Deflector and Sealing Member for 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 improper water diversion.
Innovation Solution
A deflector and sealing member system that directs water away from the backing wall and towards weep holes, featuring a deflector with angled faces and pre-scored cut lines for easy installation, and a flexible, water-impermeable sealing member for efficient water diversion.
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 sealing system is divided into distinct components: a pre-formed deflector with integrated sealing features, and separate grout material. The deflector itself is segmented into a body portion and a flange portion that can be separately installed. This segmentation allows for faster installation while maintaining sealing reliability.
Solution Approach 2:
The deflector is pre-formed with integrated sealing features, including pre-formed sealing surfaces and alignment features, before installation. This preliminary preparation eliminates the need for complex on-site forming operations and ensures consistent sealing quality without requiring skilled manual work.
2Reliability
If manual grout application is used to seal the grout space, then the grout space can be sealed, but the process becomes time-consuming due to curing requirements
Solution Approach 1:
The sealing function is segmented between the deflector structure (which provides immediate physical barrier and water diversion) and the grout material (which provides secondary sealing). This allows the system to achieve functional sealing faster while the grout cures.
Solution Approach 2:
The deflector acts as an intermediary element between the grout space and the exterior environment. It provides immediate water diversion and structural sealing, allowing the grout to cure in the background without delaying the functional sealing of the assembly.
3Productivity
If grout is applied hastily or by inexperienced workers, then installation speed increases, but the end-product becomes non-uniform with pockets that cause water pooling
Solution Approach 1:
The deflector is pre-formed with precise geometry, including uniform thickness, proper contouring, and integrated sealing surfaces. This preliminary precision work eliminates the need for skilled manual grout application and ensures uniform sealing regardless of installer experience.
Solution Approach 2:
The deflector serves as a precise template or copy of the ideal sealing geometry. By using this pre-formed component, the complex task of creating uniform grout contours is replaced with a simpler installation process that achieves the same precision results.
4Productivity
If grout contours are improperly formed, then installation becomes faster, but water may flow backwardly towards the backing wall causing moisture issues
Solution Approach 1:
The deflector is pre-formed with the correct contouring and angular geometry designed to direct water away from the backing wall. This preliminary design ensures proper water diversion without requiring skilled manual contouring during installation.
Solution Approach 2:
The complex manual mechanical task of forming proper grout contours to direct water flow is replaced by the pre-formed geometric shape of the deflector. The deflector's built-in angle and contour automatically perform the water diversion function that would otherwise require skilled manual shaping.
5Reliability
If metal flashing is used to seal the grout space, then water diversion can be achieved, but the cost increases and installation becomes time-consuming
Solution Approach 1:
The deflector combines multiple functions into a single integrated component: water diversion, sealing, and structural support. This merging eliminates the need for separate metal flashing layers and reduces the number of installation steps, increasing productivity while maintaining water diversion reliability.
Solution Approach 2:
The deflector appears to be made from a composite or multi-material construction that provides both structural integrity and water-resistant properties. This composite approach replaces the traditional metal flashing while achieving the same protective function with faster installation.
6Ease of operation
If flexible rubber flashing is used to seal the grout space, then installation becomes easier, but the flashing may sag or deteriorate over time leading to moisture contact
Solution Approach 1:
The deflector is segmented into a rigid body portion for structural stability and a flange portion for sealing. This segmentation allows the main structure to provide long-term durability while the flange provides the flexible sealing interface, combining the advantages of both rigid and flexible materials.
Solution Approach 2:
The deflector appears to use composite construction that combines materials with different properties - likely a rigid base material for durability and a flexible sealing material for the sealing surfaces. This composite approach achieves both ease of installation and long-term reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables quick, uniform, and efficient sealing of grout spaces, reducing the risk of moisture-related issues by effectively directing water away from the backing wall and into weep holes, even when installed by unskilled workers.
Implementation Method 1
The grout is typically contoured to help direct water downwardly and forwardly away from the backing wall and towards the weep holes
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.