Mortar and debris collection device and system

Abstract: A mortar and debris collection device for a cavity wall (10) construction has a non-water absorbent body (28) formed with circuitous paths therethrough making the body water-permeable. The collection device has a porosity sufficient to permit water to pass therethrough but insufficient to permit mortar and other debris to pass therethrough to weep holes (18) or other water channels covered by the collection debris. The device may be freely placed on the wall base within the cavity (16) to cover the opening of a weep hole (18), or may also be placed on existing wall ties (32) within the cavity (16).

Description: FIELD OF THE INVENTION This invention generally relates to mortar and debris collection devices, such as are used in association with cavity wall constructions. More particularly, in the course of construction of a masonry cavity wall, mortar and other debris falls into the cavity, and may then block weep holes, channels or other water outlets necessary to prevent moisture build-up within the wall cavity. This invention more specifically relates to a device and system for collecting loose mortar and other debris in order to prevent the same from blocking the weep holes that ventilate such a cavity wall construction. BACKGROUND OF THE INVENTION The present invention found its origin in so-called masonry cavity wall constructions. Masonry cavity walls have inner and outer vertical walls. The inner wall is typically constructed from wood with an inner surface of drywall, structural clay tile; vertical stacks of mortared bricks; or a shear concrete surface. The outer wall is generally constructed from vertical stacks of bricks that are held together by mortar. A space, or cavity, exists between the two walls, which may be partially filled with insulation. It is applicant's understanding that the Brick Institute defines a "cavity wall" as having a space greater than about 5 cm (2 inches) but not more than 10 cm (4 inches) between the masonry wythes. A crack in the wall can allow water to enter the cavity. More often, however, moisture can condense on the inside of the wall under changing temperatures. Either way, water may collect in the cavity between the inner and outer wall. The presence of moisture in the space between the inner wall and outer wall is undesirable for a number of reasons. First, the trapped moisture can degrade the inner and outer wall, causing a weakening of the structure. Second, the presence of water under freezing temperatures may also cause cracks in the walls when the water expands as it freezes. Trapped water in the cavity between the inner and outer walls may cause the walls to become discolored, and may even leak into the dwelling. To overcome the problems associated with water trapped within a masonry cavity wall, weep holes or channels are commonly placed along the base of the outer wall. The weep holes allow water to pass from the cavity to drain outside the wall structure. During construction of a masonry cavity wall, excess mortar and other debris can and does fall between the inner and outer wall. When the bricks are stacked during the erection of the outer wall, for example, mortar droppings are squeezed into the space between the walls. The excess mortar, as well as other debris, drops to the base of the cavity, and can block the weep holes. Wicks have been used in weep holes. For instance a cotton wick, such as a segment of cotton rope, has been used in weep holes. Such wicks can be extended from the weep hole up within the cavity to a height considered sufficient to exceed any build-up of mortar droppings. Moisture withid the cavity is absorbed by the wick, and passed to the outside face of the wall. Wicks are preferably made from cotton, because nylon or hemp are considered less efficient in transferring water. The cotton wick, however, may become broken or squashed, and will rot with time. Accordingly, the weep hole may still become blocked during and after construction, thereby preventing moisture in the cavity from passing to the outside of the wall. Another attempt to overcome the problems associated with obstructed weep boles is described in U.S. Patent No. 4,852,320. The '320 patent describes embodiments of a mortar collection device located in the wall cavity. One embodiment is adapted to collect mortar but deflect water. This mortar collection device has an upper surface with sufficient inclination to cause moisture to slide off, but is purportedly insufficiently inclined to prevent mortar from falling off. A second embodiment has a plurality of vertically aligned passageways of dimension sufficient to allow moisture to pass therethrough, but of insufficient dimension to allow mortar to pass therethrough. This honeycomb-like mortar collection device of the '320 patent is made from a non-water absorbent material, such as plastic. It can be seen, nonetheless, that mortar or other debris may still roll down the surface of one or more of the collection devices of the '320 patent and plug a weep hole. Also, the '320 patent mortar collection devices are specially adapted to be carried on reinforcement rods extending between the inner and outer wall. They are not shown adapted to simply rest on the base of the wall, so as to completely cover the weep holes. Furthermore, in the second embodiment of the '320 patent described above having the vertical passageways, small pieces of mortar on other debris may still pass through the holes extending through the unit, thereby allowing the debris to reach the base of the wall and plug the weep holes. It would be desirable to have a mortar and debris collection device capable of resting on the base of the wall in the space between the inner and outer walls to cover and protect the weep holes, as well as being supportable at different heights on the wall without the use of any additional fixation device or special attachment design feature. Furthermore, a collection device should prevent mortar droppings and other debris of any appreciable size from reaching the weep holes. SUMMARY OF THE INVENTION Accordingly, it is a principal objective of this invention to provide a mortar and debris collection device that can rest on the base of the wall cavity to cover and protect one or more weep holes preventing mortar or debris of any significant size from reaching a weep hole and thereby blocking the holes. In addition, a related objective is to provide such a collection device which can be placed at different heights within the cavity without the use of any fixation device or special adaptation of the collection device. Another objective is to provide a surface configuration for such a collection device which facilitates adequate dispersal of debris thereon to assure a water path remains to the collection device. These and further objects which will become apparent hereinbelow are achieved by mortar and debris collection devices according to claims 1, 20 and 22. To the foregoing and other ends, the improved mortar and debris collection device of this invention comprises, in one aspect of the invention, a water-permeable body formed with circuitous (non-linear) pathways therethrough, which body can be readily placed within a cavity wall construction. The inventive collection device can preferably be a non-absorbent water-permeable fibrous block having a porosity sufficient to permit water to pass therethrough, but insufficient to permit mortar or other debris of appreciable size to pass therethrough. Another embodiment contemplates laterally extending projections formed on a supporting board which form the circuitous path. The collection device is intended to be placed on the wall base within the cavity to cover up and block one or more weep hole openings from mortar and debris. Water can migrate through the porous mass to a drain outlet, such as the weep holes, but mortar and debris cannot. It is furthermore contemplated that the collection device may also be placed on existing supports, such as ties, along the walls. No special fixation means for emplacement of the collection device is therefore required, and the collection device need not be specifically adapted for the particular application. A preferred form of the collection device has upwardly extending protrusions, such as protrusions defining overhangs as well as steps, which serve to break up mortar and debris falling on top of the collection device. This prevents ponding of the material on the surface of the collection device. In one embodiment of the invention, a plurality of screens having a porosity sufficient to permit water to pass therethrough but insufficient to permit mortar or other larger-size debris to pass therethrough, are organized in an overlapping arrangement in a collection device. The screens are overlapped such that a vertical line perpendicular to the base of the wall must intersect at least one screen in the device. Mortar and the like falling under the influence of gravity within the cavity must thereby contact at least one of the screens, and preferably two, preventing the mortar and debris from reaching the wall base and blocking a weep hole. The objectives and advantages of the invention will be further understood with reference to the following detailed description of embodiments of the invention read in light of the accompanying drawings, in which: BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a sectional view of a prior art mortar collection device located in a cavity between an inner and outer wall; FIG. 2 is a sectional view similar to that of FIG. 1, but of a first embodiment of a collection device made according to the present invention; FIG. 3 is a perspective view partly in section and partially broken away of the embodiment of FIG. 2 located in a wall cavity; FIG. 4 is an enlarged perspective view of a portion of the embodiment of the collection device shown in FIG. 3; FIG. 5 is a perspective view of another embodiment of the inventive collection device; FIG. 6 is a perspective view of yet another embodiment of the inventive collection device; FIG. 7 is a perspective view of still another embodiment of the inventive collection device; FIG. 8 is a perspective view of a further embodiment of the invention; FIG. 9 is a perspective view of an embodiment similar to FIG. 4 having a fine porous layer therein; FIG. 10 is a perspective view of an embodiment having a stepped configuration across its horizontal thickness; FIG. 11 is yet another embodiment employing a cleated lateral surface; FIG. 12 is a cross-sectional view of an embodiment similar to that of FIG. 11 having projections on both sides; FIG. 13 is a cross-sectional view of an embodiment employing opposed lateral surfaces having projections thereon; and FIG. 14 is a front elevational view of a portion of the fibrous mass. DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION Brick masonry cavity walls 10, as shown in FIGS. 1, 2 and 3, consist of two wythes of masonry separated by an air space. The interior masonry wythe (the inner wall) 12 may be brick, hollow brick, structural clay tile, wood or hollow or solid concrete masonry units, for example. The exterior masonry wythe 14 (the outer wall) is brick. The cavity 16 between the two wythes may be either insulated or left open as air space. The cavity has a typical width of about 2 to about 4 1/2 inches, but could be smaller, although non-standard. A common problem associated with a cavity wall construction is how to allow moisture, as from seepage or condensation, to pass from the cavity to outside the wall. Weep holes 18 creating an unobstructed opening passing from the cavity to the outside of the wall are provided to this end. Generally, the weep holes 18 will be placed approximately two feet apart at the base of the outer wall 14. Moisture collecting in the cavity is intended to run down the cavity wall and be directed by flashing 20 toward the weep holes 18. The flashing 20 is composed of materials such as sheet metals, bituminous membranes, plastics or vinyls. A cotton wick 22 may be placed within the weep hole extending into the cavity. The moisture from inside the cavity will he absorbed and passed to the other end of the wick. The end of the wick is left outside the wall to let the moisture evaporate outside the wall. In the course of construction of a cavity wall 10 as shown in FIGS. 1-3, mortar 24 and other debris will commonly fall into the cavity 16 between the inner wall 12 and outer wall 14. FIG. 1 illustrates a prior art system for passing water to the outside face of the masonry wall 10. A cotton wick 22 is inserted within a weep hole 18 and extends through the veneer face and into the cavity 16. Moisture within the cavity is absorbed by the wick 22 and passed to the outside face of the wall. The wick 22 is preferably made from cotton, with nylon or hemp being considered less efficient than cotton in transferring moisture to the outside surface of the wall. In the prior art structure depicted in FIG. 1, mortar and debris may fall all the way to the base of the wall 26, where the weep holes 18 are located. Because there is no easy access to the interior of the cavity 16, mortar and debris falling within the cavity 16 is not readily removable. If enough mortar 24 builds up around the weep holes 18, or if it simply lodges in the weep holes 18, the weep holes 18 will become plugged, causing water to pond between the walls 12, 14. The water can then leak into the structure, or cause cracking, deterioration and/or discoloration of the walls. Wicks have been found insufficient by themselves to assure that water can always pass through the weep holes. FIG. 2 shows one embodiment of an improved mortar and debris collection device of the present invention. A fibrous body 28 according to the present invention rests on the base 26 of the cavity between the inner wall 12 and the outer wall 14, covering at least one weep hole 18. In this embodiment, the body has a generally rectangular shape with a flat bottom edge that will rest flush against the wall 14. The width of the body is roughly determined by the width of the cavity 16. The body is preferably composed of nonabsorbent plastic, such as, for example, the filament-type plastic used for surface walk-off mats. These materials are preferred because they are water-impervious, relatively inexpensive and can be formed into cutable blocks or sheets. A quantity of one or more of these materials is formed in a mass of random fibers with a density which is sufficient to catch and support mortar and other debris thereon without significant collapse, but allow water to pass freely therethrough. A cotton wick 22 may be attached to, or formed with, the body 28 to aid in the passage of water from the wall. The wick 22 can serve to hold the body 28 in place. When used with such an integral wick 22, the body 28 would be emplaced when the wick holes were formed. Otherwise, it is contemplated that the mortar collection device of this invention will simply be set at the base 26 of the wall foundation covering respective weep holes 18, without the need of any fixation device. Flashing 20 can furthermore be directly attached to the bottom and/or back of the body 28. The porosity of the body 28 made from the fibrous material can be quite varied, so long as it effectively serves to strain out the mortar and debris before it reaches the weep holes. Most mortar and debris will be quite large, i.e., greater than 3,2 or 1,6 mm (1/8 or 1/16 of an inch) or clearly visible to the naked eye, so a porosity sufficient to catch sub relatively large particulate matter will suffice to prevent plugging of the weep holes. Besides being emplacable on the base of the Cavity 16, fibrous bodies 28 may be placed on wall tie rods 32 above the base 26 of the cavity. The tie rods 32 are often part of the cavity wall structure, tying the inner wall 12 and the outer wall 14 together. As particularly shown in FIGS. 3 and 4, the body 28 would advantageously include reinforcing rods 30 extending along the bottom of the body to support and better distribute weight on the body 28 when not simply resting on the base 26 of the cavity 16. The reinforcing rods 30 will better enable a collection device to span adjacent tie rods 32 and still work effectively. A system using the collection device of FIGS. 2-4 would, for example, include bodies 28 placed on the base 26 in sufficient number to cover and block some or all of the weep holes 18 in the cavity 16. It could further include bodies 28, having the reinforcing rods 30, placed on tie rods 32. The body 28 of the embodiment of FIGS. 2-4 has trapezoidal-like cutouts 36. Two slanted edges 38 of the body and a bottom edge 40 of the body (the latter running roughly parallel to the longitudinal axis of the body) define the cutout 36. The dovetailed cutouts 36 thereby formed in the body 28 yield protrusions which help break up the mortar and other debris falling thereon to prevent ponding of moisture in the mortar and debris that collect on the collection device surface. The overhangs formed by the slanted sides 38 are intended to assure that gaps remain in fallen mortar and debris for water to progress to the body 28. FIG. 5 illustrates another embodiment of this invention having a fibrous mass 41 with a stepped configuration along its length created by a series of slanted edges 44. The top step 48 may have a length of approximately 6 to 8 inches, for example. The height of each step may be approximately 10,16 cm (4 inches). Again, the stepped cutout 42 is intended to break up mortar and debris falling thereon to thereby prevent the ponding of moisture. FIG; 6 illustrates another embodiment of this invention with the fibrous mass 50 having rectangular cutouts formed by a series of perpendicular edges 54. In a presently Contemplated embodiment, the steps would have a height of approximately 10,16 cm and a length of approximately 20,32 cm (8 inches). FIG. 7 illustrates yet a further embodiment of this invention. The debris collecting fibrous body 58 has dove-tailed cutouts formed from non-planar curved steps 60. This is another shape for the upper surface of the collection device designed to break up the mortar and other debris falling thereon, to thereby prevent the ponding of moisture on the surface of the body 58. FIG. 8 illustrates another embodiment of this invention. Three series of planar screens 62, 64 and 66 having a porosity sufficient to permit water to pass therethrough but at least collectively insufficient to permit mortar and other debris to pass therethrough are arranged to form the collection device. A first plurality of screens 62 extend on one horizontal plane. On a second and lower horizontal plane, a plurality of screens 64 are arranged in spaced apart relation. On a third and still lower horizontal plane, a plurality of screens 66 are arranged in spaced apart relation, but with portions overlapping with screens 64 of the second horizontal plane. A vertical line extending substantially perpendicular through the collection device of FIG. 8 must therefore pass through,at least one and motre often two screens in this embodiment. Generally, the screens should have a width determined by the width of the cavity 16. The screens Can be formed of a sufficiently rigid screen material to maintain their shape when attached to vertical rods 68 or Like supporting structure, or may each be provided with a rigid frame. Screen 62 may have a large mesh size to Catch only the larger particles, with Screens 64 and 66 having a smaller mesh. Wicks 22 may be attached to the base of the rods 68. Screen 62 might also be omitted entirely, if desired. Whether present or not, however, mortar droppings and other debris falling into the cavity 16 above the screen Collection device of FIG. 8 must contact at least one screen to thereby become trapped and isolated from the weep holes. FIG. 9 illustrates a modified embodiment similar to that of FIG. 4, except that a thin layer of material 70 is provided above the bottom of the fibrous body, which material has the ability to pass water but substantially no visible solids. Such a material could be the type of landscaping material used to control weeds. The layer could be located 2,5 to 5 cm (1 to 2 inches) above the bottom, for example. FIG. 10 illustrates an embodiment having a stepped upper surface extending across its horizontal thickness, i.e., perpendicular to its long axis. Steps 72a, 72b and 73a, 73b of the fibrous mass serve to prevent "bridging" of material across the space of the wall cavity (i.e., extending between the inner wall 12 and outer wall 14). FIG. 11 is another variation on the basic inventive concept which utilizes a supporting base, such as a backing board 80, having a plurality of projections 82 extending from one or both (see FIG. 12) of its lateral surfaces. The projections 82 would preferably be staggered so as to provide a tortuous path for water and debris, and also preferably made of a flexible material so as to permit the FIG. 11 embodiment to fit within most common cavity wall spaces. The FIG. 11 embodiment is intended to be placed in the cavity 16 (e.g., FIG. 3) with the backing board 80 against one wall and the projections 82 extending across the gap and engaging the opposite wall. FIGS. 12 and 13 are modified embodiments similar in concept to FIG. 11. The FIG. 12 embodiment, shown here only in cross-section, has projections 82 extending from both lateral sides of the backing board 80. It would be placed in the middle of the cavity 16, with projections 82 engaging respective walls. The FIG. 13 embodiment, again shown here only in cross-section, uses relatively thin backing boards 80' which are arranged in opposed relationship so that the projections 82 extending from respective lateral sides intermesh. The FIG. 13 embodiment would be placed in cavity 16 with the backing boards 80' abutting the walls defining the cavity. Thus, while the collection device and system of this invention have been described with respect to a number of different embodiments, those of skill in this art will recognize changes and modifications in material, structure and form and the like which will still fall within the scope of the claims of this invention. More particularly, the invention shows advantages when the mortar and debris collection device for use in a cavity wall construction having an inner wall and an outer wall with weep holes formed therein through which weep holes water can drain from a weep hole opening communicating with a cavity defined between the walls, comprises: a water-permeable porous body of non-water absorbent randomly oriented fibrous material positioned in alignment with at least some of said weep hole openings, said body having a porosity sufficient to permit water to pass therethrough but mortar and debris is substantially prevented from passing therethrough, said body having an upper surface including upwardly extending protrusions yielding peaks and valleys adapted to break up accumulations of mortar and debris falling thereon, at least a portion of said body having a thickness dimension substantially the same as the cavity between said inner and outer walls. It is particularly advantageous if the mortar and debris collection device for use in a cavity wall construction having an inner wall and an outer wall with weep holes formed through a wall through which weep holes water can drain from a weep hole opening communicating with a cavity defined between the inner and outer walls, is provided with: a body of randomly oriented non-water absorbent fibrous material formed into a water-permeable porous mass, said body being positioned in alignment with at least some of weep hole openings and having a porosity sufficient to permit water to pass therethrough but substantially insufficient to permit mortar and debris to pass therethrough, said body having a height and width sized to cover at least one of the weep hole openings and emplaceable within the cavity without any fixation device required, at least a portion of said body having a thickness dimension substantially the same as the cavity between said inner and outer walls. Furthermore, said body is emplaced within the cavity and rests on a wall base at the bottom of the cavity to cover at least one respective opening and block the opening from mortar and debris. A particular aspect of the invention is seen in a drainage system for use in a cavity wall construction having an inner wall and an outer wall with weep holes formed therein adjacent a wall base at the bottom of the walls through which weep holes water can drain from a weep hole opening communicating with a cavity defined between the walls, comprising: a plurality of horizontally elongated debris blocking bodies, each of said bodies being made of non-water absorbent material formed into a permeable mass having a porosity sufficient to permit water to pass therethrough but insufficient to permit debris which is greater than about 1,6 mm (1/16 inch) to pass therethrough, each of said bodies having an upper surface upon which mortar and debris can collect, said bodies being emplaced within the cavity and at least some of said bodies resting on the wall base in alignment with and covering at least one respective opening and blocking the opening from debris, at least a portion of said body having a thickness dimension substantially the same as the cavity between said inner and outer walls. In an other advantageous embodiment the drainage system for use in a cavity wall construction having an inner wall, an outer wall, a wall base between the walls at the bottom of the cavity wall construction, and ties extending between and joining the walls above the base, with at least one weep hole formed in a wall through which weep hole water can drain from a weep hole opening communicating with a cavity defined between the walls comprises: a plurality of mortar and other debris blocking bodies, each of said bodies being horizontally elongated along a major length with a surface upon which mortar and debris can collect, made of non-water absorbent material formed into a water-permeable porous mass of randomly oriented passages which interrupt the downward movement of free-falling material, said porous mass having a porosity sufficient to permit water to pass therethrough but insufficient to permit mortar and debris to pass therethrough, said bodies being emplaced within the cavity on the wall base in alignment with and covering at least one respective opening and blocking the opening from such mortar and debris, at least a portion of said bodies having a thickness dimension substantially the same as the cavity between said inner and outer walls. It is also particularly advantageous to provide for debris collection device for use in a cavity wall construction having an inner wall and an outer wall with weep holes formed therein adjacent a cavity wall base through which weep holes water can drain from a weep hole opening communicating with a cavity defined between the walls, comprising: a plurality of screens, each said screen having a porosity sufficient to permit water to pass therethrough but insufficient to permit mortar and other debris having a size greater than about 1,6 mm (1/16 inch) to pass therethrough; and means for organizing said screens in overlapping arrangement in a plurality of generally parallel planes with screens in one or more of said planes being spaced one from another, said screens so organized giving the debris collection device a thickness at least as great as the horizontal distance between the inner and outer walls-at the cavity wall base and defining a volume for the debris collection device, said screens being overlapped such that a vertical line perpendicular to said planes through said volume must intersect at least one screen, whereby mortar and other debris falling under the influence of gravity within the cavity and into said volume must contact at least one such screen. It has been found to be advantageous to have a mortar collecting device for use in a cavity wall construction having an inner wall and an outer wall with weep holes formed therein through which weep holes water can drain from a weep hole opening communicating with a cavity defined between the walls, comprising: a supporting member having two lateral side faces, said supporting member having a vertical height and longitudinal length adapted to yield an area greater than that of at least one such channel opening; a plurality of projections extending outwardly from each said side lateral face, said projections being provided in staggered arrangement such that a vertical line extending parallel to each said side lateral face will contact at least one such projection, thereby forming a circuitous path for debris passing along each said side lateral face, whereby said collecting device when emplaced within the cavity with said projections overlying at least one such channel opening serves to prevent debris from plugging the channel opening. Furthermore, it has been also found particularly advantageous to devise a mortar collecting device for use in a cavity wall construction having an inner wall and an outer wall with weep holes formed therein through which weep holes water can drain from a weep hole opening communicating with a cavity defined between the walls, comprising: a pair of opposed supporting members each having a lateral face, each said supporting member having a vertical height and longitudinal length adapted to yield an area greater than that of at least one such channel opening; a plurality of projections extending between said lateral faces, said projections being provided in staggered arrangement such that a vertical line extending parallel to each said side lateral face will contact at least one such projection, thereby forming a circuitous path for debris passing between said opposed supporting members along a lateral face, whereby said collecting device when, emplaced within the cavity overlying at least one such weep hole opening serves to prevent debris from plugging the weep hole opening. Moreover, it is noted that an other embodiment of the invention a mortar collecting device for use in a cavity wall construction having an inner wall and an outer wall with weep holes formed therein adjacent a cavity bottom through which weep holes water can drain from a weep hole opening communicating with a cavity defined between the walls is provided, comprising: a water permeable body positioned in alignment with at least some of said weep hole openings, said body having non-linear water pathways formed therein which interrupt the downward movement of free-falling material and yielding a porosity sufficient to permit water to pass therethrough, said body having a horizontal axis relative to the cavity bottom, said body further including a layer of material extending along said horizontal axis which material passes water therethrough, at least a portion of said body having a thickness dimension substantially the same as the cavity between said inner and outer walls, said body having an upper surface including upwardly extending protrusions to prevent ponding of material falling on said upper surface. The body is formed of randomly oriented non-absorbent fibrous material formed into a water permeable porous mass, said body having a porosity sufficient to permit water to pass therethrough but insufficient to permit mortar and other debris having a size greater than about 1,6 mm to pass therethrough, said body having a height and width sized to cover at least one of the weep hole openings. A further advantageous device for mortar and debris collection according to the invention for the use in a cavity wall construction having an inner wall and an outer wall with weep holes formed therein through which weep holes water can drain from a weep hole opening communicating with a cavity defined between the walls, comprises: a water-permeable body having circuitous non-linear pathways therethrough extending from an upper surface upon which water and debris can fall, and yielding a porosity for said body sufficient to permit water to pass therethrough, but mortar and other debris is substantially prevented from passing therethrough, said body being formed of a water-resistant fibrous mass and emplaceable within the cavity without any fixation device required. In this embodiment said body is elongated along a long axis and further includes at least one reinforcing rod affixed to said body extending generally parallel to said long axis. Advantages can be obtained when a mortar and debris collection devise for use in a cavity wall construction having an inner wall and an outer wall with weep holes formed therein through which weep holes water can drain from a weep hole opening communicating with a cavity defined between the walls, is provided with a water-permeable body having circuitous non-linear pathways therethrough extending from an upper surface upon which water and debris can fall, and yielding a porosity for said body sufficient to permit water to pass therethrough, but mortar and other debris is substantially prevented from passing therethrough, said body being elongated along a long axis and having an upper surface with a non-planar contour along said long axis, and flashing affixed to said body along a body bottom which is opposite to said upper surface and generally parallel to said long axis. It has also been noted that it is particularly useful that a mortar and debris collection device for use in a cavity wall construction having an inner wall and an outer wall with weep holes formed therein through which weep holes water can drain from a weep hole opening communicating with a cavity defined between the walls, comprises: a water-permeable body having circuitous non-linear pathways therethrough extending from an upper surface upon which water and debris can fall, and yielding a porosity for said body sufficient to permit water to pass therethrough, but mortar and other debris is substantially prevented from passing therethrough, said body being elongated along a long axis and having a horizontal thickness defined perpendicular to said long axis, said body also having an upper surface with a non-planar contour of stepped configuration along said upper surface. In a particular aspect of the invention a mortar and debris collection device for use in a cavity wall construction having an inner wall and an outer wall with weep holes formed therein through which weep holes water can drain from a weep hole opening communicating with a cavity defined between the walls is provided, Comprising a water-permeable porous body of non-water absorbent randomly oriented fibrous material having a porosity sufficient to permit water to pass therethrough, said body having an upper surface including upwardly extending protrusions which define overhangs along said upper surface to provide gaps in material collected on said upper surface. In a different aspect of the invention there is provided a mortar and debris collection device for use in a cavity wall construction having an inner wall and an outer wall with weep holes formed through a wall through which weep holes water can drain from a weep hole opening communicating along with a cavity defined between the inner and outer walls, comprising a body of randomly oriented non-water absorbent fibrous material formed-into a water-permeable porous mass, said body having a porosity sufficient to permit water to pass therethrough but substantially insufficient to permit mortar and debris to pass therethrough, said body having a height and width sized to cover at least one of the weep hole openings, a wick for wicking water extending from said body at a body bottom, said wick adapted to fit within the weep hole, and flashing attached to said body bottom. In a further particularly advantageous aspect of the invention a drainage system is provided for use in a cavity wall construction having an inner wall, an outer wall, a wall base between the walls at the bottom of the cavity wall construction, and ties extending between and joining the walls above the base, with at least one channel formed in a wall through which channel water can drain from a channel opening communicating with a cavity defined between the walls comprising: a plurality of mortar and other debris blocking bodies, each of said bodies being made of non-water absorbent material formed into a water-permeable porous mass of randomly oriented passages, said porous mass having porosity sufficient to permit water to pass therethrough but insufficient to permit mortar and debris to pass therethrough, said bodies being emplaced within the cavity on the wall base covering at least one respective opening and blocking the opening from such mortar and debris, said bodies having a thickness at least as great as the distance between the inner and outer walls at the wall base, with each said bodies freely resting on one or more of the wall base and ties. It also have been found that it is particularly effective to devise a drainage system for use in a cavity wall construction having an inner wall, an outer wall, a wall base between the walls at the bottom of the cavity wall construction, and ties extending between and joining the walls above the base, with at least one weep hole formed in a wall through which weep hole water can drain from a weep hole opening communicating with a cavity defined between the walls comprising: a plurality of mortar and other debris blocking bodies, each of said bodies being made of non-water absorbent material formed into a water-permeable porous mass of randomly oriented passages, said porous mass having a porosity sufficient to permit water to pass therethrough but insufficient to permit mortar and debris to pass therethrough, said bodies being emplaced within the cavity on the wall base covering at least one respective opening and blocking the opening from such mortar and debris, at least some of said bodies being elongated along a major length and include a reinforcing rod extending along said major length to provide further rigidity to said body, as for supporting said body between ties in the cavity. Where technical features mentioned in any claim are followed by reference signs, those reference signs have been included just for the sole purpose of increasing intelligibility of the claims and accordingly, such reference signs do not have any limiting effect on the scope of each element identified by way of example by such reference signs.

Claims: A mortar and debris collection device for use in a cavity wall (10) construction having an inner wall (12) and an outer wall (14) with weep holes (18) formed therein through which weep holes (18) water can drain from a weep hole opening communicating with a cavity (16) defined between the walls (12, 14), comprising: a water-permeable body (28, 41, 50, 58) positioned in alignment with at least some of said weep hole openings, said body (28, 41, 50, 58) having circuitous non-linear pathways therethrough which interrupt the downward movement of free-falling material and extending from an upper surface (40, 48, 54, 60, 62, 72a-b, 73a-b) upon which water and debris can fall, and yielding a porosity for said body (28, 41, 50, 58) sufficient to permit water to pass therethrough, but mortar and other debris is substantially prevented from passing therethrough, at least a portion of said body (28, 41, 50, 58) having a thickness dimension substantially the same as the cavity (16) between said inner (12) and outer (14) walls, said upper surface (40, 48, 54, 60, 62, 72a-b, 73a-b) of said body (28, 41, 50, 58) having a non-planar contour. The collection device of claim 1 wherein said body (28, 41, 50, 58) has a horizontal thickness defined perpendicular to a long axis, and has said non-planar contour along said thickness on said upper surface (72a-b, 73a-b). The collection device of claim 1 wherein said body (28, 41, 50, 58) is elongated along a long axis and has said upper surface (40, 48, 54, 60, 62, 72a-b, 73a-b) with said non-planar contour of peaks and valleys along said long axis adapted to break up accumulations of mortar and debris falling thereon. The collection device of claim 1 wherein said body (28, 41, 50, 58) is elongated along a long axis and has said upper surface (40, 48, 54, 60, 62, 72a-b, 73a-b) with said non-planar contour of stepped configuration along said upper surface. The collection device of claim 1 wherein said body (28, 41, 50, 58) is elongated along a long axis and has said upper surface (40, 48, 54, 60, 62, 72a-b, 73a-b) with upwardly extending protrusions defining overhangs, thereby providing gaps in material collected such as to prevent ponding of mortar and debris on said upper surface. The collection device of any of claims 2-3 and 5 wherein said body (58) has an upper surface with a repeating dovetailed contour (60) along its long axis. The collection device of any of the preceding claims, wherein said water-permeable body (28, 41, 50, 58) is made out of non-water absorbent randomly orientated fibrous material. The collection device of claims 7, wherein said water-permeable body (28, 41, 50, 58) has a porosity sufficient to permit water to pass therethrough but insufficient to permit mortar and other debris having a size greater than about 1,6 mm (1/16 inch) to pass therethrough. The collection device of any of the preceding claims further including a wick (22) for wicking water attached to said body (28, 41, 50, 58), said wick (22) being adapted to fill a weep hole (18). The collection device of any of the preceding claims wherein said body (28, 41, 50, 58) is emplaceable within said cavity without any fixation device required. The collection device of any of the preceding claims, wherein said body includes at least one flashing (20) affixed to said body along a body back and/or bottom. The collection device of any of the preceding claims, wherein said body (28, 41, 50, 58) includes at least one reinforcing rod (30) affixed to said body extending generally parallel to said long axis. The collection device of any of the preceding claims wherein said body (28, 41, 50, 58) includes a thin layer of material (70) provided above the bottom of said body, said material (70) having the ability to pass water but substantially no visible solids. The collection device of any of the preceding claims wherein said body (28, 41, 50, 58) is adapted to be emplaced within the cavity (14) resting on a wall base at the bottom of the cavity (14), with the body (28, 41, 50, 58) covering at least one respective weep hole opening and blocking the weep hole opening from mortar and debris. The collection device of any of claims 1 to 13 wherein said body (28, 41, 50, 58) is adapted to be emplaced within the cavity (14) resting on tie rods (32) extending between and joining said walls (12, 14) of the cavity (14), with the body (28, 41, 50, 58) covering at least one respective weep hole opening and blocking the weep hole opening from mortar and debris. The collection device of any of the preceding claims wherein the body (28, 41, 50, 58) portion having a thickness dimension substantially the same as the space between said inner and outer walls is located at the lower end of said body (28, 41, 50, 58). The collection device of any of the preceding claims wherein said body (28, 41, 50, 58) has substantially the same thickness dimension throughout its length and height. The collection device of any of the preceding claims wherein said body (28, 41, 50, 58) is positioned in alignment with at least some of said weep hole openings by being positioned directly outwardly of said openings. A drainage system for use in a cavity wall construction having an inner wall (12) and an outer wall (14) with weep holes (18) holes formed through one of the walls (12, 14) adjacent a wall base at the bottom of the walls (12, 14) through which weep holes (18) water can drain from a weep hole opening communicating with a cavity (16) defined between the walls (12,14), comprising: a plurality of collecting devices according to one or more of the preceding claims being positioned in alignment with and covering at least some of the respective weep hole (18) openings and blocking said weep hole (18) openings from mortar and other debris. A mortar and debris collection device for use in a cavity wall (10) construction having an inner wall (12) and an outer wall (14) with weep holes (18) formed therein through which weep holes (18) water can drain from a weep hole (18) opening communicating with a cavity (16) defined between the walls (12, 14), comprising: a plurality of screens (62, 64, 66), each of said screens (62, 64, 66) having a porosity sufficient to permit water to pass therethrough but insufficient to permit mortar and other debris having a size greater than about 1,6 mm (1/16 inch) to pass therethrough, and means for organizing said screens (62, 64, 66) in overlapping arrangement in a plurality of generally parallel planes with said screens (62, 64, 66) in one or more of said planes being spaced one from another, said screens (62, 64, 66) so organized giving the debris collection device a thickness at least as great as the horizontal distance between the inner wall (12) and the outer wall (14) at the cavity wall base and defining a volume for the debris collection device, said screens (62, 64, 66) being overlapped such that a vertical line perpendicular to said planes through said volume must intersect at least one screen (62, 64, 66), whereby mortar and other debris falling under the influence of gravity within the cavity and into said volume must contact at least one such screen (62, 64, 66). A drainage system for use in a cavity wall construction having an inner wall (12) and an outer wall (14) with weep holes (18) formed through one of the walls (12, 14) adjacent a wall base at the bottom of the walls (12, 14) through which weep holes (18) water can drain from a weep hole opening communicating with a cavity (16) defined between the walls (12,14), comprising: a plurality of collecting devices according to claim 20 being positioned in alignment with and covering at least some of the respective weep hole (18) openings and blocking said weep hole (18) openings from mortar and other debris. A mortar and debris collecting device for use in a cavity wall construction having an inner wall (12) and an outer wall (14) with weep holes (18) formed therein through which weep holes (18) water can drain from a weep hole opening communicating with a cavity (16) defined between the walls, comprising: a supporting member (80, 80') having a lateral face, said supporting member (80, 80') having a vertical height and longitudinal length adapted to yield an area greater than that of at least one such weep hole opening, a plurality of projections (82) extending from said lateral face, said projections (82) being provided in staggered arrangement such that a vertical line extending parallel to said lateral face will contact at least one such projection (82), thereby forming a circuitous path for debris passing along said lateral face, whereby said collecting device when emplaced within the cavity (16) with said projections (82) overlying at least one such weep hole opening serves to prevent debris from plugging the weep hole opening. The collecting device of claim 22 wherein said support member (80) is a backing board having a planar lateral face, and said projections (82) are adapted to extend across the cavity (16) and contact one wall (12, 14) with said backing board abutting the other wall (14, 12). The collecting device of claim 23 wherein said projections (82) are flexible or resilient. A drainage system for use in a cavity wall construction having an inner wall (12) and an outer wall (14) with weep holes (18) holes formed through one of the walls (12, 14) adjacent a wall base at the bottom of the walls (12, 14) through which weep holes (18) water can drain from a weep hole opening communicating with a cavity (16) defined between the walls (12,14), comprising: a plurality of collecting devices according to any of claims 22-24 being positioned in alignment with and covering at least some of the respective weep hole (18) openings and blocking said weep hole (18) openings from mortar and other debris.

Inventors: SOURLIS TOM, SOURLIS, TOM
Applicants: SOURLIS TOM, SOURLIS, TOM
Application year: 1993
Main classification: E04B1
IPC codes: E04B1