Patent Publication Number: US-7707789-B2

Title: Crawlspace access panel

Description:
BACKGROUND 
   1. Field 
   The present invention relates to a crawlspace access cover. 
   2. Brief Description of Related Developments 
   Basements or crawlspaces may allow moisture and water vapor, for example, from dirt or concrete floors, to enter the building structure located above the space causing multiple problems, such as insect infestation or structural problems. A solution exists to provide a lining over the inside of the crawlspace where the lining provides a vapor barrier between the dirt floor or vapor source and the structure to isolate the structure from the high humidity environment. One such system is disclosed in U.S. Pat. No. 6,575,666, which is incorporated by reference herein in its entirety. Further, the accessway opening of conventional basements or crawlspaces, through the building or foundation outerwalls, may nevertheless remain a cause of undesired moisture and outside air infiltration into the basement/crawlspace that compromises and limits the effectiveness of the vapor barrier. For example, conventional crawlspace access panels are primarily decorative in nature and are not sealed in any way such as for example, to prevent the passage of air through the crawlspace opening. Conventional crawlspace panels are typically made of a very thin material on the order of for example, 0.08 inches thick. These panels are also not fastened to the crawlspace opening in a secure manner. As such, these conventional panels do not offer any type of structural barrier against unwanted entry of exterior moisture or hot air (in the hot climates) and cold air (in cold climates) into the crawlspace. As such there is a desire for a crawlspace access panel that overcomes the above deficiencies of these conventional crawlspace access panels. 
   SUMMARY OF THE EXEMPLARY EMBODIMENT(s) 
   The present invention is directed to a crawlspace access cover. In one exemplary embodiment, a crawlspace access panel assembly for covering a crawlspace accessway opening through a building exterior wall is provided. The crawlspace access panel assembly includes a substantially rigid panel member adapted to cover the opening. A seal attached around a perimeter of the substantially rigid panel. A number of fasteners connected to the substantially rigid panel for removably fastening the substantially rigid panel to the exterior wall. The fasteners being located only on a minimum number of sides of the substantially rigid panel to stably hold the panel to the exterior wall. When fastened the fasteners only on the minimum number of sides of the substantially rigid panel urge the panel against the exterior wall causing the seal to seat around the perimeter so that the substantially rigid panel seals the opening. 
   In another exemplary embodiment, a crawlspace access panel assembly for covering a crawlspace accessway opening through a building exterior wall is provided. The assembly includes a structural foam panel adapted to cover the opening. A sealing member attached around a perimeter of the structural foam panel, the sealing member being on a side of the structural foam panel member, wherein the sealing member effects sealing between the structural foam panel member and the building exterior wall. A number of fasteners connected to the substantially rigid panel for removably fastening the substantially rigid panel to the exterior wall. When fastened only one pair of fasteners will stably seat the panel on the exterior wall and cause the sealing member to seal the opening around the perimeter of the panel. The structural foam panel is removably secured to the building exterior wall. 
   In accordance with an exemplary embodiment, a method of installing a crawlspace access panel assembly for covering a crawlspace accessway opening through a building exterior wall is provided. The method includes providing a substantially rigid panel having a seal attached around a perimeter of the substantially rigid panel. Providing at least two removable fastening members each having an anchor and a knob/screw assembly for insertion into the anchor. Securing the anchors of the at least two removable fastening members within the building exterior wall on opposite sides of the crawlspace accessway opening. Placing the substantially rigid panel over the crawlspace accessway opening in the building exterior wall and removably inserting the knob/screw assembly of the at least two removable fastening members through a corresponding aperture in the substantially rigid panel and into a corresponding anchor. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The foregoing aspects and other features of the present invention are explained in the following description, taken in connection with the accompanying drawings, wherein: 
       FIG. 1A  is a side elevation view of a building having a crawlspace encapsulated according to an exemplary embodiment, shown partially in cross-section; 
       FIG. 1B  is an isometric exploded view of a crawlspace access cover assembly in accordance with an exemplary embodiment; 
       FIG. 2  is a section view of a crawlspace access cover assembly in accordance with an exemplary embodiment; 
       FIG. 3  is a partial section view of a crawlspace access cover assembly in accordance with an exemplary embodiment; 
       FIG. 4  is a flow diagram according to a method of an exemplary embodiment; and 
       FIG. 5  shows a fastener of a crawlspace access cover assembly in accordance with an exemplary embodiment. 
   

   DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENT(s) 
   Referring to  FIGS. 1A and 1B , an elevation view of a building having a crawlspace access cover  10  in accordance with an exemplary embodiment and an exploded view of a crawlspace access cover assembly  10  are shown. Although the embodiments will be described with reference to the exemplary embodiments shown in the drawings, and described below, it should be understood that the present invention can be embodied in many alternate forms of embodiments. In addition, any suitable size, shape or type of elements or materials could be used. 
   Referring now to  FIGS. 1A and 1B , a building  92  such as a house is illustrated supported upon peripheral foundation walls  90  on a peripheral footing  93  buried in the ground beneath the frost line. Also an access opening  91  may be provided in the foundation  90 , above ground level  14 . The opening  91  may be sized to allow a person passage through the opening to go inside the crawlspace. Alternatively, a hatch door may be provided in the roof or ceiling to permit access into the crawlspace when necessary. Any air vents present in the crawlspace walls  90  or foundation may be sealed or covered with a crawlspace liner or otherwise as air circulation may not be desired after the crawlspace is sealed. Floor  17  of the crawlspace may be poured concrete, or may be a dirt floor. In alternate embodiments the crawlspace floor may be provided with an inner peripheral water drainage trench  18  or tile filled with aggregate and may contain a perforated water drainage conduit  13 . The trench may open to a sump pit which, depending upon the slope of the terrain, may contain a sump pump (not shown) and a discharge pipe  19  (shown in  FIG. 1A  and representing the sump pump connected thereto) which extends up and over the foundation and drains to an external location whenever the water level of the sump pit rises to the activation level of the sump pump. In the exemplary embodiment, a pit or void  16  may be formed in the crawlspace floor  17 . The pit  16 , which may be excavated through the existing floor may not have a pump or reservoir or pipe  19 . Pit  16  may have a drain and alarm system (not shown) adapted for use with, for example, a crawlspace liner  15  encapsulating the crawlspace and sealing the floor  17  or other seal barrier sealing the floor. As disclosed in U.S. patent application entitled “CRAWLSPACE DRAIN AND ALARM SYSTEM”, filed on Jan. 30, 2006, and incorporated by reference herein in its entirety, the crawlspace may have an accessway with an opening  91  and in an outer wall of the foundation  90 . The opening is closed with a cover assembly  10  having a rigid panel member  20 , a sealing member  30 , and removable fasteners  40 . The removable fasteners  40  include wall anchors  70 . 
   In the exemplary embodiment shown, the liner  15  extends over and seals the crawlspace floor  17 , and may also have portions  15 A extending over and sealing other portions of the crawlspace boundaries, such as the foundation walls  90 . In alternate embodiments, the liner may have any desired shape. In still other embodiments, any suitable vapor barrier such as a sealed concrete floor may be used to encapsulate the chamber. In this embodiment continuous sealed crawlspace liner  15  is provided, such as of plastic film, which may be monofilm, for example, a sixteen mil thick durable heavy duty, fiber-reinforced multi-ply plastic film or rubber sheeting. The crawlspace liner  15  may be for example an integral continuous durable water barrier film or laminate or may be formed of wide strips of such film or laminate, such as six feet in width, which are overlapped and sealed along the edges thereof with waterproof caulk or adhesive tape to provide a continuous sealed barrier liner  15  of the required dimensions. The crawlspace liner  15  may be installed over the dirt floor  17  and over the sump pit  16 , if present, and may be extended vertically-upward to the tops of the crawlspace walls. The liner  15  may be sealed against the inner surface of the foundation walls  90  peripherally surrounding and enclosing the crawlspace. The liner  15  may be sufficiently durable to resist tearing and piercing under the weight of the installers. The upper surface of the liner  15  may be white in color to brighten the crawlspace. The vertical peripheral crawlspace liner extensions  15 A are extended and supported against the inner surfaces of the foundation walls  90  and sealed thereto at an elevation which is above the exterior ground level, for example, to the tops of the foundation walls. The continuous marginal liner extensions  15 A are sealed or bonded to each other and to the entire peripheral inner wall of the foundation  90  adjacent the top thereof, for example, by use of an adhesive tape or a continuous bead  15 B of suitable adhesive or caulk composition such as a polyurethane composition. Nylon fasteners may be used to support the liner  15  vertically over the foundation  90  during installation and prior to caulking. The crawlspace liner  15  and its extended marginal border areas  15 A prevent the entry of water vapor from the soil or ground into the crawlspace environment and prevent external ground water or flood water entry into the crawlspace and on top of the crawlspace liner  15 , over the dirt floor  17 , where it can become trapped and stagnant and can generate mold and fungus and water vapor which can deteriorate and rot structural wood support members of the building  92 . Any exterior ground water which might penetrate the foundation  90 , such as through a cement block wall, is trapped beneath the liner extensions  15 A and flows down into the dirt floor of the crawlspace and into the drain tile channel  18 , if present. This keeps the head space  94  of the crawlspace, or the crawlspace environment, dry. Thus, the installed crawlspace liner may totally encapsulate the crawlspace environment and completely isolates the building envelope and upper living spaces from the earth there below and from the dampness, insects and radon contained therein, to provide a healthier home environment. 
   According to an exemplary embodiment, the rigid panel member  20  is shown in  FIG. 1B  as being rectangular in shape. In alternate embodiments the panel member may be any suitable shape. The panel member  20  may be provided for example, as a two-foot by four-foot panel. In alternate embodiments the panel member may be provided in any suitable size to sufficiently cover a crawlspace opening. In alternate embodiments, the panel member  20  may be made utilizing any suitable manufacturing method with any suitable corrosion resistant material. For example, the panel member  20  may be made of solid plastic or a plastic structural foam and produced through injection molding. The plastic may be for example, polyethylene or polypropylene. The plastic may be dyed so that the panel member  20  may be molded in a predetermined color such as for example, black, gray, white or any other suitable color, so that the panel member  20  will not need painting. 
   The structural foam may allow the panel member  20  to be more rigid than a solid panel of the same size and have a high strength to weight ratio. The structural foam process allows for the production of rigid plastic products that have a cellular foamed core surrounded by an outer skin forming a completely integrated structure. Because of the lighter weight resulting from the structural foam process, the panel member  20  may be easier to install than a panel made of solid material. 
   In accordance with an exemplary embodiment, the panel member may have a thickness T for example, in the range of one-quarter of an inch to one inch. In alternate embodiments the panel member may be any suitable thickness. In alternate embodiments, the thickness T of the panel  20  may be variable. For example, the side of the panel member  20  facing the wall may be flat while the opposite side of the panel member  20  may be generally ramped or pitched in shape with the center of the panel being the thickest point. The thickness T of the panel member  20  by itself, or when combined with the increased rigidity resulting from the structural foam, may allow the panel member  20  to provide a secure cover that is functionally capable of preventing unwanted access into the crawlspace. The rigidity or stiffness of the panel member  20  may also allow for the use of fasteners on a minimum number of sides when securing the panel member  20  to a foundation or wall  90 , or a ceiling (not shown). As can be seen in  FIG. 1B , for example, one removable fastener may be used on each of two sides A, B of the access panel member  20  to stably hold the panel to the foundation or wall  90 . The rigidity of the access panel member  20 , as described above, may allow for an equal pressure distribution around the perimeter of the access panel  20  against the foundation or wall  90  so that when, for example, the two sides A, B of the access panel  20  are secured against the foundation or wall  90  with removable fasteners  40  the substantially rigid panel  20  urges the panel against the foundation or wall  90  causing the seal  30  to seat around the perimeter of the opening  91  so the panel  20  seals the opening  91 . In alternate embodiments, any number of fasteners or sides may be used in securing the panel  20  to the foundation or wall  90 . 
   As can be seen in  FIG. 1B , the panel member  20  has two through holes  80  located along opposite sides A, B of the panel member  20 . In alternate embodiments any number of through holes may be located along any side of the panel member  20 , for example sides A, B, C and D. Through holes  80  may be of a sufficient size to allow for example, the treaded rod portion  60  of the removable fastener  40  to pass through the panel member  20 . Although each of the through holes  80  are shown in  FIG. 1B  as being cylindrical in shape, in alternate embodiments one or more of the holes may be elongated. For example, the hole  80  along side A of the panel member  20  may be a slot running parallel with side A. This elongated slot may aid in the installation of the panel member  20  when the hole  80  in the panel member  20 , for example, is not substantially in-line with a hole  95  (as seen in  FIG. 2 ) which is made to receive the wall anchor  70  to which the threaded rod  60  of fastener  40  is inserted. For example, a user/installer may insert one fastener in hole  80  along side B of the panel member  20  and rotate the panel member  20  so the slotted hole (not shown) along side A lines up with a corresponding hole  95  and wall anchor  70  in the foundation or wall. 
   Still referring to  FIG. 1B , the sealing member  30  may be made of any suitable material to make or form an airtight seal with an irregular or rough surface such as for example, a masonry wall or textured ceiling. For example, the sealing member  30  may be made of weather stripping. The sealing member may have a suitable cross section to form an airtight seal between the panel member  20  and wall or foundation  90 . The sealing member  30  may be fixedly attached around a perimeter of the panel member  20  on the side of the panel member  20  that will face the wall or foundation  90  when the panel member  20  is installed, as can be seen in  FIG. 2 . The sealing member  30  may be fixedly attached to the panel member  20  with any suitable adhesive such as for example, a glue type adhesive or a tape adhesive. In alternate embodiments, any suitable type of fastening method may be used to fix the seal member  30  to the panel member  20 . 
   The removable fasteners  40 , as shown in  FIG. 1B , may have a knob and screw assembly  45  and a wall anchor  70 . The knob and screw assembly  45  has a knob  50 ,  50 A and a threaded rod  60 . The knob may have any suitable shape, such as for example, the circular shaped knob  50  or the generally “T” shaped knob  50 A so that sufficient grip may be exerted on the knob to allow tightening of the fastener  40 . The circular knob  50  may be spun by grasping the perimeter of the knob  50  and rotating the knob either clockwise or counterclockwise. The generally “T” shaped knob  50 A may be spun by striking or rotating one side of the “T” about the center of the knob  50 A. The knob  50 ,  50 A may also have a shoulder  100 , as seen in  FIG. 2 , so that when the fastener  40  is tightened the shoulder  100  presses against the panel member  20  so that the panel member  20  is securely held against the foundation or wall  90 . The threaded rod  60  may be molded into the knob  50 ,  50 A. In alternate embodiments, the threaded rod  60  may be screwed into the knob  50 ,  50 A and secured with a high strength thread locker or cross pin. In other embodiments the threaded rod  60  may be fixed within the knob  50  by any suitable means. In still other alternate embodiments, the treated rod may be fixed to the anchor  70  so that a knob with a threaded hole may be threaded onto the anchor/rod assembly. In other alternate embodiments the fasteners  40  may have any other configuration such as rotatable clasps or catches. 
   The knob  50 ,  50 A and threaded rod  60  may be made of corrosion resistant material, such as for example nylon or plastic. In alternate embodiments the knob and threaded rod may be made from stainless steel, zinc or a material having a galvanized or zinc coating. In yet other alternate embodiments any suitable material may be used. It should be noted that the knob  50 ,  50 A and the rod  60  do not have to be made of the same material, for example both the knob  50 ,  50 A and the threaded rod  60  may be made of plastic or nylon or the knob may be made of plastic and the rod may be made of zinc. Any suitable combination of materials may be used for the knob and threaded rod. 
   Referring also to  FIG. 5 , the wall anchor  70  may be adapted to be placed in any type of material such as for example, wood, drywall or masonry. When inserting the wall anchor  70  into, for example, a masonry or concrete foundation, the wall anchor  70  may be cylindrical in shape and divided into a front and back portion. The front portion of the anchor  70  or the portion of the wall anchor  70  that receives the threaded rod  60 , may have internal threads  71  and the back portion of the anchor may be slotted to form a plurality of expandable arms  72  that extend longitudinally along the axis of the anchor  70 . There may be, for example, a tapered insert  73  (shown with phantom lines) located within the anchor  70  such that, when the threaded rod  60  is screwed into the threaded or front portion of the anchor  70 , the tapered insert  73  is forced into the back portion of the anchor  70  causing the expandable arms  72  to expand outward thereby gripping the inside of the hole in which the anchor  70  is placed. In alternate embodiments, any suitable type of wall anchor may be used. The anchor  70  may be made of a corrosion resistant material such as plastic, nylon, stainless steel, zinc or a material having a galvanized or zinc coating. In alternate embodiments any suitable material may be used. In yet other alternate embodiments, any suitable fastening system may be used to secure the panel member  20  to the wall  90 . 
   Referring now to  FIGS. 2 ,  3  and  4 , a method of installing a crawlspace access panel in accordance with an exemplary embodiment will now be described. Although the installation of the access panel will be described as being installed on a masonry foundation wall, the access panel may be installed on any other suitable wall surface made of any type of material such as for example, floors and ceilings. 
   In accordance with an exemplary embodiment, a crawlspace access panel member  20  is provided (Block  300 ,  FIG. 4 ). The panel member  20  has a sealing member  30  as described above. The sealing member  30  may be provided to the user/installer preinstalled on the access panel  20  or the seal  30  may be provided for the user to install on the access panel  20 . At least two removable fastening members  40 , as described above, are also provided (Block  301 ,  FIG. 4 ). 
   The user/installer forms holes such as for example, blind hole  95  in the foundation. The holes may be made with a masonry drill bit of a suitable size so that the wall anchors  70  fit snuggly within the holes  95 . In alternate embodiments any suitable tool may be used to form holes for the wall anchors. The holes  95  may also be of a suitable depth to allow the wall anchors  70  to sit flush with or below the surface of the foundation wall  90 . The hole pattern made in the foundation around the crawlspace opening  91  corresponds to the hole pattern of the holes  80  on the panel member  20 . Because the panel member  20  overlaps the crawlspace opening  91 , as shown in  FIG. 3 , the panel member  20  itself may be used as a template when forming the holes  95 . The user/installer presses the wall anchors  70  into the holes  95  (Block  302 ,  FIG. 4 ). In alternate embodiments a suitable adhesive may be used to secure the wall anchors within the holes. 
   The user/installer places the panel member  20  over the crawlspace opening so that the seal  30  is between the panel member  20  and the surface of the foundation wall  90 , as shown in  FIG. 2  (Block  303 ,  FIG. 4 ). The knob and thread assemblies  45  are inserted, by the user/installer through the holes  80  in the access panel  20  and into the wall anchors  70  (Block  304 ,  FIG. 4 ). The knob and thread assemblies  45  may be screwed into the wall anchors  70  so that the wall anchors arms may expand, as described above, within the holes  95 , securing the wall anchors  70  within the holes  95 . In alternate embodiments, the user/installer may insert one of the knob and thread assemblies and rotate the panel member  20  so that the remaining holes  80  are in line with their corresponding holes  95  in the foundation wall. The tightening of the knob and thread assemblies  45  causes the shoulder on the knob  50 ,  50 A to press against the panel member  20  thereby causing the seal  30  to compress between the panel member  20  and the foundation wall  90  as shown in  FIGS. 2 and 3 . As discussed above, the rigidity of the panel member  20  allows for the even compression of the seal member  30  along the perimeter of the panel member  20  while using a minimum number of removable fasteners. The even compression of the seal  30  may create an air tight seal between the panel member  20  and the foundation wall  90 . The user/installer may optionally cut the perimeter edges of the panel member  20  to remove any excess material or stock from the overlapping portion X of the panel member  20  (Block  305 ,  FIG. 4 ). As may be realized a substantially similar method of installing the crawlspace access panel may be used where the threaded rod  60  is fixed to the anchor  70  in that the panel  20  can be placed on the threaded rods  60  (which are fixed in the wall with the anchors) via the holes  80  and a knob having the threaded hole can be removably threaded onto the rods  60  thereby securing the panel  20  to the wall  90 . 
   It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.