Self-Sealing Fasteners for Water-Resistive Building Panels
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Solution Overview
Problem
Traditional building construction methods face challenges with water and air penetration due to inadequate mat adhesion in building panels, leading to increased porosity and failure to meet building code requirements for air and water resistance, particularly in the northeastern United States and eastern Canada.
Innovation Solution
The development of self-sealing fasteners and building panels with integrated water-resistive air barrier properties, where the fasteners feature a coating material or polymer annulus that forms a seal upon installation, eliminating the need for external sealants and enhancing water and air barrier performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional building panels with mat facer and gypsum core are used, then manufacturing is simple and cost-effective, but water and air penetration increase due to poor slurry infiltration and inadequate mat adhesion
Solution Approach 1:
The mat facer is pre-treated with a sizing agent during manufacturing before the gypsum slurry is applied. This preliminary action enhances the mat's ability to adhere to the core material and control slurry infiltration, preventing porosity and water/air penetration issues that would require complex retrofits later.
Solution Approach 2:
The invention modifies the physical and chemical parameters of the mat facer through sizing treatment, changing its surface properties to optimize slurry absorption and adhesion. This parameter change improves water and air barrier performance without requiring complex structural modifications to the panel assembly.
2Reliability
If sealant and tape are applied to fasteners to achieve water-resistive properties, then water and air penetration is reduced, but labor time and installation complexity increase significantly
Solution Approach 1:
The invention combines the fastener function with the sealing function into a single integrated component. The fastener itself is designed with features that provide water and air barrier properties, eliminating the need for separate sealant and tape applications. This merging maintains reliability while dramatically improving installation productivity.
Solution Approach 2:
The fastener is designed to be self-sealing, providing water and air barrier protection through its own structure or integrated features rather than requiring external sealing materials. This self-service approach eliminates additional labor steps while maintaining the water-resistive air barrier performance.
3Reliability
If fabric wraps are used as water resistive air barriers, then water and air penetration is reduced, but wind resistance decreases and installation becomes difficult at heights
Solution Approach 1:
Instead of using a continuous fabric wrap that is difficult to handle and install, the invention segments the barrier function into discrete fastener units. Each fastener provides localized sealing at penetration points, making installation straightforward and eliminating the handling and positioning difficulties associated with large fabric wraps at height.
4Reliability
If liquid coating water resistive air barrier is applied, then effective water barrier is achieved, but water vapor permeance is reduced affecting wall drying ability
Solution Approach 1:
The invention applies water barrier protection locally at fastener penetration points rather than as a continuous coating across the entire panel surface. This localized approach provides effective water barrier protection where needed while preserving the natural water vapor permeance of the panel materials in non-coated areas, allowing walls to dry properly.
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
The self-sealing fasteners and panels significantly reduce water and air penetration, passing hydrostatic head tests and other performance standards, thereby streamlining installation, reducing material costs, and ensuring compliance with building codes without the need for additional sealing materials.
Implementation Method 1
the heat generated along the fastener body when the fastener is driven into the surface of the building panel
Implementation Method 2
a polymer annulus disposed at an interface the neck and the head of the fastener... softens, spreads out, and compress
Implementation Method 3
coating material having a low viscosity at high shear rates, such that when the fastener is driven into a surface... the coating material flows to coat the fastener body
Data Source
AI summary
Self-sealing fasteners and associated building panels, systems, and methods are provided. In one aspect, a fastener includes an elongated fastener body with an external surface extending between the first end and the second end, and a coating material disposed on at least a portion the external surface. In another aspect, a fastener includes an elongated fastener body with an external surface extending between the first end and the second end, and a polymer annulus surrounding at least a portion of the external surface of the of the elongated fastener body at or adjacent the head of the fastener.