in water soaked areas and even exposed to salt water without degradation. Having a sealing device on the composite joists like those described herein to separate the joists from the decking can be helpful in many ways. This will thermally isolate the conductive composite joists from the surface decking thus reducing thermal energy transfer and/or reducing noise transfer between the materials. The barrier substrates described herein may also reduce moisture from puddling on top of the joists and absorbing into the back side of the deck board.

Another alternative joist option gaining traction in the construction market is the LVL Pressure treated joists. These are similar to LVL beams used for interior construction in the building shell, however the laminations are pressure treated during the manufacturing process, making them suitable for exterior deck frame use. The LVL PT joists can span greater than a wood joist, are straighter, hold more load, are available in longer lengths, and the widths are more consistent than pressure treated joists. In order to prevent delamination of the product during use, the manufacturer mandates that the top edges of the joist be covered with a Joist Tape™ sealant. This saves the LVL PT joists from delamination issues, but, and as described above, such tapes can allow water and moisture to puddle on top of the joists, against the bottom side of the deck board. However, aspects of this disclosure may protect the joist and surface decking at the same time, by having a sealant with an airflow water void space firmly created between the joists and the attached surface boards.

Water is one of the leading causes leading to deck joist and deck board failure. Water penetration invites insect damage, mold and fungal formation, fastener corrosion, as well as visual staining and structural damage. Water collecting between deck joist and other supports that are sandwiched or butted together, areas where fasteners penetrate joist, and areas where joist contact the bottom of deck boards are often the primary areas of degradation. The deterioration of deck boards, framing members, beams, and the like can be accelerated by water, moisture, salt used by homeowners for melting ice, deck cleaners, deck oils, and other chemicals used in deck maintenance. The current invention solves these problems by shielding the joist, while allowing airflow to remove standing water, chemicals, and moisture from in between two or more adjoining building components.

The moisture, condensation, and standing water between the structural framing member and the back of the deck board material can cause an acceleration of rot, cupping, twisting, splitting, mold or fungal formation, fastener failure, corrosion, and other issues that cause premature deck board or framing member failure. By eliminating or reducing the moisture trapped under the deck board where the structural member touches, the lifespan of both the framing and the decking material can be extended. The structural integrity of the building materials can be retained, leading to a safer, more visually pleasing structure, and longer lasting lifespan of the components.

The rotting of deck framing joist and beams has been partially addressed by an existing product sold by the inventor called Wise Wrap™ Joist Tape™ deck flashing tape. This product has recently been utilized to give longevity to the joist as it helps to shield the joist from rain, standing water, morning dew, and the moisture that normally would sit on top of the joist or in between joist that are butted together. This Joist Tape™ sealant shields the framing member, but can do so at some detriment to the surface decking as water and moisture can sit on top of the impervious Joist Tape™ sealant for an extended period of time causing issues with the surface decking. As the deck board makes direct contact with the Joist Tape™ sealant it soaks water directly into the deck board. This can cause many deck boards to warp, split, twist, cup, bow, rot, or mold.

Existing Self-adhesive Joist Tape™ may also reduce some squeaks created when walking on deck boards. Squeaks are often noticeable when fasteners become loose or joists and or deck boards warp or move. Upon stepping on these items an undesirable squeaking noise can be created. Although existing products attempt to address this issue the resolution is not absolute. The current invention hereby presented may solve these problems as the device shields materials from one another while still allowing for airflow and the addition of mechanical fasteners for a firm connection.

With composite, hardwood, or other high end deck boards, a common practice is to install a border around the perimeter of the deck surface. This is often done to hide the end grain of the center deck boards. Otherwise, the grooved sides of deck boards can be seen on the end grain and on the last outside deck board. Seeing the grooved edges of deck boards may be undesirable for designers and/or the end consumers. In the construction industry, the practice of installing a perimeter border is called “Picture Framing” or referred to as a “Picture Frame.” In order to support the bordered picture frame deck boards, additional structural joist and blocking must be added to support the ends of the deck boards which terminate before the outside structural joists. This is typically achieved by placing a pressure treated 2×6 or 2×8 laying flat in between the outer two deck joists. This creates a wider flat spot, giving the installer an area to end the center boards and to support both edges of the perimeter picture frame board. This flat spot is less than ideal for water drainage, but is necessary to create the desired picture framed deck structure. This creates an area of intensified rot as instead of having a typical 1.5″ wide joist top in which some water can run off, there is now an 8″ to 10″+wide area of flat framing which holds a large amount of water in the picture framed area. The attempted solution to this problem to date has been to cover this flat joists area with several strips, or wider rolls, of joists tape. Water can get trapped on top of these flat areas, or seep between strips, causing rot and degradation to both the joists and the surface deck boards. Other attempts to resolve have been to drill holes in the flat board, however this funnels water into a hole with end grain exposed where water soaks into the board, again inducing rot. The hole solution is also inadequate as it cannot rid the water from a flat surface, and drilling too many holes weakens the board. This problem is already being noticed in the trade and decks are being replaced due to these issues. Unfortunately, many are being replaced using the same methods, and future premature product failure is again expected. The new invention of a barrier device with Airflow Water Void technology is a fast and economical solution to prevent the repeated product failures associated with picture framed deck designs. In some aspects, the substrate material according to this disclosure can be formed at varied and differing widths, e.g., for application to an edge of a joist, for application to a (wider) broad side of a blocking board or joist, and/or for application to surface of other sizes and configurations.

Static electricity is also a well-documented problem with composites, PVC, and HDPE decking. Static attracts dirt and can shock users. On docks that are used for refueling boats, static electricity discharge from decking can result in explosions of gasoline vapors. A conductive metal grounding wire track can be utilized as a portion of the spacing material in order to electrically ground the decking material, thus reducing any annoying, potentially painful, or even deadly static discharge. This grounding wire in the spacing device is then connected to a standard electrical grounding rod driven in the ground to a depth of 6 feet or more per International Building Code for grounding for electrodes. Consumers are currently forced to either to live with the static shock discharging into their children and pets, or to frequently apply a potentially toxic chemical to minimize some of the static discharge. One example of a chemical application is Heavy Duty Staticide® Products like this can include toxic chemicals and substances such as Quaternary ammonium compounds, Isopropanol, coco alkylbis (hydroxyethyl) methyl, nitrates, and other substances. Consumers may prefer less toxic and/or chemical free solutions to building component issues. Aspects of the current disclosure may obviate the need for these chemical treatments.

Aspects of this disclosure may be described and illustrated in relation to decking arrangements. However, the techniques and systems described herein may be implemented in several ways and/or building systems, generally including any systems in which two normally-abutting elements can benefit from spacing, as detailed herein. Example implementations are provided below with reference to the figures.

FIG. 1 is an exploded perspective view of a building structure 100 according to aspects of this disclosure. In FIG. 1, the building structure 100 includes a joist 102, a deck board 104, and a textured barrier substrate 106.

As illustrated, the joist 102 may be a dimensional member having a top surface 108 extending between opposing (generally parallel) sides 110 (only one of which is visible in FIG. 1). The joist may be wood, e.g., pressure treated, metal, e.g., aluminum, polymeric, composite, and/or any other conventional material used for joists. Although the joist 102 is illustrated as being oriented such that the top surface 108 is arranged generally horizontally, in other example implementations, one of the sides 110 may be arranged generally horizontally, e.g., in the “picture frame” arrangement described above. As will be appreciated, although only a single joist is illustrated, multiple aligned joists are generally provided.

The deck board 104 may be any conventional decking or flooring material. As shown, the deck board 104 generally includes an upper surface 112 and an opposing, lower surface 114 (obscured in FIG. 1). The upper surface 112 and the lower surface 114 extend longitudinally between ends 116 and laterally between edges 118. In the example illustrated, the edges 118 include grooves 120. In conventional decking systems, the grooves 120 may be configured to receive portions of clips or clamps (not shown). The grooves 120 may be optional. Although only a single instance of the deck board 104 is illustrated, multiple aligned deck boards 104 are provided in the building structure 100.

In conventional decking systems, the lower surface 114 of the deck board 104 is placed on the top surface 108 of the joist 102, and the deck board 104 is secured to the joist 102. For example, clips that engage with the grooves 120 may be screwed into the top surface 108 of the joist 102, e.g., between adjacent instances of the deck board 104. As detailed above, in these conventional arrangements, water or other contaminants can come to rest on the top surface 108 of the joist, e.g., between adjacent instances of the deck board 104. Once on the joist 102, the moisture can be absorbed by the joist 102 and/or the lower surface 114 of the deck board.

The textured barrier substrate 106 may mitigate this water absorption and associated damage. As illustrated, the textured barrier substrate 106 generally includes an elongated substrate 122 and a plurality of protrusions 124 extending from the substrate 122. The protrusions 124 are generally illustrated as an array of bumps or posts.

In use, the substrate 122 may be disposed on the top surface 108 of the joist 102, such that the protrusions 124 extend away from the joist 102. For example, a surface of the textured barrier substrate 106 opposite the side including the protrusions 124 may include an adhesive backing or the like to facilitate coupling of the substrate 122 to the joist 102. In other examples, the substrate 122 may be tacked, glued, nailed, or otherwise secured to the joist 102. Moreover, the substrate 122 may have a width, e.g., measured as a distance between longitudinal edges, that generally corresponds to a width of the joist 102 (e.g., a distance between the opposing sides 110) to properly align the substrate 122 on the top surface 108 of the joist 102. With the textured barrier substrate 106 secured to the top surface 108 of the joist 102, the deck board 104 will sit on the protrusions 124. Thus, and as detailed further herein, the lower surface 114 of the deck board 104 is spaced from the joist 102 (e.g., by a height of the protrusions 124) and spaces between the protrusions 124 can act as openings or vent channels, e.g., for air and/or moisture.

In examples, the textured barrier substrate 106 may be configured as a joist tape including protrusions or other spacer like objects preinstalled on, in, through, or under membrane layer(s) comprising the tape. When secured to a joist, the protrusions 124 create separation between the deck board and the joist, to allow airflow to the bottom of the deck board, e.g., by allowing air to flow through channels defined at least in part by the spacer objects, the substrate, and/or the bottom of the deck board. The spacers may prevent rot and/or may allow for the proper spacing above screw heads protruding up in metal joist, thus the undesirable method of notching the back of the deck boards may not be required.

Some aspects of this disclosure may relate to a tape that relies on a self-adhesive and/or waterproof membrane tape as a base for the spacers in order to seal the top of the joist, but other embodiments can allow for the tape to be a non-adhesive substrate, e.g. for cost reduction. In some aspects, the substrate can have an open pattern of mesh like material affixed to allow water to pass over the tape. This embodiment can be combined with additional rigid spacers to provide rigid support to the underside of the deck board at the same time. The preferred embodiment has the spacers pre-adhered to, pierced through, and/or embedded within the tape backer, but other embodiments can utilize an extruded strip made from a more rigid material such as plastic, rubber, or vinyl. The spacers can be used to either create spacing between two or more construction components for many described or anticipated reasons including any combination of; moisture reduction, reduction of standing water, static electricity reduction, voltage grounding, reduction of heat or cold transfer, attachment mechanics, noise reduction or induction caused by the movement of construction components against each other in service, galvanic reaction reduction between components, height spacing to overcome protuberances such as screw heads in otherwise flat surfaces, reduction of time water or other liquid comes in contact with components on either side of the device, increasing the longevity of a construction component, decreasing the mold or fungal formation in on or around a construction component, and/or prevention of chemical reaction between two or more construction components of varying materials.

FIG. 2 is a side view of the building structure 100 showing additional aspects. In FIG. 2, the same reference numerals introduced in FIG. 1 represent the same components. Specifically, FIG. 2 shows the textured barrier substrate 106 disposed on the joist 102 and the deck board 104 on the textured barrier substrate 106. In this illustration, two instances of a clip 202 are shown, each securing the deck board 104 to the to the joist 102, with the textured barrier substrate disposed therebetween. The clip 202 includes a flange or cap 204 that extends laterally from a central fastener 206 (e.g., a screw). As illustrated, the cap 204 extends into the groove 120 of the deck board 104, and the fastener 206 is secured to the joist 102. The clip 202 is shown for illustration only; other types of clips, clamps, and/or other fasteners are known for securing a deck board 104 to a joist 102. In some examples, a fastener, such as a nail or screw, may be passed through a portion of the deck board 104 and into the joist 102.

As also shown in FIG. 2, the protrusions 124 extend from the substrate 120 toward the deck board 104. The protrusions 124 support the deck board 104 at a position spaced from the substrate 120 (and thus spaced from the joist 120). Between the protrusions 124 are channels or voids 128. In examples, the voids 128 are sized and/or shaped such that the moisture may pool or collect on the substrate 122 in the voids 128 without contacting the deck board 108. Moreover, because the voids are open to the atmosphere, any water in the voids 208 may be exposed to the ambient environment, air flow, and/or the like, which may cause the moisture to exit the voids.

In some examples of this disclosure, the ratio of surface contact of the device to the material (e.g., the deck boards) being spaced is hereby taught to be greater than 1% of the contact surface. The 1% is calculated as a percentage of the surface area of the spacing device footprint.

As also shown in FIG. 2, the textured barrier substrate 106 may be formed as a roll 210. For example, the roll may have a predetermined length of the textured barrier substrate 106 and/or may facilitate ready application of the substrate to the joist 102.

As shown in FIGS. 3A-3E, a number of protrusions and/or configurations of protrusions are contemplated. More specifically, FIG. 3A shows a first substrate 300 in which protrusions 302 are formed as laterally extending ridges, e.g., extending between side edges of the first substrate 300. In this example, in use, voids are formed between the protrusions 302, much like illustrated in FIG. 2. For instance, the voids are generally formed as channels that extend between the opposing edges of the first substrate 300.

FIG. 3B shows a second substrate 304 that includes a single protrusion 306. The single protrusion 306 may be a longitudinally extending ridge. In the illustrated example, the protrusion 306 is centrally located on the second substrate 304, although such is not required. For example, the protrusion 306 may be offset relative to a longitudinal center line and/or the protrusion 306 may be angled relative to the longitudinal center line. Although only the single protrusion 306 is shown in the example of FIG. 3B, in other examples multiple instances of the single protrusion 306 may be used. For instance, two of the protrusions 306 may be arranged generally in parallel. However, because the example protrusion 306 is continuous, adding multiple instances could result in longitudinally-extending channels, which may undesirably retain water and/or debris. In examples, it may be preferable to ensure any water contacting the top of the second substrate 304 (or any substrate for that matter) has a path to an edge of the substrate.

FIG. 3C shows a third substrate 308 having a continuous protrusion 310. Like the protrusions 302, 306, the continuous protrusion 310 may be formed as a ridge, but instead of extending linearly, the continuous protrusion 310 may extend along a varied path. The illustrated path approximates a repeating wave, but may take other forms. For instance, the continuous protrusion 310 may provide additional and/or varied points of contact for the deck board, compared to the protrusion 306 discussed above.

FIG. 3D shows a fourth substrate 312 having a plurality of angled protrusions 314. The angled protrusions 314 are formed as ridges, similar to the protrusion 302, 306, 310 discussed above, but are differently arranged. Notably, and like the protrusions 302, the protrusions 314, by being spaced from each other in the longitudinal direction, will facilitate the formation of lateral voids extending from side edge to the side edge of the substrate 312.

FIG. 3E shows a fifth substrate 316 having a plurality of formed protrusions 318. The formed protrusions 318 may have irregular, asymmetrical, and/or other varied shapes, and may be separated from each other in a longitudinal direction, as in other examples described herein. As will be appreciated, any protrusions that provide the spacing described herein may be used.

FIGS. 4A-4D show additional examples of protrusions, which may be the protrusions 124 described above. More specifically, FIGS. 4A-4D are side views showing example features of textured barrier substrates according to examples of this disclosure.

In FIG. 4A, an example substrate 400 includes a number of protrusions having different profiles. For example, a first protrusion 402 has a substantially square or rectangular cross-section, a second protrusion 404 has a triangular cross-section, a third protrusion 406 has an arcuate profile, a fourth protrusions is substantially triangular, but with arcuate sides, and a fifth protrusion 410 has a bulbous profile. These profiles are for example. In examples, a single substrate may have only one of the example profiles and/or a combination of protrusions having more than one of the profiles and/or other profiles. As will be appreciated, each of the protrusions 402, 404, 406, 408, 410 is formed on top of the substrate 400.

In FIG. 4B, an example substrate 412 includes a number of protrusions that are formed as member extending through the substrate 412. For example, a first protrusion 414 includes a head 416 that extends above the substrate, e.g., as the protrusion. The first protrusion 414 also includes a post 418 that extends through the substrate 412 and a cap or flange 414 on the backside of the substrate 412. For example, the first protrusion can be affixed to the substrate 412 by inserting the first protrusion 414 into an opening in the substrate 412 such that the flange 414 passes through the substrate and the post 418 is disposed in the opening. A second protrusion 422 is similar to the first protrusion 414, having a head 424, a post 426, and a flange 428. The head 424 is formed as a sphere in this example.

Also in FIG. 4B, a third protrusion 430 includes a head 432 and a post 434. In this example, the post 434 may be a tack or other fastener that can be used to not only secure the protrusion 430 to the substrate 412, but to be pressed into the joist. These configurations are for example only; other arrangements that include a post or other member that can be passed through the substrate to secure the protrusion to the substrate also are contemplated and will be appreciated by those having ordinary skill in the art with the benefit of this disclosure.

In FIG. 4C, an example substrate 436 shows alternative arrangements that are formed, at least in part, by embedding portions of the protrusion in the substrate 436. For example, a first protrusion 438 is formed by embedding a solid member 440 in the substrate 436. Without limitation, the substrate 436 may include a number of layers and the solid member 440 may be disposed between layers. In other examples, the substrate 436 may be formed by a molding processing, and the solid member 440 may be disposed in the mold such that the substrate 436 is formed over the solid member 440. FIG. 4C also shows a second protrusion 442 that includes a head 444 and an embedded post 446 extending form the head 444. As shown, the embedded post 446 is embedded in the substrate 436, e.g., via insertion, over-molding, and/or other processes.

In FIG. 4D, an alternative example includes a substrate 448 on which protrusions 450 are disposed, as in previous examples. In this example, however, a mesh like structure 452 is disposed between the protrusions 450. The mesh-like structure may be less rigid than the protrusions 450 and/or may help to collect and/or disperse moisture that may accumulate between the protrusions 450, as described herein.

FIGS. 5A-5E show additional examples of substrates, like the substrate 122 described above. Specifically, FIGS. 5A-5E are perspective end views showing example features of textured barrier substrates according to examples of this disclosure.

In FIG. 5A, an example substrate 502 is substantially planar. That is, a top surface of the substrate 502 is substantially parallel to a bottom surface of the substrate. FIG. 5A also shows an example of an optional adhesive backing 504, which may be formed on the bottom surface of the substrate 502. FIGS. 5B-5E show alternative profiles.

In FIGS. 5B and 5C, example substrates 506, 508, respectively, have angled surfaces resulting from a ridged or peaked cross-section. In FIG. 5C, the peak is substantially centrally-located, whereas in FIG. 5B, the peak is closer to an edge of the substrate 506. As will be appreciated, the angled surfaces may facilitate runoff of moisture and/or debris, e.g., toward edges of the respective substrates 506, 508. In FIG. 5D, an example substrate 510 has an arcuate profile, e.g., generally having a convex shape. As with the angled surfaces of the substrates 506, 508, the convex shape may facilitate runoff of moisture toward edges of the substrate 510. FIG. 5E shows an example substrate 512 having a concave profile. Here, moisture may collect proximate a longitudinal center of the substrate 512, e.g., the concave shape may act as a cup that collects moisture. However, when the substrate 512 is applied to a joist that is angled along its length (as is generally customary), the concave channel will be tilted along its longitudinal axis, thus acting as a trench or channel through which moisture can run along the length of the joist. As will be appreciated, any of the embodiments described herein can use combinations of the protrusions and/or the profiled substrates to achieve a desired outcome.

FIG. 6 shows an alternative building structure 600 including an alternative textured barrier substrate 602 for application to the joist 102. The textured barrier substrate 602 is generally wider than the substrates shown above, and generally includes a central portion 604 and outer portions 606. The outer portions 606 may be movable relative to the central portion 604, e.g., along fold or bend lines 608. In use, the central portion 604 abuts a top surface of the joist 102 and the outer portions are folded down and contact sides of the joist 102. As illustrated, protrusion 610 are formed on the central portion 604, but may not be provided on the outer portions 606. The outer portions 606 may provide improved sealing and/or provide greater contact area, for example.

FIG. 7 shows an alternative building system 700 according to another example of this disclosure. The building system 700 generally includes deck boards 702 and a textured barrier substrate 704 that are configured to cooperate to secure the deck boards 702 to the joist 102. In this example, the textured barrier substrate 704 includes protrusions 706, which may be any of the protrusions described herein, as well as application fasteners 708. The application fasteners 708 may be provided as tacks or spikes that can be pressed or driven into the joist 102. In other examples, the application fasteners 708 may be separate fasteners, e.g., nails, screws, or the like, that are used to secure the textured barrier substrate 704 to the joist 102. In still further examples, the application fasteners 708 may be omitted in favor of an adhesive backing or the like.

The textured barrier substrate 704 also includes a number of attachment fasteners 710 extending above the protrusions 706. In examples, the attachment fasteners may be posts or the like that extend beyond the protrusions and cooperate with mating features on the deck boards 702, e.g., to retain the deck boards 702. In the illustrated example, the deck boards 702 include undercut grooves 712 that are configured to receive the attachment fasteners 710. More specifically, the fasteners 710 in the illustrated example include a flared head that compresses as the deck board 702 is pressed onto the fasteners 710. Once the flared head passes into the undercut groove 712, the head expands (e.g., to the position illustrated), to resist removal of the deck boards 702.

FIGS. 8A and 8B show additional aspects of this disclosure. For example, FIG. 8A shows a first alternative building structure 802 and FIG. 8B shows a second alternative building structure 808. In examples, the building structures 802, 808 may employ metal joists, e.g., aluminum or the like, as the joists 102.

In the example of FIG. 8A, the joist 102 includes screws 804 that are used to hold the joist 102 together. As is known in the art, the screws 804 extend a height above the joist 102. In this example, a textured barrier substrate 806 is disposed (laterally) between the screws 804. Moreover, the protrusions of the substrate 806 extend above, e.g., are taller than, the heads of the screws 804. Thus, a deck board (not shown) can be coupled onto the joist 102 and, because of the textured barrier substrate 806, will be disposed above the heads of the screws 804.

The example of FIG. 8B is similar, except that screws 812 pass through a textured barrier substrate 810. Again, the height of the protrusions is such that clearance is provided for the heads of the screws 812, allowing the deck board to be attached without modifying the deck board to accommodate the screw head.

This disclosure anticipates a variety of forms depending upon the products being connected, area used, and issues to be addressed. All of these stated or anticipated variables are within the scope of the invention. The invention is not limited to the following as they are mere examples of a few of the ways in which the invention can be adapted, furthermore the variances can be either deployed in singular or in any combination thereof. Specific aspects of this disclosure may facilitate utilization of an adhesive barrier tape or non-adhesive tape as a base or substrate for the airflow water void structure. The barrier tape may be rigid or flexible. The barrier substrates described herein may be produced for the user in a strip, sheet, or roll to be installed on a jobsite, or preinstalled on a building product in the factory. According to aspects of this disclosure, the shape and structure of airflow water void structure may be formed from combination of structure, width, and thicknesses. In some examples, the airflow water void can be created in many fashions including the uses of double-headed, or thick headed pin like structures, pre-installed onto the barrier strip. The installer would hammer the preinstalled pins into the joist. The thick head of the pin protruding above the barrier tape would provide the airflow water void. In examples of this disclosure, the barrier tape or strip can be either flat, convex, angled, or free formed in a manner to encourage water drainage away from the area of joined materials, e.g., toward edges of the strip. In examples, the protrusions may be solid or hollow, rigid, or pliable, and of any geometric shape including either round, balls, oval, straw like, freeform, square, rectangular, pin like, cone shaped, or any combination thereof. Also in examples, spacers preinstalled to the barrier can be in any arrangement or combination, of which the positioning can be either horizontal, vertical, angled, freeform, randomized, arranged in a pattern, or any combination thereof. In some examples, the top of the airflow water void structure can be fashioned to either be flat, contoured, or have either receivers or protuberances to connect the opposing deck board to the joists in either a rigid or flexible fashion.

Although aspects of this disclosure are initially tailored toward deck construction to service the immediate need, the invention can also solve a multitude of connection problems both within and outside of the building frame structure. For example, the application can be applied in between floor slabs to wood flooring. When used with hardwood flooring over a concrete slab it gives separation to the concrete so that the wood does not wick up moisture. Moisture in hardwood flooring causes cupping, swelling, twisting, delamination, finish coating degradation, splitting, and thus subsequently safety concerns such as tripping hazards. Moisture in flooring can also cause aesthetic concerns on the finish surface as it is absorbed through the wood. It can also be utilized between items such as uneven wall studs and drywall or paneling, between reactive building products such as lead and copper roof flashings, roof sheathing to wood shakes, and other building product to building product connections.

It may be deployed against houses as a water shield and spacer between the house and the deck framing. Flashing in this area is often aluminum which cannot be allowed to be in contact with the new chemicals of pressure treated or corrosion develops. Airflow between house and deck frame ledger board is beneficial as it reduces rot. Items exist in this application such as self-adhesive joist tape and metal flashing, however they do not allow for an Airflow Water Void for product longevity of products on both sides of the barrier.

In the description of embodiments, reference is made to the accompanying drawings that form a part hereof, which show by way of illustration specific embodiments of the claimed subject matter. It is to be understood that other embodiments may be used and that changes or alterations, such as structural changes, may be made. Such embodiments, changes or alterations are not necessarily departures from the scope with respect to the intended claimed subject matter. While the steps herein may be presented in a certain order, in some cases the ordering may be changed so that certain inputs are provided at different times or in a different order without changing the function of the systems and methods described. The disclosed procedures could also be executed in different orders. Additionally, various computations that are herein need not be performed in the order disclosed, and other embodiments using alternative orderings of the computations could be readily implemented. In addition to being reordered, the computations could also be decomposed into sub-computations with the same results.

Although the discussion above sets forth example implementations of the described techniques, other architectures may be used to implement the described functionality, and are intended to be within the scope of this disclosure. Furthermore, although specific distributions of responsibilities are defined above for purposes of discussion, the various functions and responsibilities might be distributed and divided in different ways, depending on circumstances.

Furthermore, although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described. Rather, the specific features and components are disclosed as exemplary forms of implementing the claims.