Mesh seam connection element

Abstract

A mesh tape bonded to the outer edge or outward side of sheet panel products. The mesh tape is applied so that the tape overhangs the edge of the panel for the purpose of adjoining to the adjacent panel following installation of the panels at a job site. The mesh may be applied to two edges of the sheet panel, one along the panel width and another along the panel length. When installed, the panel edge with the mesh tape applied is overlapped with the edge of an adjacent panel that does not have tape applied, both along the length and width, thus allowing for a faster, more robust and reliable installation of panel sheathing.

Claims

1. A method of manufacturing a panel sheet with embedded mesh tape in a factory, comprising: producing a panel sheet through a primary press process; providing a first length of mesh tape with an inner edge and an outer edge; affixing the inner edge of the first length of mesh tape on a face of the panel sheet along a first edge of the panel sheet; after affixing the inner edge of the first length of mesh tape to the face of the panel sheet, applying at a factory a WRB layer or coating to the face of the panel sheet and over the inner edge of the first length of mesh tape; and curing the WRB layer or coating to integrate the first length of mesh tape with the panel.

2. The method of claim 1, further comprising the steps of: providing a second length of mesh tape with an inner edge and an outer edge; and affixing the inner edge of the second length of mesh tape on the face of the panel sheet along a second edge of the panel sheet.

3. The method of claim 2, wherein the second edge of the panel sheet is adjacent to the first edge of the panel sheet.

4. The method of claim 1, further comprising the steps of: bending the outer edge of the first length of mesh tape at an angle downward with respect to the plane of the face of the panel sheet; setting the angle in the first length of mesh tape.

5. The method of claim 4, wherein the angle is set by applying heat.

6. The method of claim 1, wherein the first length of mesh tape comprises water-resistant mesh tape.

7. The method of claim 1, wherein the panel sheet comprises a manufactured wood product with multiple layers.

8. The method of claim 1, wherein the face of the panel sheet is an outer face of the panel sheet.

9. The method of claim 1, wherein the step of affixing the inner edge of the first length of mesh tape on a face of the panel sheet along a first edge of the panel sheet comprises positioning the first length of mesh tape such that the outer edge extends a distance outward from the first edge of the panel sheet.

10. The method of claim 9, wherein the distance is sufficient to cover a seam between the first edge of the panel sheet and a corresponding edge of a second panel sheet installed adjacent thereto.

11. The method of claim 1, wherein the mesh tape is embedded in the first panel sheet during a factory manufacturing process of the first panel sheet.

12. The method of claim 4, wherein the angle downward is approximately 20 degrees.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a view of a multi-panel system in accordance with an embodiment of the present invention.

(2) FIG. 2 shows a side view of a panel edge with mesh tape affixed between the top of the panel and the WRB coating or layer.

(3) FIG. 3 shows a side view of a panel edge with mesh tape affixed between two layers of the panel.

(4) FIG. 4 shows a side view of a panel edge with mesh tape affixed above the top of the panel in the WRB coating or layer.

(5) FIG. 5 shows a side view of a panel edge with mesh tape affixed on the top of the WRB coating or layer.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

(6) In various exemplary embodiments, the present invention comprises a mesh tape 20 that is bonded to one or more outer edges or outward sides of sheet panel products 2. The mesh tape is applied so that the tape overhangs the edge of the panel for the purpose of adjoining to the adjacent panel following installation of the panels at a job site. In one embodiment, the mesh is applied (as described below) to two edges of the sheet panel, one along the panel width 4 and another along the panel length 6. When installed, the panel edge with the mesh tape applied is overlapped with the edge of an adjacent panel 8 that does not have tape applied, both along the length and width, as seen FIG. 1. The mesh tape extending from an outermost edge of a panel array (and thus not overlapping with an adjacent panel edge) may be cut off or folded under the panel or around a corner or edge, if not needed to extend to an adjacent frame or stud.

(7) The mesh tape may extend for substantially all of the edge on which it is installed. In several embodiments, one or both ends of the mesh tape may extend further beyond the end of the edge, so that mesh tape may overlap and cover areas such as the center area between four corners of four adjacent panels, as seen in FIG. 1, or around corners. The mesh tape extension may be cut off or folded under the panel or around a corner or edge if not needed. The length of the extension may vary. In several embodiments, the length of the extension is approximately equal to the width of tape extending outward from the middle of the edge.

(8) The present invention thus allows for a faster, more robust and reliable installation. The mesh tape (e.g., fiberglass reinforcing tape) is applied and affixed to the desired sides or edges of a panel during the panel manufacturing process. In one embodiment, the tape is applied directly to the panel prior to application of the factory WRB layer or coating 10. The tape is thereby sandwiched between the base panel and WRB layer or coating, as seen in FIG. 2, and when cured, becomes tightly bonded and integrated to the panel with WRB coating. Additional adhesives and coating thickness may be used to ensure performance. In several embodiments, the product thus comprises a construction panel with factory-applied (or pre-applied) WRB coating and mesh tape.

(9) In alternative embodiments, the tape may be applied during or after the WRB application process, so the tape is located in the WRB coating, or on top of the WRB coating, as seen in FIGS. 4 and 5.

(10) In various exemplary embodiments, during the manufacturing process the tape is applied so that up to approximately one half of the width of the tape will be adhered to the panel (i.e., between the base panel and WRB coating), and the remaining portion or half will hang over the panel edge so that it can be joined easily to an adjacent panel during installation.

(11) Furthermore, in several embodiments, while the tape is being applied in the manufacturing process, the side of the tape not in contact with the panel, i.e., that which hangs over the panel edge to later be joined to the adjacent panel during installation at a job site, is set with an angle downward with respect from the panel face. In one embodiment, the angle is approximately 20 degrees. The angle will be permanently set by flexing the free side of the tape downward after the tape is adhered to the panel, and applying the appropriate amount of heat to mold and then set the angle in the tape. When cooled, the downward sloping angle of the tape will require force to flex upward (i.e., the tape has memory for the set angle) to become flat with the horizontal face of the panel. The purpose for downward angle of the tape and tape memory is to ensure the angled part of the tape lays flat on the adjacent panel during and after installation of the panels. This will ensure that when a fluid applied WRB system is completed in the field that the sealant, whether sprayed or troweled onto the tape, will create a close interaction with the adjacent panel to create a robust sealing system.

(12) In an exemplary embodiment, a manufacturing process according to the present invention comprises production of a panel, such as an OSB, through the primary press process, affixing of mesh tape along two adjacent edges of the panel wherein approximately one-half of the mesh tape (longitudinally) is securely affixed to the top panel face along said edges, application (such as by one or more spray nozzles) of a WRB layer or coating on the top panel face, curing, mechanically bending the free side of the mesh tape at a downward angle, and applying heat to set the free side of the tape at that angle. In alternative embodiments, as seen in FIG. 3, the mesh tape is installed between layers in a manufactured wood product (such as OSB), or portions of a mesh tape product are secured between sequential layers of a multi-layer panel.

(13) Thus, it should be understood that the embodiments and examples described herein have been chosen and described in order to best illustrate the principles of the invention and its practical applications to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited for particular uses contemplated. Even though specific embodiments of this invention have been described, they are not to be taken as exhaustive. There are several variations that will be apparent to those skilled in the art.