Patent Publication Number: US-2022232818-A1

Title: Weep Hole Guard

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent application 62/969,127, filed Feb. 2, 2020. 
    
    
     STATEMENT REGARDING FEDERALLY FUNDED RESEARCH OR DEVELOPMENT 
     Not applicable 
     FIELD OF INVENTION 
     The present invention relates to a breathable cover or insert for exterior masonry walls in homes and buildings, where ventilation passages commonly known as weep-holes exist near the foundation that can serve as a path for pest intrusion. The device is not limited to brick masonry walls, but can include types of exterior walls with vent openings such as concrete block and other variations of exterior wall structures. 
     BACKGROUND OF THE INVENTION 
     In the United States, there are millions of existing residential homes that have brick exteriors. Masonry walls such as brick siding are often the choice of home owners due to aesthetics and durability, which is why brick is one of the most popular exterior materials for single-family homes in suitable climates. Brick siding usually has an air gap behind it and the home sheathing which is attached to the house interior wall. As governed by building code (ref: 2021 International Building Code Section 1404.4.2 and 2015 International Residential Code Section R703.8.6) and illustrated in  FIG. 1 a   , bricklayers build an exterior siding using brick  11  and mortar  12  on a cement foundation  13  supported by ground  14 . Periodically, said bricklayers leave an opening with no mortar between bricks  11  located adjacent to the foundation level  13 . This opening is commonly called a weep-hole  10 . The opening is typically ½ inch wide and approximately the height of the brick  11 , dimension D 1 .  FIG. 1 b    shows a sectional view cut through said weep-hole and defines typical brick siding with wall construction (brick  11 , mortar  12 , foundation  13 , ground  14 , wall footer  16 , vertical stud  17 , sheathing  18  and flash  19 ) including air flow paths  15  and vertical air gap  20 . This method prevents moist air from getting trapped in said vertical gap or air space behind the wall, thus allowing moisture and condensation to freely vent to the exterior, so as to prevent rot and mildew from forming. This simple solution is effective, but the very purpose for a breathing space allows pests (insects, snakes, mice and other critters) to climb inside and make a nest, which can damage the wall integrity. In some cases pests can even establish themselves in the attic passages and find a way into the home interior. The location of the weep-hole at the base of the wall also allows splashing water from rain and lawn sprinklers to intrude, which can mold and rot wooden wall footing. 
     Problem and Need 
     Once a house is built, it is not immediately obvious how a weep-hole retrofit can solve the pest and water problem. Some homeowners have stuffed various types of copper meshing in the holes to prevent intrusion. Other manufacturers have attempted to market various barriers or covers for protection that have not been well adopted by industry and homeowners. After installation, most devices are not easy to remove for inspection. Furthermore, homes typically have weep-holes every 2-3 feet along the foundation, so you need a large number (about 50-100) devices per residential home to fully complete a retrofit job. When building exterior siding, most bricklayers set the weep-hole width by estimation, so the gap can vary from ¼ to ¾ inch wide and there is a lot of variation. A low cost and easy to install solution is thus needed to solve this challenging problem. 
     Prior Art—Existing Products on the Market and Shortcomings 
     Regarding prior art in the field, there are several products being marketed as weep-hole covers or barriers, which are the two main methods of prevention. Covers attempt to address this problem by sealing the entry point and leaving a perforated or screen opening for airflow that unfortunately leaves little opportunity for air to freely move. In the country of Australia, there appears to be significant interest in weep-hole covers. The Weepa brand cover (U.S. Pat. No. 8,171,677) is limited to installation during new construction, but is effective at meeting bushfire compliance codes specific to this locale. The Bug Out Barrier (U.S. Pat. No. 6,360,493) is a cover that must be glued to the outside of the brick and is marketed in the US. It is literally a box cover with a hinged, perforated lid that is glued to the outside of the brick face, not installed in the hole. The invention is made of clear plastic with UV protection and the oversized dimensions are 3½ inches long by 1⅛ inches wide. To install, you prepare the brick exterior face, add caulk adhesive, and apply them to the brick face. This takes time and preparation, and makes the cover frame difficult to remove. Another version in this patent refers to a new construction installation within the weep-hole. A previously disclosed invention (U.S. Pat. No. 5,203,795) is comprised of a multi-part system that incorporates an outside cover and an offset “V” shaped anchor deeper inside the weep-hole. To remove the anchor, a flat-bladed screwdriver is needed to pry the part loose and extract it from the weep-hole. The device method requires the outside cover to be much larger and unsightly than the weep-hole itself. 
     Another approach with some variants is to install barriers or inserts. The Rid-O-Mice brand cover is a stainless steel, u-shaped device that states it is simple to install, but it usually needs residual mortar between bricks chiseled or drilled out prior to installation, thus risking damage to the mortar and bricks. If the side walls are not clean, then the cover won&#39;t slide in. You will likely need to trim the product first to get the right height, using metal shears. To install it, you insert it half-way by hand, then pound it in the rest of the way with a board and hammer. A newer device called the Weep Hole Screen (U.S. Pat. No. 9,903,108) utilizes an additional tool to push a flexible screen into the weep-hole, several millimeters into the wall. Both styles described are hard to remove for inspection. Finally, there is a weep-hole barrier which is sold by Tamlyn Metal Products. The Retrofit Weep Hole Cover is made from sheet metal and is gray in color. It comes in 5 inch or 10 inch stock lengths, must be cut to specific size and may need a contractor to install them. Like Rid-O-Mice brand, the Tamlyn device is installed wide or open end first. Although it does not extend as deep as the Rid-O-Mice model, this type of insert also tends to need cleanout of residual mortar to install and function properly, because the weep-hole walls are contacted by the insert as it is pushed or pounded in place. When these covers are installed, care must be taken to avoid inserting them too far as there is no depth-stop feature. 
     All products and inventions previously described have one or more drawbacks that the present invention improves upon, as will be shown. 
     BRIEF SUMMARY OF THE INVENTION 
     Based on an evaluation of the existing US market and its shortcomings, product needs were analyzed and this aided in guiding the functions of the present invention which is designed for installation after construction of the masonry wall. The first object of the present invention is to provide a simple one-piece fabrication, using a mold or extrusion to minimize cost. The overall height of the one-piece part is selected to fit most weep-hole openings. The second object of the present invention is to provide a one-hand, one-step insertion for installation. Ease of installation/simplicity of use determines utility and customer acceptance. The third object of the present invention to provide a self-adjusting feature to accommodate most brick opening widths, typically from ¼ inch to a maximum ¾ inch range. When masons install brick rows at the foundation, the spacing is not exact and can vary widely. However, variations causing a smaller hole than this range should be carefully knocked out with a chisel to avoid general ventilation blockage. The fourth object of the present invention is to provide combination flange and grip features to prevent the user from installing the device beyond the brick siding outer face. This feature of the present invention acts as a depth-stop function which ensures the device installation process is repeatable, and does not allow the device to get embedded too deep into the opening so that it is not easily retrievable. The fifth object of the present invention is for the device to adapt to variations in brick opening height range. The present invention can be easily cut by scissors and separated into larger and smaller pieces. By taking two larger pieces from separate weep-hole covers, a two-part stacked assembly can be inserted to fill a taller hole. When masons install brick at the foundation, the mortar in the weep-hole can either be left out at the top of the opening, or build-up can unintentionally overfill the opening slightly which demands a taller or shorter weep-hole cover, respectively. The sixth object of the present invention is to retain itself (stay in place) without resting on the bottom of weep-hole opening. This ensures the device stays in place on its own indefinitely, using spring load and/or grip features. For plastic use, an important consideration is ensuring careful material selection of stiffness and creep properties along with incorporating sunlight (ultraviolet ray or UV) inhibitors. The seventh object of the present invention is to provide a minimum airflow passage of at least 50% of the ratio of the total part hole-area to total frontal-area of a weep-hole, assuming an average opening ½ inch wide×2 9/16 inch tall. A large number of holes on the present invention, especially on non-contact faces ensures that the air flow passage is not overly constricted. The last object of the present invention is to have the device easily removable for inspection and cleanout of the weep-hole. A weep-hole cover is not meant to be a permanent guard, and occasional weep-hole inspection is needed. 
     The advantages of the present invention and how it solves previously existing problems while adhering to all of the above requirements shall be subsequently detailed and further elaborated. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING 
         FIG. 1 a    is a front elevation view of a portion of a brick (masonry) wall with a weep-hole located adjacent to the base of the foundation. 
         FIG. 1 b    is a sectional view of basic wall construction with weep-hole passage, showing the air ventilation path. 
         FIG. 2  is a perspective view of the preferred embodiment for the invention. 
         FIG. 3  depicts the section shape for the present invention, in free-state (no load, resting shape). 
         FIG. 4  is a top view of the weep-hole cover as-installed in accordance with the invention. 
         FIG. 5  shows an alternate embodiment of the invention with additional features incorporated. 
         FIGS. 6 a , 6 b , and 6 c    is a comparison of the invention as-installed for various weep-hole widths, when the device is squeezed for insertion. 
         FIG. 7  is a side view of the weep-hole cover as-installed in accordance with the invention. 
         FIG. 8  shows an alternate embodiment, using a combination of two large pieces of the present invention as-installed. 
     
    
    
     DETAILED DESCRIPTION OF PRESENT INVENTION 
     Referring to  FIG. 2 , there is shown the preferred embodiment of the weep-hole cover  30  in a perspective view. The present invention is a single part, comprised of three distinct, connecting faces (plates) which include the vee-walls  31 , the apex wall  32  at the distal end and the exterior flanges  33  at the proximal end. By its nature of symmetry, the weep-hole cover comprises said exterior flange on opposing sides of the vee shape. Furthermore, the weep-hole cover is defined by a plurality of through-holes on faces  31  and face  32 . Contact faces  34  are intended for engaging the exterior masonry wall surfaces and limiting depth of insertion. On said vee-wall faces  31 , a horizontal hole pattern  35  is repeated vertically, thus creating a matrix in order to allow air passage. Similarly on apex face  32 , a vertical hole pattern  36  is defined. In this embodiment there are shown a total of 50 holes that perforate non-contact walls. If the present invention were to be unfolded, as in a flat-pattern, total area with perforations is proportionally large compared to the size (frontal area) of a weep-hole opening. With a quantity of 50 holes, the total air passage area is approximately 50% of the area of a weep-hole opening of ½ inch wide by 2 9/16 inch height. On the exterior flanges  33 , corners are rounded for aesthetics and handling. 
       FIG. 3  depicts the section shape for the present invention in a free-state. It is shown in a no load condition, or its resting shape (free-state). For dimension D 2 , the apex face  32  at the distal end is approximately 1.0 inch depth relative to the masonry contact faces  34  of the proximal exterior flanges  33 , and said apex is centralized to form section shape symmetry about the centerline. Dimension D 3  represents the width of said apex at its most distal end, which is preferably 0.2 inches or less to allow for insertion into the most narrow of weep-holes. The angle D 4  of the vee-wall face  31  relative to the apex face  32  is preferably 65-70 degrees. The overall width of the vee shape in free-state is greater than the maximum intended weep-hole opening of ¾ inch, so that when the part is squeezed and inserted into said weep-hole, a spring retention force is created. Wall and flange thickness dimensions D 5  and D 6  are preferably 0.05-0.07 inch, depending on material properties. Selection of wall  31  thickness will define the stiffness of the part, whereas the flange  33  thickness is selected for ease of gripping by fingers. Flange  33  width D 7  is governed by masonry exterior wall contact, and structural integrity or compression stability of the vee-shape when the part is squeezed prior to insertion into the weep-hole. 
     As may be surmised, the presented dimensions in  FIG. 3  have proven to be optimum for part functionality, however as dimension D 3  decreases towards zero, the result is that a sharp vee-shape is formed, thus creating simple planar intersections with a vertex. Overall, dimension D 2  can vary from 0.5-2.5 inches, whereas dimension D 4  can vary from 45-85 degrees if desired to create a family of designs. As dimension D 2  increases in length, dimension D 4  will correspondingly increase in angle to accommodate similar size weep-holes. 
       FIG. 4  is a top view of the weep-hole cover  30  as-installed in weep-hole  10  of the masonry brick  11 . Installation is unaffected by excess mortar  23  that may remain deeper in said weep-hole. To install said cover, the user simply squeezes the opposing exterior flanges  33  together in the direction of E and inserts said cover into the weep-hole in the F direction until the flange contact faces  34  meet the masonry exterior faces  21 . Masonry interior faces  22  are shown for orientation. Operations E and F are compound forces that occur simultaneously. Installation is complete when the user discontinues squeezing said flanges and releases said cover, thus employing an interference friction fit with the weep-hole walls. The advantage of the spring feature facing outward can be appreciated, which allows easy removal for inspection as compared to prior art. 
     There are several additional features or embodiments which enhance the basic function of the weep-hole cover  30  previously given in  FIG. 2 . As can be seen in  FIG. 5 , one alternate embodiment is comprised of a plurality of teeth  37  on the vee-wall faces  31 , adjacent to the exterior flange faces  34 . The feature improves the engagement and retention of said vee-wall faces to the masonry weep-hole wall edges near the opening. An additional alternate embodiment is defined by a plurality of finger grip features  38  on the outward edge of the exterior flanges  33 . Each scalloped contour of said grip is sized to fit a finger and facilitates ease of handling the weep-hole cover during installation. In  FIG. 5 , it can be further shown that a lateral slit or cutting line  39  is provided, preferably 0.02-0.05 inches wide, which perforates the vee-wall faces  31  and a portion of the exterior flanges  33 . It is intentionally located a distance from the part center-height. Said lateral slit facilitates ease of cutting the weep-hole cover into two unequal heights of pieces for the purpose which will be explained subsequently. Within  FIG. 5 , features  32 ,  35  and  36  are shown for reference. 
       FIGS. 6 a , 6 b  and 6 c    refer to end-views of the same weep-hole cover  30  previously shown in  FIG. 3  and which are illustrated under various conditions of vee-wall compression. Overall width variation when installed in different weep-holes is given and the part gradually increases in width when moving from left to right in the figures. In  FIG. 6 a   , the dimension D 8  is typically ¼ inch and this is considered the smallest opening in weep-hole construction by brick layers. The geometry of said cover is compressed and the opposing vee-walls are nearly parallel. As depicted in  FIG. 6 b    compression is gradually relaxed. This width dimension D 9  is ½ inch and this represents the average weep-hole width in brick siding.  FIG. 6 c    shows the largest anticipated weep-hole width D 10  of ¾ inch, and the accompanying shape of said weep-hole cover. This variation shown does not preclude weep-hole widths outside of the range of dimensions D 8  to D 10  or of any intermediate widths for the present invention. The alternate embodiment of teeth  37  is indicated to show the relative movement of this feature. 
       FIG. 7  depicts a side-view section of the present invention from  FIG. 5  as-installed, using the same vantage of  FIG. 1 b   . The foundation  13  below and brick  11  above the weep-hole  10  are shown with construction mortar  12 , and the brick exterior  21  and interior  22  wall faces are referenced. When the weep-hole cover  30  is installed, the part is centered vertically between said foundation and the upper brick course with mortar, leaving only small clearance gaps. As previously stated, some excess mortar  23  left over from the masonry process is common, especially further inside the weep-hole which does not affect installation. 
     In some instances, when mortar  12  (shown in  FIG. 7 ) is missing during masonry construction of weep-hole  10 , especially under said upper brick course  11  but also foundation  13 , another method can be employed. As shown in  FIG. 8 , an alternate embodiment weep-hole cover  40  is installed in the instance of a reduced quantity of mortar  24 . This embodiment is simply comprised of 2 larger pieces of part  30  which are stacked in order to fill excess gaps in said missing mortar. Scissors or a similar cutting tool may be used to trim the part  30  along the cutting line  39  previously shown in  FIG. 5 . Conversely, the remaining smaller pieces of part  30  can be combined and stacked to create a small version of the disclosed invention. 
     ADDITIONAL VARIATIONS OR ALTERNATE EMBODIMENTS 
     It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the above-described embodiments, without departing from the broad general scope of the present disclosure. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive. Other variations of the preferred embodiment may include, but are not limited to: 
     Overall height, depth, and width of weep-hole cover  30 ; 
     Apex  32  face width (dimension D 3 , or distance from vertical edge to vertical edge); 
     Vee angle and/or wall thicknesses, dimensions D 4 , D 5  and D 6  respectively; 
     Additional ridges or teeth along vee-walls  31  to further grip brick faces; 
     Number, sizes, shapes and patterns of vent holes  35 ,  36  (round, rectangular, or other); 
     Apex  32  with an omission of holes; 
     Apex  32  with a flat or radius form, or a sharp outer edge; 
     Fillet and corner radii at intersection of faces  31 ,  32  and  33 ; 
     The present invention formed in a flat-pattern and creased into a vee-shape along bend lines or living hinges; 
     Exterior flange  33  edge contour (variations of shapes for finger grip); 
     Exterior flange  33  proximal face imprints (variations of decorative shapes on the exterior faces such as diamonds, scroll work); 
     Colors and finish of the part; 
     Material choices of metal stainless steel, formed/molded plastic or other spring-like material; 
     Pesticide coating of weep-hole cover  30  for additional barrier protection; 
     Additional fine-mesh screen added to interior faces of vee-wall  31 , apex  32 , and/or; 
     Rubber sealed version for flood prevention (no holes, with breathable outward only membrane). 
     APPLICATION/USE AND CLAIMS 
     The present invention protects homes and can be used on most exterior brick siding with existing weep-holes.  FIG. 3  shows how the device is installed; simply squeeze the exterior flanges together as needed in direction E and push the narrow distal end in the weep-hole opening in the direction F, until said flanges rest against the brick outer faces. This depth control feature prevents pushing it too far in every time. No tools or sealants are needed for installation. The vee-wall shape and apex avoids contacting inner weep-hole walls, compensates for unevenness and avoids mortar interference further in the weep-hole; it also adjusts for various weep-hole widths as given in  FIG. 4  and  FIGS. 6 a -6 c   . The vee-wall spring feature faces outward to the brick exterior and this allows easy removal for inspection. It can be sized for any brick height to accommodate all sizes. The present invention can also be installed on existing apartments, condominiums, and store buildings; anything with a masonry wall that has rectangular weep-holes. This does not limit the present invention from having a modified shape to fit other hole geometries, however.