Deflector Sealing Grout Space Water Diversion
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Solution Overview
Problem
Current methods for sealing grout spaces between exterior brick veneer and backing walls are labor-intensive, time-consuming, and prone to non-uniformity, leading to moisture-related issues like mold due to inefficient water diversion.
Innovation Solution
A deflector device with a triangular shape and pre-scored cut lines is installed between the veneer and backing wall, directing water towards weep holes through a flexible sealing member, allowing for quick and uniform sealing by unskilled workers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual grout application is used to seal the grout space, then the grout space can be sealed, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent extracts the sealing function from manual grout application by introducing a pre-formed deflector component that provides both sealing and water diversion functions in a single installed element, eliminating the need for separate manual grouting operations
Solution Approach 2:
The deflector is divided into multiple sections with pre-scored cut lines, allowing workers to quickly configure the component to fit different corner and wall configurations without complex custom fabrication, thereby maintaining productivity while ensuring proper sealing
2Reliability
If manual grout application is used, then sealing can be achieved, but uniformity and consistency are difficult to maintain
Solution Approach 1:
The deflector component is pre-formed with the correct geometry, contours, and integrated water diversion features before installation. This preliminary preparation ensures uniform sealing performance across all installations while simplifying the installation process to a straightforward placement operation that does not require skilled manual contouring
Solution Approach 2:
The patent changes the physical state of the sealing material from a manual applicate (grout) to a pre-formed structural component (deflector) with consistent geometric parameters, ensuring uniform thickness, contour, and water diversion angle in every installation
3Productivity
If grout is applied hastily or by inexperienced workers, then installation time is reduced, but non-uniform thickness and pockets form causing water pooling
Solution Approach 1:
The patent removes the variable human skill factor from the sealing process by replacing manual grout application with a pre-formed deflector component that inherently provides uniform thickness and proper contouring, allowing any worker to achieve consistent results without specialized training
Solution Approach 2:
The deflector is pre-manufactured with precise geometric dimensions, uniform thickness, and proper water diversion contours before installation. This preliminary precision manufacturing ensures that no matter who installs it or how quickly, the sealing uniformity and water diversion effectiveness remain consistent
4Ease of operation
If flexible rubber flashing is used to seal the grout space, then installation is simpler, but the flashing can sag or deteriorate over time leading to moisture intrusion
Solution Approach 1:
The deflector is constructed from a composite of rigid and flexible materials, combining the structural stability and durability of rigid materials with the weather resistance and adaptability of flexible materials. This composite construction provides long-term durability while maintaining installation simplicity
Solution Approach 2:
The deflector incorporates flexible elements that allow it to conform to slight irregularities in the backing wall and veneer surfaces, ensuring continuous contact and effective sealing while the overall rigid structure prevents sagging and deterioration over time
Data Source
AI summary
An apparatus and method for sealing a grout space provided between a backing wall and a veneer layer. The grout space sealing apparatus includes a deflector that is installed at an intersection of a backing wall and a horizontal surface and a sealing member that is positionable over the deflector and extends onto the backing wall above the deflector and/or across the horizontal surface in front of the deflector. The grout space sealing apparatus causes water that has permeated the exterior veneer to run down an exterior surface of the sealing member. The water is directed along the exterior surface of the sealing member away from the backing wall and towards weep holes provided in the veneer.