US20260098404A1

US20260098404A1 - Continuous Insulation Sheathing for Construction

Info

Publication number: US20260098404A1
Application number: US19/348,964
Authority: US
Inventors: Thomas L. Savoy; Divya Chopra
Original assignee: Henry Co LLC
Current assignee: Henry Co LLC
Priority date: 2024-10-03
Filing date: 2025-10-03
Publication date: 2026-04-09
Also published as: WO2026076377A1

Abstract

The present invention generally relates to insulation sheathing in interior or exterior wall constructions for residential and business applications. More specifically, the invention pertains to an improved insulation sheathing (IS) system such as a wall sheathing (IWS) system that prevents waterproofing failure, mold, mildew, and wood rot, associated with conventional wall constructions. Particularly, this invention relates to insulation sheathing combined with a weather-resistive barrier that allows for drainage of moisture in wall construction applications. The product may be used as continuous or non-continuous insulation sheathing. In one embodiment, this invention relates to a first IS panel, such as an IWS panel, used for construction purposes, comprising the following layers: an insulation facer layer having an outer surface and an inner surface; a first insulation layer having an outer surface and an inner surface; and a weather-resistive barrier (WRB) layer having an outer surface and an inner surface; wherein the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer; wherein the inner surface of the WRB layer is secured to the outer surface of the first insulation layer through an adhesive layer; wherein, the WRB layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and wherein the extension flap of the WRB layer further comprises a removably attached release-liner attached to the extension flap portion of the WRB layer's inner surface.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims benefit under 35 U.S.C. § 119(e) of Provisional U.S. patent application Ser. No. 63/703,021, filed Oct. 3, 2024, the contents of which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention generally relates to insulation sheathing in interior or exterior wall constructions for residential and business applications. More specifically, the invention pertains to an improved insulation and sheathing (IS), for example, insulation and wall sheathing (IWS) system that prevents waterproofing failure, mold, mildew, and wood rot, associated with conventional wall constructions. Particularly, this invention relates to insulation sheathing combined with a weather-resistive barrier that allows for drainage of moisture in wall construction applications. The product may be used as continuous or non-continuous insulation sheathing.
In one embodiment, this invention relates to a first IS panel, such as an IWS panel, used for construction purposes, comprising the following layers:

- (i) an insulation facer layer having an outer surface and an inner surface;
- (ii) a first insulation layer having an outer surface and an inner surface; and
- (iv) a weather-resistive barrier (WRB) layer having an outer surface and an inner surface;
- Wherein the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;
- wherein the inner surface of the WRB layer is secured to the outer surface of the first insulation layer through an adhesive layer;
- wherein, the WRB layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and
- wherein the extension flap of the WRB layer further comprises a removably attached release-liner attached to the extension flap portion of the WRB layer's inner surface.
  In one embodiment, this invention also relates to an insulation sheathing system comprising two insulation sheathing panels: a first insulation sheathing panel and a second insulation sheathing panel, wherein the panels are juxtaposed side by side in one plane, wherein at least one panel comprising an extension flap with a removably attached release liner on the back side of the extension flap that can be used to adhere the two panels into an IS such as an IWS system.

BACKGROUND

Insulation and weather-resistant barrier system construction for example, roof or wall panel construction systems of residential or commercial buildings do not typically provide simple, efficient, and safe means of installation. Most often in these systems, extra steps must typically be added to the installation process to prevent liquid moisture, air, and heat from passing through the wall.
Constructing a wall with a weather barrier requires not only that panels be attached to framing members, but also a house-wrap is unrolled and spread over the walls. The house-wrap is attached to the sheathing panels with staples or button cap nails and fenestration openings for windows or doors must be cut out of the wrap and the flaps from these openings folded back and stapled down. The house-wrap is often difficult to install because it is in typical nine-ft wide rolls, which can be cumbersome to maneuver by workers on scaffolding or in windy conditions. While it is important that the barrier layer shed bulk water, it should allow for the escape of water vapor. Moreover, since house-wraps are only fastened at limited points, pockets or voids form between the sheathing and house wrap. If the barrier were to trap water vapor in a wall panel, the build-up of moisture could lead to rot or mold growth. Further, certain sheathing materials, such as oriented strand board (OSB), are known to irreversibly swell and warp when exposed to moisture.
Furthermore, small gaps along the edges of adjoining panels typically remain after installation assembly. These thermal gaps within the building envelope allow undesirable thermal energy entry and escape through the walls. Although house wrap can provide some protection, breaks or tears in the house wrap often form during installation or construction. Foam insulation sheathing has also been used to improve thermal resistance performance of building structures. However, insulation sheathing also presents certain limitations and challenges. In addition to frequently suffering physical damage during installation and construction, the structural properties of insulation sheathing relegates it to limited building applications. Insulation wall-sheathing panels are typically fastened as exterior cladding to the outermost, exterior facing of the wall with nails, screws, or staples. Once again, this is an extra step that must be added to the installation process. Moreover, as an additional fastened layer, pockets or voids inevitably form between it and the surface it is secured to. Moreover, most insulation sheathing can also limit external finishing options.
It is desirable for wall sheathing panels to shed precipitation, such as rain and snow, during construction so that the interior remains dry. Accordingly, there is a need in the art for wall-sheathing panels, which are resistant to bulk water but permeable to water vapor, provide improved thermal resistance and create a simplified, safe, and time-saving installation process.
Similarly, for installing roof panels, may problems arise in installation including unsafe environment for workers. When large rolls of sheet are installed, it becomes a problem.
Given the foregoing, there is a continuing need to develop improved insulated sheathing (IS) panels for roof and wall construction that prevent or minimize the penetration of bulk water, which come pre-equipped with a water permeable barrier layer applied during manufacture, and which have improved thermal performance.

SUMMARY OF THE INVENTION

In the present invention, a vapor semi-permeable, weather-resistive drainage product is created in a single inline process. Particularly, the present invention provides for a vapor semi-permeable insulation sheathing that provides insulation, a weather-resistive barrier, and an air-barrier formed through pressure and heat. In one embodiment, the patterned embossment on the sheathing provides an avenue for moisture, which gets behind the exterior weather barrier, a means to escape.
In one embodiment, this invention relates to a first IS panel, such as an IWS panel, used for construction purposes, comprising the following layers:

- (i) an insulation facer layer having an outer surface and an inner surface; and
- (ii) a first insulation layer having an outer surface and an inner surface;

wherein the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;
wherein, the insulation facer layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap;
wherein the extension flap of the insulation facer layer further comprises a removably attached release-liner attached to the insulation facer layer's outer surface; and
wherein the insulation facer layer does not have embossment on its outer surface.
In another embodiment, this invention relates to an IS panel, such as an IWS panel, as recited above, used for construction purposes, comprising the following layers:

- (i) an insulation facer layer having an outer surface and an inner surface;
- (ii) optionally, an open-celled insulation layer having an outer surface and an inner surface;
- (iii) a first insulation layer having an outer surface and an inner surface; and
- (iv) a WRB layer having an outer surface and an inner surface;
  wherein, if present, the inner surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer, and if not present, the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;
  wherein, if present, the outer surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the first insulation layer;
  wherein, the insulation facer layer, optionally, comprises embossment on its surface;
  wherein the inner surface of the WRB layer is secured to the outer surface of the first insulation layer through an adhesive layer;
  wherein, the WRB layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and
  wherein the extension flap of the WRB layer further comprises a removably attached release-liner attached to the extension flap portion of the WRB layer's inner surface.

In yet another embodiment, this invention relates to an IS panel, such as an IWS panel, as recited above, used for construction purposes, comprising the following layers:

- (i) an insulation facer layer having an outer surface and an inner surface;
- (ii) a first insulation layer having an outer surface and an inner surface; and
- (iii) a WRB layer having an outer surface and an inner surface;
  wherein, the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;
  wherein the inner surface of the WRB layer is secured to the outer surface of the first insulation layer through an adhesive layer;
  wherein, the WRB layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and
  wherein the extension flap of the WRB layer further comprises a removably attached release-liner attached to the extension flap portion of the WRB layer's inner surface.

In one embodiment, this invention relates to an IS panel, such as an IWS panel, as recited above, used for construction purposes, comprising the following layers:

- (i) an insulation facer layer having an outer surface and an inner surface;
- (ii) an open-celled insulation layer having an outer surface and an inner surface;
- (iii) a first insulation layer having an outer surface and an inner surface; and
- (iv) a WRB layer having an outer surface and an inner surface;
  Wherein the inner surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;
  wherein, the outer surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the first insulation layer;
  wherein the inner surface of the WRB layer is secured to the outer surface of the first insulation layer through an adhesive layer;
  wherein, the WRB layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and
  wherein the extension flap of the WRB layer further comprises a removably attached release-liner attached to the extension flap portion of the WRB layer's inner surface.

In another embodiment, this invention relates to an IS panel, such as an IWS panel, used for construction purposes, comprising the following layers:

- (i) an insulation facer layer having an outer surface and an inner surface;
- (ii) optionally, an open-celled insulation layer having an outer surface and an inner surface;
- (iii) first insulation layer having an outer surface and an inner surface; and
- (iv) a first WRB layer having an outer surface and an inner surface, or a water-proof intumescent coating fluid applied to the first insulation layer;
  wherein, if present, the inner surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer, and if not present, the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;
  wherein, if present, the outer surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the first insulation layer;
  wherein, the insulation facer layer, optionally, comprises embossment on its surface;
  wherein the inner surface of the WRB layer, if present, is secured to the outer surface of the first insulation layer through an adhesive layer;

wherein, the insulation facer layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and
wherein the extension flap of the insulation facer layer further comprises a removably attached release-liner attached to the extension flap portion of the insulation facer layer's inner surface.
In yet another embodiment, this invention relates to an IS panel, such as an IWS panel, as recited above, used for construction purposes, comprising the following layers:

- (i) an insulation facer layer having an outer surface and an inner surface;
- (ii) an open-celled insulation layer having an outer surface and an inner surface;
- (iii) first insulation layer having an outer surface and an inner surface; and
- (iv) a first WRB layer having an outer surface and an inner surface;
  wherein the inner surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;
  wherein the outer surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the first insulation layer;
  wherein the inner surface of the WRB layer is secured to the outer surface of the first insulation layer through an adhesive layer;

wherein, the insulation facer layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and
wherein the extension flap of the insulation facer layer further comprises a removably attached release-liner attached to the extension flap portion of the insulation facer layer's inner surface.
In one embodiment, this invention relates to an IS panel, such as an IWS panel, as recited above, used for construction purposes, comprising the following layers:

- (i) an insulation facer layer having an outer surface and an inner surface;
- (ii) first insulation layer having an outer surface and an inner surface; and
- (ii) a first WRB layer having an outer surface and an inner surface;
  Wherein the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;
  wherein the inner surface of the WRB layer is secured to the outer surface of the first insulation layer through an adhesive layer;

wherein, the insulation facer layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and
wherein the extension flap of the insulation facer layer further comprises a removably attached release-liner attached to the extension flap portion of the insulation facer layer's inner surface.
In another embodiment, this invention relates to an IS panel, such as an IWS panel, as recited above, used for construction purposes, comprising the following layers:

- (i) an insulation facer layer having an outer surface and an inner surface;
- (ii) first insulation layer having an outer surface and an inner surface; and
- (iii) a water-proof intumescent coating fluid applied to the first insulation layer;
  wherein the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;

- (i) an insulation facer layer having an outer surface and an inner surface;
- (ii) an open-celled insulation layer having an outer surface and an inner surface;
- (iii) first insulation layer having an outer surface and an inner surface; and
- (iv) a water-proof intumescent coating fluid applied to the first insulation layer;
  wherein the inner surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;
  Wherein the outer surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the first insulation layer;

wherein, the insulation facer layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and
wherein the extension flap of the insulation facer layer further comprises a removably attached release-liner attached to the extension flap portion of the insulation facer layer's inner surface.
In one embodiment, this invention relates to an IS panel, such as an IWS panel, used for construction purposes, comprising the following layers:

- (i) an insulation facer layer having an outer surface and an inner surface;
- (ii) optionally, an open-celled insulation layer having an outer surface and an inner surface;
- (iii) a first insulation layer having an outer surface and an inner surface; and
- (iv) a water-proof intumescent coating fluid applied to the outer surface of the first insulation layer;
  wherein, if present, the inner surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer, and if not present, the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;
  wherein, if present, the outer surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the first insulation layer;
  wherein, the insulation facer layer, optionally, comprises embossment on its surface;
  wherein said IS panel, such as an IWS panel, comprises a split-liner tape at least on one side of the IS panel, such as an IWS panel, and attached at the outer surface of the insulation facer layer, or wherein said IS panel, such as an IWS panel, comprises a split liner tape at least on one side of the IS panel, such as an IWS panel, and attached at the outer surface of the first insulation layer on which the water-proof intumescent coating fluid is applied;
  wherein said split-liner tape exceeds the dimension of the IS panel, such as an IWS panel, from at least one of its edges to create an extension flap; and
  wherein the extension flap of the split-liner tape further comprises a removably attached release-liner attached to the extension flap portion of the split-liner tape's inner surface.

In another embodiment, this invention relates to an IS panel, such as an IWS panel, as recited above, used for construction purposes, comprising the following layers:

- (i) an insulation facer layer having an outer surface and an inner surface;
- (ii) a first insulation layer having an outer surface and an inner surface; and
- (iii) a water-proof intumescent coating fluid applied to the outer surface of the first insulation layer;
  wherein the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer; wherein the IS panel, such as an IWS panel, comprises a split-liner tape at least on one side of the IS panel, such as an IWS panel, and attached at the outer surface of the insulation facer layer, or wherein said IS panel, such as an IWS panel, comprises a split liner tape at least on one side of the IS panel, such as an IWS panel, and attached at the outer surface of the first insulation layer on which the water-proof intumescent coating fluid is applied;
  wherein said split-liner tape exceeds the dimension of the IS panel, such as an IWS panel, from at least one of its edges to create an extension flap; and
  wherein the extension flap of the split-liner tape further comprises a removably attached release-liner attached to the extension flap portion of the split-liner tape's inner surface.

- (i) an insulation facer layer having an outer surface and an inner surface;
- (ii) a first insulation layer having an outer surface and an inner surface; and
- (iii) a water-proof intumescent coating fluid applied to the outer surface of the first insulation layer;
  wherein the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;
  wherein said IS panel, such as an IWS panel, comprises a split-liner tape at least on one side of the IS panel, such as an IWS panel, and attached at the outer surface of the insulation facer layer;
  wherein said split-liner tape exceeds the dimension of the IS panel, such as an IWS panel, from at least one of its edges to create an extension flap; and
  wherein the extension flap of the split-liner tape further comprises a removably attached release-liner attached to the extension flap portion of the split-liner tape's inner surface.

- (i) an insulation facer layer having an outer surface and an inner surface;
- (ii) a first insulation layer having an outer surface and an inner surface; and
- (iii) a water-proof intumescent coating fluid applied to the outer surface of the first insulation layer;
  wherein the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;
  wherein said IS panel, such as an IWS panel, comprises a split liner tape at least on one side of the IS panel, such as an IWS panel, and attached at the outer surface of the first insulation layer on which the water-proof intumescent coating fluid is applied;
  wherein said split-liner tape exceeds the dimension of the IS panel, such as an IWS panel, from at least one of its edges to create an extension flap; and
  wherein the extension flap of the split-liner tape further comprises a removably attached release-liner attached to the extension flap portion of the split-liner tape's inner surface.

- (i) an insulation facer layer having an outer surface and an inner surface;
- (ii) an open-celled insulation layer having an outer surface and an inner surface;
- (iii) a first insulation layer having an outer surface and an inner surface; and
- (iv) a water-proof intumescent coating fluid applied to the outer surface of the first insulation layer;
  wherein the inner surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;
  wherein the outer surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the first insulation layer;
  wherein said IS panel, such as an IWS panel, comprises a split-liner tape at least on one side of the IS panel, such as an IWS panel, and attached at the outer surface of the insulation facer layer;
  wherein said split-liner tape exceeds the dimension of the IS panel, such as an IWS panel, from at least one of its edges to create an extension flap; and
  wherein the extension flap of the split-liner tape further comprises a removably attached release-liner attached to the extension flap portion of the split-liner tape's inner surface.

- (i) an insulation facer layer having an outer surface and an inner surface;
- (ii) an open-celled insulation layer having an outer surface and an inner surface;
- (iii) a first insulation layer having an outer surface and an inner surface; and
- (iv) a water-proof intumescent coating fluid applied to the outer surface of the first insulation layer;
  wherein the inner surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;
  wherein the outer surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the first insulation layer;
  wherein said IS panel, such as an IWS panel, comprises a split liner tape at least on one side of the IS panel, such as an IWS panel, and attached at the outer surface of the first insulation layer on which the water-proof intumescent coating fluid is applied;
  wherein said split-liner tape exceeds the dimension of the IS panel, such as an IWS panel, from at least one of its edges to create an extension flap; and
  wherein the extension flap of the split-liner tape further comprises a removably attached release-liner attached to the extension flap portion of the split-liner tape's inner surface.

In one embodiment, this invention relates to an IS panel, such as an IWS panel, used for construction purposes, comprising the following layers:

- (i)(a) an optionally embossed insulation facer layer, OR
- (i)(b) an optionally embossed insulation facer layer, wherein the insulation facer layer has extension flaps with a removably attached release-liner;
- (ii)(a) a first insulation layer with a water-proof intumescent coating fluid applied to it, OR
- (ii)(b) a first insulation layer without a water-proof intumescent coating fluid applied to it;

AND

- (iii) one or more of the following layers:
- (iii)(a) an open-celled insulation layer,
- (iii)(b1) in case the first insulation layer does not have the water-proof intumescent coating fluid applied to it, and wherein the insulation facer layer does not have extension flaps, a WRB layer with extension flaps with a removably attached release-liner, OR
- (iii)(b2) in case the first insulation layer does not have the water-proof intumescent coating fluid applied to it, and wherein the insulation facer layer does have extension flaps with removably attached release-liner, a WRB layer without any extension flaps,

AND

- (iii)(c1) in case the first insulation layer does have the water-proof intumescent coating fluid applied to it, and in case the insulation facer layer does not have extension flaps, a split-liner tape with extension flaps and a removably attached release-liner attached to at least one side of the insulation facer layer,

OR

- (iii)(c2) in case the first insulation layer does have the water-proof intumescent coating fluid applied to it, and in case the insulation facer layer does not have extension flaps, a WRB layer without extension flaps and a split-liner tape with extension flaps and a removably attached release-liner attached to at least one side of the WRB layer.

In another embodiment, this invention relates to an IS panel, such as an IWS panel, as recited above, comprising a polymeric material.
In yet another embodiment, this invention relates to an IS panel, such as an IWS panel, as recited above, wherein the polymeric material is a thermoplastic resin that is polystyrene, polyisocyanurate, polyolefin, or polyurethane foams and beads, GPS, open-celled foam, expanded polystyrene, extruded polystyrene, polyisocyanurate, and combinations thereof.
In one embodiment, this invention relates to an IS panel, such as an IWS panel, as recited above, wherein the insulation facer comprises a plastic film, a thin metal foil, a metallized polymeric film, perforated metalized polymeric film, a paper or thin cellulose, a non-woven polymeric fabric, a fiberglass scrim, or combinations of the foregoing.
In another embodiment, this invention relates to an IS panel, such as an IWS panel, as recited above, wherein the extension flap extends in length from about 0.5% of the minimum dimension of the first IS panel, such as an IWS panel, to about 50% of the length of the maximum dimension of the IS panel, such as an IWS panel.
In yet another embodiment, this invention relates to an IS panel, such as an IWS panel, as recited above, wherein the adhesive on the inner surface of the insulation facer or the WRB layer that adheres to the insulation layer is the same or different as the adhesive on the extension flap having a removably attached release liner.
In one embodiment, this invention relates to an insulation sheathing system comprising at least two IS panel, such as an IWS panel, s, wherein the two panels are juxtaposed side by side in one plane, wherein each panel comprises an IS panel, such as an IWS panel, as recited above.
In another embodiment, this invention relates to an insulation sheathing system as recited above, wherein the two panels are fitted or attached to each other via the extension flap arrangement, with the release liner now removed and the extension flap extending from one panel to the second panel and providing the joining of the two panels.
In yet another embodiment, this invention relates to an insulation sheathing system as recited above, comprising two IS panel, such as an IWS panel, s, wherein the panels are juxtaposed side by side in one plane, wherein each panel comprises either a groove or a tongue at least on one side of the panel, and/or at least one extension flap on one side of the panel.
In one embodiment, this invention relates to an insulation sheathing system as recited above, wherein the two panels are fitted or attached or joined to each other via the tongue-and-groove arrangement and/or through the adhesion of the extension flap of one panel to the second panel.
In another embodiment, this invention relates to an insulation sheathing system as recited above, wherein the tongue and the groove are a continuous feature along the length of a panel in the system comprising at least two insulation sheathing panels.
In yet another embodiment, this invention relates to an insulation sheathing system as recited above, wherein the tongue and the groove arrangement is discrete such that each tongue is divided into multiple protrusions along the length of the side of a panel, and the corresponding side of the receiving panel comprises multiple grooves in form of depressed troughs to receive the multiple protrusions.
In one embodiment, this invention relates to a process for preparing a continuous insulation sheathing as recited above, comprising providing polystyrene for the insulation sheathing process, attaching the insulation facer on to the insulation sheathing, and optionally embossing a design on the insulation facer side of the continuous insulation sheathing.
In another embodiment, this invention relates to a process as recited above, comprising a polymeric material.
In yet another embodiment, this invention relates to a process as recited above, wherein the polymeric material is a thermoplastic resin that is polystyrene, polyisocyanurate, polyolefin, or polyurethane foams and beads.
In one embodiment, this invention relates to a process as recited above, wherein the insulation facer comprises a plastic film, a thin metal foil, a metallized polymeric film, a perforated metallized polymeric film, a paper or thin cellulose, a non-woven polymeric fabric, a fiberglass scrim, and combinations of the foregoing.
In another embodiment, this invention relates to an IS panel, such as an IWS panel, prepared by the process as recited above.
In yet another embodiment, this invention relates to a process an IWS system within an exterior stucco wall construction comprising an insulation sheathing as recited above.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 describes an insulation sheathing comprising an insulation foam and an insulation face.

FIG. 2 describes an insulation sheathing with an embossed design on the insulation facer.

FIG. 3 describes a process for preparing the insulation sheathing with an embossed design on the insulation facer.

FIG. 4 describes a finished insulation sheathing comprising an embossed pattern for water drainage on the insulation sheathing that has been prepared in the continuous in-line process.

FIG. 5 is the schematic of the tongue-and-groove extension in a panel.

FIG. 6 is the schematic of the tongue-and-groove extension in a non-continuous form in a panel.

FIG. 7 is the schematic of a panel with various examples of an extension flap with a release liner.

FIG. 8 describes an IS panel, such as an IWS panel, comprising an insulation facer and an insulation layer with an extension flap extending from the insulation facer.

FIG. 9 describes an IS panel, such as an IWS panel, comprising an insulation facer and an insulation layer with a WRB layer and an extension flap extending from the WRB layer.

FIG. 10 describes an IS panel, such as an IWS panel, comprising two insulation layers and a facer layer, with an extension flap extending from the WRB layer.

FIG. 11 describes an IS panel, such as an IWS panel, wherein the extension flap extends from the insulation facer layer and the insulation layer further comprises an open-celled insulation foam layer.

FIG. 12 describes an IS panel, such as an IWS panel, wherein the insulation facer comprises an extension flap and the insulation layer has an intumescent coating applied to it.

FIG. 13 describes an IS panel, such as an IWS panel, with insulation facer with an extension flap covering two insulation layers including one with an open-celled foam and a water-proof intumescent coating fluid applied to the regular insulation layer.

FIG. 14 describes an IS panel, such as an IWS panel, with an insulation facer attached to the insulation layer, wherein a water-proof intumescent coating is applied to the insulation layer and a split-liner tape is applied to the insulation layer on the same side as the intumescent coating layer.

FIG. 15 describes an IS panel, such as an IWS panel, comprising an insulation facer layer, an insulation layer, and an intumescent coating applied to the insulation layer, wherein a split-liner tape is attached to the insulation facer layer.

DETAILED DESCRIPTION OF THE INVENTION

Before the present compositions, articles, devices, and/or methods are disclosed and described, it is to be understood that the aspects described below are not limited to specific methods as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting. As used in the specification and in the claims, the term “comprising” may include the embodiments “consisting of” and “consisting essentially of.”
Disclosed are materials, compositions, and components that can be used for, can be used in conjunction with, can be used in preparation for, or are products of the disclosed method and compositions. These and other materials are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, and the like of these materials are disclosed that while specific reference of each various individual and collective combinations and permutation of these compounds cannot be explicitly disclosed, each is specifically contemplated and described herein. Thus, if a class of adhesives A, B, and C are disclosed as well as a class of additives D, E, and F and an example of a combination A-D is disclosed, then even if each is not individually recited, each is individually and collectively contemplated. Thus, in this example, each of the combinations A-E, A-F, B-D, B-E, B-F, C-D, C-E, and C-F are specifically contemplated and should be considered disclosed from disclosure of A, B, and C; D, E, and F; and the example combination A-D. Likewise, any subset or combination of these is also specifically contemplated and disclosed. Thus, for example, the sub-group of A-E, B-F, and C-E are specifically contemplated and should be considered disclosed from disclosure of A, B, and C; D, E, and F; and the example combination A-D. This concept applies to all aspects of this disclosure including, but not limited to, compositions, and steps in methods of making and using the disclosed compositions. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific embodiment or combination of embodiments of the disclosed methods, and that each such combination is specifically contemplated and should be considered disclosed.
Unless expressly stated otherwise, it is not intended that any method outlined herein be construed as requiring that its steps be performed in a particular order. Accordingly, where a method claim does not expressly recite an order to be followed by its steps, or where neither the claims nor the descriptions specifically state that the steps are to be limited to a precise sequence, it should not be inferred that a specific order is intended or required. This holds for any possible non-express basis for interpretation, including, but not limited to logical flow or arrangement of steps; interpretations derived from the grammatical organization, syntax, or punctuation; and the quantity or variety of embodiments detailed in the specification. The description of the invention should not be read as mandating a fixed sequence of steps, unless such a requirement is articulated explicitly.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. In case of conflict, the present specification, including definitions, will control.
Except where expressly noted, trademarks are shown in upper case.
Unless stated otherwise, all percentages, parts, ratios, a, are by weight. Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another aspect includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another aspect. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint. It is also understood that there are a number of values disclosed herein, and that each value is also herein disclosed as “about” that particular value in addition to the value itself. For example, if the value “10” is disclosed, then “about 10” is also disclosed. It is also understood that each unit between two particular units are also disclosed. For example, if 10 and 15 are disclosed, then 11, 12, 13, and 14 are also disclosed.
Unless stated otherwise, pressures expressed in psi units would be gauge, and pressures expressed in kPa units would be absolute. Pressure differences, however, are expressed as absolute (for example, pressure 1 is 25 psi higher than pressure 2).
When an amount, concentration, or other value or parameter is given as a range, or a list of upper and lower values, this is to be understood as specifically disclosing all ranges formed from any pair of any upper and lower range limits, regardless of whether ranges are separately disclosed. Where a range of numerical values is recited herein, unless otherwise stated, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the scope of the present disclosure be limited to the specific values recited when defining a range.
When the term “about” is used, it is used to mean a certain effect or result can be obtained within a certain tolerance, and the skilled person knows how to obtain the tolerance. When the term “about” is used in describing a value or an endpoint of a range, the disclosure should be understood to include the specific value or endpoint referred to.
As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but can include other elements not expressly listed or inherent to such process, method, article, or apparatus.
The transitional phrase “consisting of” excludes any element, step, or ingredient not specified in the claim, closing the claim to the inclusion of materials other than those recited except for impurities ordinarily associated therewith. When the phrase “consists of” appears in a clause of the body of a claim, rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole.
The transitional phrase “consisting essentially of” limits the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel characteristic(s) of the claimed invention. A “consisting essentially of” claim occupies a middle ground between closed claims that are written in a “consisting of” format and fully open claims that are drafted in a “comprising” format. Optional additives as defined herein, at a level that is appropriate for such additives, and minor impurities are not excluded from a composition by the term “consisting essentially of”.
Further, unless expressly stated to the contrary, “or” and “and/or” refers to an inclusive and not to an exclusive. For example, a condition A or B, or A and/or B, is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
The use of “a” or “an” to describe the various elements and components herein is merely for convenience and to give a general sense of the disclosure. This description should be read to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise. As used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.
The term “predominant portion” or “predominantly”, as used herein, unless otherwise defined herein, means greater than 50% of the referenced material. If not specified, the percent is on a molar basis when reference is made to a molecule (such as hydrogen and ethylene), and otherwise is on a weight basis (such as for additive content).
The term “substantial portion” or “substantially”, as used herein, unless otherwise defined, means all or almost all or the vast majority, as would be understood by the person of ordinary skill in the context used. It is intended to take into account some reasonable variance from 100% that would ordinarily occur in industrial-scale or commercial-scale situations.
All parts, percentages and ratios used herein are expressed by weight unless otherwise specified.
In this specification and in the claims which follow, reference will be made to a number of terms which shall be defined herein.
“Optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where the event or circumstance occurs and instances where it does not.
While aspects of the present invention can be described and claimed in a particular statutory class, such as the system statutory class, this is for convenience only and one of skill in the art will understand that each aspect of the present invention can be described and claimed in any statutory class. Unless otherwise expressly stated, it is in no way intended that any method or aspect set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not specifically state in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including matters of logic with respect to arrangement of steps or operational flow, plain meaning derived from grammatical organization or punctuation, or the number or type of aspects described in the specification. Throughout this application, various publications are referenced. The disclosures of these publications in their entireties are hereby incorporated by reference into this application in order to more fully describe the state of the art to which they pertain. The references disclosed are also individually and specifically incorporated by reference herein for the material contained in them that is discussed in the sentence in which the reference is relied upon. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, the dates of publication provided herein may be different from the actual publication dates, which can require independent confirmation. In the context of the present description, all publications, patent applications, patents and other references mentioned herein, if not otherwise indicated, are explicitly incorporated by reference herein in their entirety for all purposes as if fully set forth.

Definitions

By “planarly and contactably” is meant that two layers of an IS panel are in the planar and are in contact with each other in a planar manner, that is, not at the edge but a substantial planar area of the two layers are in contact or are capable of contact.
By “attached” is meant, for example in “planarly and contactably attached,” that two layers are securely tied to each other, even with an adhesive in some cases or as the case maybe with fasteners. But in general, “attached” conveys the meaning that between the two planar layers there is a substantial connection and if there is non-connection, it is only nominal. Attachment could be strong or weak attachment.
By “secured” is meant that two layers are in contact with each other and are substantially connected, similar to the meaning of the term “attached.”
By “adjacent” is meant that two layers are planarly in contact, but their attachment may or may not be as secure when the term “attached” or “secured or “adhered” is used. For example, two layers could be simply place on top of each other, as adjacent to each other.
To be clear, if two IS panels or IS panel, such as an IWS panel, s are placed adjacent each other, it is to convey the meaning that they are place side-by-side, as in a panel assembly.
By “IS panel” is meant that such panel serves the purpose at a minimum of insulation and mechanical strength and is used for construction purposes, such as building construction.
Similarly, an “IS panel, such as an IWS panel,” is meant that such panel serves the purpose at a minimum of insulation and mechanical strength for construction purposes, such as building construction, but for use in wall configuration.
The following describes exemplary embodiments of the present invention in the building construction context, which pertains to insulated sheathing (IS) for example, for example insulated wall-sheathing (IWS) panels for a panelized sheathing assembly and system attached to a frame structure of the building, and that are suitable for use in the construction of residential and commercial buildings.
While the description herein is provided in terms of insulated wall sheathing, it is an exemplar of the broader insulated sheathing panels, which pertains to the present invention.
The following describes exemplary embodiments of the present invention in the building construction context, which pertains to insulated wall-sheathing (IWS) panels for a panelized sheathing assembly and system attached to a frame structure of the building, and that are suitable for use in the construction of residential and commercial buildings.

I. Illustrative Embodiments

Embodiment 1

As shown in FIG. 8 , in one embodiment, the present invention relates to a first IS panel, such as an IWS panel, (100) used for construction purposes, comprising the following layers:

- (i) an insulation facer layer (101) having an outer surface and an inner surface; and
- (ii) a first insulation layer (103) having an outer surface and an inner surface;

wherein the inner surface of the first insulation layer (103) is planarly and contactably attached to the inner surface of the first insulation layer (101);
wherein, the insulation facer layer (101) exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap (108);
wherein the extension flap (108) of the insulation facer layer further comprises a removably attached release-liner (110) attached to the insulation facer layer's (101) outer surface; and
wherein the insulation facer layer (101) does not have embossment on its surface.

Embodiment 2

As shown in FIG. 9 , in one embodiment, the present invention relates to a first IS panel, such as an IWS panel, (200) used for construction purposes, comprising the following layers:

- (i) an insulation facer layer (201) having an outer surface and an inner surface;
- (ii) a first insulation layer (203) having an outer surface and an inner surface; and
- (iii) a WRB layer (204) having an outer surface and an inner surface;
  wherein the inner surface of the first insulation layer (203) is planarly and contactably attached to the inner surface of the insulation facer layer (201);
  wherein, the insulation facer layer (201), optionally, comprises embossment on its surface;
  wherein the inner surface of the WRB layer (204) is secured to the outer surface of the first insulation layer (203) through an adhesive layer (206);
  wherein, the WRB layer (204) exceeds the dimension of the first insulation layer (203) from at least one of its edges to create an extension flap (209); and
  wherein the extension flap (209) of the WRB layer (204) further comprises a removably attached release-liner (211) attached to the extension flap (209) portion of the WRB layer's (204) inner surface.

Embodiment 3

As shown in FIG. 10 , in one embodiment, the present invention relates to a first IS panel, such as an IWS panel, (300) used for construction purposes, comprising the following layers:

- (i) an insulation facer layer (301) having an outer surface and an inner surface;
- (ii) an open-celled insulation layer (302) having an outer surface and an inner surface;
- (iii) first insulation layer (303) having an outer surface and an inner surface; and
- (iv) a WRB layer (304) having an outer surface and an inner surface;
  wherein the inner surface of the open-celled insulation layer (302) is planarly and contactably attached to the inner surface of the insulation facer layer (301);
  wherein the outer surface of the open-celled insulation layer (302) is planarly and contactably attached to the inner surface of the first insulation layer (303);
  wherein, the insulation facer layer (301), optionally, comprises embossment on its surface;
  wherein the inner surface of the WRB layer (304) is secured to the outer surface of the first insulation layer (302) through an adhesive layer (305);
  wherein, the WRB layer (304) exceeds the dimension of the first insulation layer (303) from at least one of its edges to create an extension flap (309); and
  wherein the extension flap (309) of the WRB layer (303) further comprises a removably attached release-liner (311) attached to the extension flap (309) portion of the WRB layer's (303) inner surface.

Embodiment 4

As shown in FIG. 11 , in one embodiment, the present invention relates to a first IS panel, such as an IWS panel, (400) used for construction purposes, comprising the following layers:

- (i). an insulation facer layer (401) having an outer surface and an inner surface;
- (ii) an open-celled insulation layer (402) having an outer surface and an inner surface;
- (iii) first insulation layer (403) having an outer surface and an inner surface; and
- (iv) a first WRB layer (404) having an outer surface and an inner surface;
  wherein the inner surface of the open-celled insulation layer (402) is planarly and contactably attached to the inner surface of the insulation facer layer (401);
  wherein the outer surface of the open-celled insulation layer (402) is planarly and contactably attached to the inner surface of the first insulation layer (403);
  wherein, the insulation facer layer (401), optionally, comprises embossment on its surface;
  wherein the inner surface of the WRB layer (404) is secured to the outer surface of the first insulation layer (302) through an adhesive layer (405);

wherein, the insulation facer layer (401) exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap (408); and
wherein the extension flap (408) of the insulation facer layer (401) further comprises a removably attached release-liner (410) attached to the extension flap portion (408) of the insulation facer layer's (401) inner surface.

Embodiment 5

As shown in FIG. 12 , in one embodiment, the present invention relates to a first IS panel, such as an IWS panel, (500) used for construction purposes, comprising the following layers:

- (i) an insulation facer layer (501) having an outer surface and an inner surface;
- (ii) a first insulation layer (503) having an outer surface and an inner surface; and
- (iii) a water-proof intumescent coating fluid (514) applied to the first insulation layer (503);
  wherein the inner surface of the first insulation layer (503) is planarly and contactably attached to the inner surface of the insulation facer layer (501);
  wherein, the insulation facer layer (501), optionally, comprises embossment on its surface;

wherein, the insulation facer layer (501) exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap (508);
and
wherein the extension flap (508) of the insulation facer layer (501) further comprises a removably attached release-liner (510) attached to the extension flap (508) portion of the insulation facer layer's (501) inner surface.

Embodiment 6

As shown in FIG. 13 , in one embodiment, the present invention relates to a first IS panel, such as an IWS panel, (600) used for construction purposes, comprising the following layers:

- (i) an insulation facer layer (601) having an outer surface and an inner surface;
- (ii) an open-celled insulation layer (602) having an outer surface and an inner surface;
- (iii) first insulation layer (603) having an outer surface and an inner surface; and
- (iv) a water-proof intumescent coating fluid (614) applied to the outer surface of the first insulation layer (603);
  wherein the inner surface of the open-celled insulation layer (602) is planarly and contactably attached to the inner surface of the insulation facer layer (601);
  wherein the outer open-celled insulation layer (602) is planarly and contactably attached to the inner surface of the first insulation layer (603);
  wherein, the insulation facer layer (601), optionally, comprises embossment on its surface;

wherein, the insulation facer layer (601) exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap (608); and
wherein the extension flap (608) of the insulation facer layer (601) further comprises a removably attached release-liner (610) attached to the extension flap portion (608) of the insulation facer layer's (601) inner surface.

Embodiment 7

As shown in FIG. 14 , in one embodiment, the present invention relates to a first IS panel, such as an IWS panel, (700) used for construction purposes, comprising the following layers:

- (i) an insulation facer layer (701) having an outer surface and an inner surface;
- (ii) a first insulation layer (703) having an outer surface and an inner surface; and
- (iii) a water-proof intumescent coating fluid (714) applied to the outer surface of the first insulation layer (703);
  wherein the inner surface of the first insulation layer (703) is planarly and contactably attached to the inner surface of the insulation facer layer (701);
  wherein, the insulation facer layer (701), optionally, comprises embossment on its outer surface;
  wherein said IS panel, such as an IWS panel, (700) comprises a split-liner tape (716) at least on one side of the IS panel, such as an IWS panel, (700) and attached at the outer surface of the insulation layer (703) on which the water-proof intumescent coating fluid (714) is applied;
  wherein said split-liner tape (716) exceeds the dimension of the IS panel, such as an IWS panel, (700) from at least one of its edges to create an extension flap (717); and
  wherein the extension flap (717) of the split liner tape (716) further comprises a removably attached release-liner (718) attached to the extension flap (717) portion of the split-liner tape's (716) inner surface.

Embodiment 8

As shown in FIG. 15 , in one embodiment, the present invention relates to a first IS panel, such as an IWS panel, (800) used for construction purposes, comprising the following layers:

- (i) an insulation facer layer (801) having an outer surface and an inner surface;
- (ii) a first insulation layer (803) having an outer surface and an inner surface; and
- (iii) a water-proof intumescent coating fluid (814) applied to the outer surface of the first insulation layer (803);
  wherein the inner surface of the first insulation layer (803) is planarly and contactably attached to the inner surface of the insulation facer layer (801);
  wherein, the insulation facer layer (801), optionally, comprises embossment on its surface;
  wherein said IS panel, such as an IWS panel, (800) comprises a split-liner tape (816) at least on one side of the IS panel, such as an IWS panel, (800) and attached at the outer surface of the insulation facer layer (801);
  wherein said split-liner tape (816) exceeds the dimension of the IS panel, such as an IWS panel, (800) from at least one of its edges to create an extension flap (817); and
  wherein the extension flap (817) of the split liner tape (816) further comprises a removably attached release-liner (818) attached to the extension flap (817) portion of the split-liner tape's (816) inner surface.

In yet another embodiment, this invention relates to a panel or panel assembly as recited above, wherein the intumescent coating gives at least one of thermal barrier, fire resistance, and ignition barrier.
In yet another embodiment, the IS panel, such as an IWS panel, also includes an open-celled insulation layer in addition to the first insulation layer.
In one embodiment, this invention relates to a first IS panel, such as an IWS panel, used for construction purposes, comprising the following layers:

AND

- (iii)(c1) in case the first insulation layer does have the water-proof intumescent coating fluid applied to it, and in case the insulation facer layer does not have extension flaps, a split-liner tape with extension flaps and a removably attached release-liner attached to at least one side of the insulation facer layer, OR
- (iii)(c2) in case the first insulation layer does have the water-proof intumescent coating fluid applied to it, and in case the insulation facer layer does not have extension flaps, a WRB layer without extension flaps and a split-liner tape with extension flaps and a removably attached release-liner attached to at least one side of the WRB layer.

II. Insulation Facer Layer

A problem encountered when using thin insulation sheathing is physical damage from bending, impact, or breaking. Such damage may occur by acts of vandalism, high velocity winds, rain, hail, construction practices, and the like. For example, in construction, it is common for ladders placed against vertical walls to bend, damage, or even break the insulation sheathing. It is also common for construction personnel to kneel upon insulation boards during construction.
Also, foam insulation boards are subjected to oxygen-and water-vapor-transmission and structural damage, both of which, over time, contribute to deteriorating the insulation properties and reducing the structural integrity of the board. A technique to address the problems of physical damage and loss of insulation properties is to apply or adhere a facing material (called a “facer”) to at least one side of the board. Examples of such facing materials include plastic film, thin metal foil, metallized polymeric film, perforated metalized polymeric film, paper or thin cellulose, non-woven polymeric fabrics, fiberglass scrims, and combinations of the foregoing.
Important properties of facers include serving as moisture vapor and oxygen transmission barriers, providing strength and structural integrity, ease of application, and the like. Thin metal foils, such as aluminum, are commonly utilized in facers to provide moisture-vapor- and oxygen-transmission barrier properties.
Many laminates and/or facers for use in covering foam insulation boards and other products are described in the prior art. Such laminates are described in U.S. Pat. Nos. 6,872,673; 6,355,701; 6,093,481; 6,044,604; 5,695,870; 5,565,252; 5,345,738; 5,044,705; 4,985,106; 4,764,420; 4,572,865; 4,509,307; 4,284,674; 4,254,173; and 3,903,346. It is desirable to provide a laminate and/or facer for uses that require improved oxygen- and moisture-vapor barrier properties, structural integrity, strength, and weatherability.
It should be noted that all references cited above, and otherwise, in this specification are incorporated in this specification as if they were fully set forth herein.
Patterns are embossed as described later in this specification on the insulation facers. In one embodiment, one or more of the following patterns are embossed.

Geometric Pattern

By geometric pattern is mean vertical lines, horizontal lines, transverse lines, crisscross lines, lattice, circles, triangles, squares, rectangles, trapezoid, rhombus, pentagons, and other such geometric designs. More than one type of geometric structure may be present on the surface of the insulation facer in an embossed or recessed fashion.

Regular Pattern

By a regular pattern is meant that the same pattern is repeated in partial or full surface of the insulation facer. In other words, a geometric pattern would be repeated, or an irregular pattern would be repeated.

Irregular Pattern

By irregular pattern is meant the insulation facer has a random design that is not regular.

Embossing

By embossing herein is meant a relative difference in depth between the embossed pattern and the recessed pattern on the surface of the insulation facer. For example, if a pattern is embossed on the insulation facer surface, it covers the aspect where the same design is embossed or recessed. In one aspect, the textured surface is characterized by an embossed pattern of features or indentations. As used herein, “embossing” can mean embossing, debossing, scoring, or any other means to alter the texture of the facer.
Generally, separate steps are needed to create a system that is insulative, vapor semi-permeable, a weather resistive barrier, and acts as a drainage plane. The steps may include exterior insulation and a weather-resistive barrier that may or may not meet drainage needs through an outward facing attachment to the film, and placing an additional medium to the wall system to promote drainage.
In one embodiment, the insulation facer is attached to the core insulation layer using an adhesive. Exemplary adhesives are described infra.

II. Insulation Layer

Insulation Foam

Thermal insulation sheathing offers thermal barrier properties desirable for enclosures having regulated temperatures, including houses, offices, refrigerated containers, and the like. Extruded polymer foam articles such as polystyrene foam boards are thermal insulation materials for use in such enclosures including building and construction applications as well as thermal insulation containers. See for example, WO2018098570A1.
The thermal insulation sheathing that can be cut up into boards that are commonly used to enhance insulation of building structures. Relatively thin (about ¼ inch to about 3.0 inches), rectangular panels of foam board are commonly placed between the dry wall and building exteriors such as stone, brick, wood, stucco, and the like. Insulation boards employed in such applications may include, but are not limited to, those utilizing polyisocyanurate foam and extruded polystyrene, polyolefin, and polyurethane foams and beads.
It would be advantageous if such insulation sheathing also provided a weather-resistive barrier that aids in removal of moisture and waterproofing.
The thermal insulation sheathing comprises foams of thermoplastic resins such as, for example, polystyrene and polyethylene, and polyurethane. Foams can be open-celled, close-celled and/or a mixed-cell structure.
In one embodiment, the insulation foams are made of extruded polystyrene, expanded polystyrene, polyethylene, polypropylene, or polyurethane.
The insulation layer can be selected from a wide range of options. By way of example, the insulation layer can comprise expanded polystyrene, extruded expanded polystyrene, among other types of rigid, closed-cell foam materials. Other example types of foam insulation include polyisocyanurate materials, polyurethane materials, and phenolic materials. In some embodiments, the insulation layer can include a phase change material (PCM) insulation material.
The insulating layer may be between one inch and three inches thick or greater depending on the application. In some embodiments, the insulation layer is two inches thick. In some embodiments, the insulation layer comprises polyurethane or polyester. In some embodiments, the insulating layer may comprise polystyrene. Examples of polystyrene insulation include expanded polystyrene foam and extruded polystyrene foam. Additionally, or alternatively, the insulation layer may comprise a polyisocyanurate, polyurea, phenolic foam or an organic aerogel. In some embodiments, the insulating layer may comprise an inorganic insulating material, such as mineral wool, glass wool, compressed fumed silica, perlite, calcium silicate, foamed glass, or silica aerogel blanket. In some embodiments, the insulating layer can be a machined, pre-made foam containing slots of a suitable size for surrounding and affixing the reinforcement structures to the outer layer. In some embodiments, the insulating layer may comprise mineral wool. In some embodiments, the insulating layer may be a rigid pour foam or injected formed from a two-part Class I rated urethane.
They are useful industrial products because of their excellent heat-insulating, cushioning and other properties. These foams have found acceptance over the years in such applications as thermal insulation and cushioning as well as raw material for the fabrication of various shaped articles. The preparation of thermoplastic foams by extruding a heat-plastified mixture of a thermoplastic resin and a blowing agent is well known in the art and is described in U.S. Pat. Nos. 2,740,157; 3,067,147; 3,413,387; 3,413,388; 3,431,163; 3,431,164; 3,954,929 and 3,966,381 and Canadian Pat. No. 451,864. Similarly, various methods of preparing open or close-celled expanded polystyrene and other thermoplastic resins are described in art such as U.S. Pat. Nos. 3,243,485; 3,922,328; 4,399,086; 5,049,328; 5,271,886; and 7,358,280; U.S. Pat. App. Pub. Nos. US20020117769, US20130266766; and EPO patents EP0242191A2 and EP1995273A2. All art cited in this document is incorporated by reference as if fully set forth herein.
Current weather-resistive barriers that claim drainage capability are sheet films that have an external application of adhesive or coating that provides an offset for potential drainage.
In U.S. Pat. No. 6,355,333, granted to Waggoner et al., a Construction Membrane is taught. The membrane is described as resisting liquid and air penetration, being moisture vapor permeable, and being provided with integral drainage channels. The disclosed exterior wall construction which incorporates this membrane may be faced with stucco, siding, brick, or stone.
An Exterior Building Cladding Having Rigid Foam Layer With Drain Channels is shown in U.S. Pat. No. 6,886,301, granted to Schilger. Both the inside and the outside faces of the rigid foam insulation layer are provided with vertical channels 21 to remove moisture by way of thin channels 22. Exterior water penetration drains to the bottom of channels 22, and exits the wall construction by means of a drain wick 28 and flashing 25.
In Published Patent Application No. US 2011/0296781, owned by McCary, an Insulating Finishable Panel is illustrated. This construction employs a rigid-faced foam cored panel, which, in one embodiment includes foam air spacers adhered to the panel's radiant reflective surface. In another arrangement, attached foam air spacers create an air space between the insulation and the radiant reflective surface.
In Published Patent Application No. US 2008/0034690, to Gartz et al., an Underlayment With Improved Drainage is disclosed. The underlayment may include a plurality of vertical channels, and funnels at respective top and bottom edges. The funnels are provided to compensate for misalignment of vertically stacked underlayment panels.
Notwithstanding coats of paint and moisture sealant applied to the exterior layer of a stucco wall, moisture still manages to penetrate the stucco over time and collect on layers of material within the wall. Known prior art construction methods provide moisture barriers and attempt to allow the drainage of accumulated moisture. However, these methods have proven inadequate, and stucco walls continue to fail from moisture intrusion and accumulation, allowing mold to form and causing wood to rot. The exterior stucco wall construction disclosed herein provides improved drainage of the moisture which has penetrated the wall and collects therein on materials and structures. Improved longevity and integrity of the stucco wall system is thereby provided.
The insulation layer can comprise any suitable insulation material conventionally known to one of ordinary skill in the art. For example, the insulation layer can comprise a foam polymer insulation, including for example and without limitation, polyisocyanurate foam, polystyrene foam, polyurethane foam, or any combination thereof. In further exemplary aspects, the foam insulation layer comprises polyisocyanurate foam. In still further aspects, the foam insulation layer can comprise a blend or combination of a polyisocyanurate and polyurethane foam.
The foam insulation layer can comprise extruded foam, expanded foam, or a combination thereof. As one of ordinary skill in the art will appreciate, extruded foams can be prepared by melting a suitable polymer material, incorporating a blowing agent to yield a foamed gel, and extruding the foamed gel through a die to form the desired foam layer. Expanded foams can be prepared by subsequent expansion of beads containing a blowing agent, wherein the expanded beads are molded at the time of expansion to form the desired foam layer.
The foam insulation can have any desired density. For example, the foam insulation can have a density of at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or even at least about 20 pounds per cubic feet (pcf) according to ASTM D1622. In further aspects, the foam insulation can have a density in the range of about 1 pcf to about 20 pcf. In still further aspects, the foam insulation density can be any desired value within any range derived from any of the above exemplified values, including, for example, a density in the range from about 2 to about 5 pcf, or from about 1 to about 10 pcf.
The foam insulation can be either closed cell or open cell. Open cell foam is more likely to let water vapor condense inside the cells, thereby reducing the insulation value. Thus, in further exemplary aspect, the foam insulation is closed cell. In a further aspect, the foam insulation is greater than about 50, 60, 70, 80, or even greater than about 90% closed-cell according to ASTM D2856.
Since water can negatively impact thermal performance, the foam insulation preferably exhibits limited or substantially no water absorption. For example, the foam insulation exhibits a water absorption of less than about 10, 9, 8, 7, 6, 5, 4, 3, 2, or even less than about 1% according to ASTM C209. In a further aspect, the foam insulation exhibits a water absorption of less than about 10, 9, 8, 7, 6, 5, 4, 3, 2, or even less than about 1% according to ASTM C2842. In a still further aspect, the foam insulation can exhibit a water absorption in the range of about 10 to about 0%. In a yet further aspect, the water absorption can be any desired value within any range derived from any of the above exemplified values, including, for example, a water absorption in the range from about 0 to about 5%, or from about 1 to about 3.5%.
Moreover, the foam insulation layer can have any desired water vapor permeance (or transmission) value. For example, the water vapor permeance can be about 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, or even about 0 perms according to ASTM E96. In a further aspect, the water vapor permeance can be in the range of about 0 to about 20 perms. In a still further aspect, the water vapor permeance can be any desired value within any range derived from any of the above exemplified values, including, for example, a water vapor permeance in the range from about 0 to about 2 perms, or from about 1 to about 5 perms.
The insulation layer can have any desired thickness (t). This thickness (t) can be customized to fit any particular application and desired thermal resistance. For example, and without limitation, the thickness of the foam insulation layer can be in the range of from about 0.25 in. (¼″) to about 3 in. (3″). In further aspects, the thickness can be from about 0.5 in. to about 1 in. Depending on the intended application, the panel can have any desired thermal resistance value (R-value). For example, the panel can have a R-value of at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25 according to ASTM C1289-02. In a further aspect, the R-value can be in the range of about 1 to about 25. In still further aspects, the R-value can be any desired value within any range derived from any of the above exemplified values, including, for example, R-value in the range from about 1 to about 10, or from about 3 to about 7.
In various aspects, the insulation layer can optionally comprise a membrane layer. The insulation membrane layer can comprise radiant barrier material, such as metal foil, for example, aluminum foil, polymeric film or fabric, paper, or cellulosic material, reinforcing scrim, such as fiberglass scrim, or a combination thereof. In some aspects, the membrane layer comprises a single or multi-layered material which can be a laminate in which a backing material is laminated to a foam insulation layer. In other aspects, one or more optional additives can also be incorporated into or otherwise applied to the foam insulation layer. Exemplary and non-limiting additives can include flame retardants, colorants, ultraviolet absorbers, textured coatings, and the like as well as any combinations thereof.
The insulation layer can be secured to the inward facing surface of the panel, for example, by any conventionally used adhesive material known in the art to be compatible for use with foam insulation. For example, according to non-limiting aspects of the invention, the adhesive can be selected from a phenol-formaldehyde resin, hot-melt adhesive, polyvinyl acetate (PVA) resin, or any combination thereof. In still a further aspect, the adhesive can be isocyanate-based.
The insulated panels disclosed herein can exhibit improved physical strength and durability over traditional sheathing panels or foam panels. Thus, in one aspect, the inventive insulated panels can exhibit enhanced structural strength and dimensional stability when compared to a conventional or reference sheathing panel in the absence of the insulation layer when exposed to substantially the same environmental and/or physical forces under substantially similar conditions. To that end, the foam insulation layer can have a dimensional stability of about less than 5, 4, 3, 2, or even less than about 1% according to ASTM D2126. In a further aspect, the dimensional stability is preferably about less than 2%. The foam insulation layer can also have any desired compressive strength. For example, the foam insulation layer can have a desired compressive strength of at least about 1, 5, 10, 15, 20, 25, 30, 35, 40 pounds per square inch (psi) according to ASTM D1621. In a further aspect, the compressive strength can be in the range of about 1 to about 40 psi. In a still further aspect, the compressive strength can be any desired value within any range derived from any of the above exemplified values, including, for example, a compressive strength in the range from about 15 to about 30 psi, or from about 20 to about 25 psi. Likewise, the foam insulation layer can have any desired tensile strength. For example, the foam insulation layer can have a tensile strength of greater than about 300, 400, 500, 600, 700, 800, 900, 1000, 1500, 2000 pounds per cubic foot (pcf) according to ASTM D1623. In a further aspect, the tensile strength can be in the range of about 300 to about 2000 pcf. In a still further aspect, the tensile strength can be any desired value within any range derived from any of the above exemplified values, including, for example, a tensile strength in the range from about 500 to about 1000 pcf, or from about 600 to about 800 pcf.
In further aspects, the structural properties of the disclosed insulated panels make the insulated panels suitable for use in numerous structural applications, while still providing improved thermal performance. For example, in one aspect, the inventive insulated panels can be used as braced wall panels, when used in accordance with 2006 IBC Section 2308.3 and 2006 IRC Section R602.10.1. In another aspect, the inventive insulated panels are considered equivalent to Construction Method 3 described in Section 2308.9.3 of the 2006 IBC and Section R602.10.3 of the 2006 IRC. In another aspects, the inventive insulated panels are suitable for use an alternative to wood structural panels in the construction of wood shear walls, when installed in accordance with 2006 IBC Section 2305.3.
It should be noted that all references cited above, and otherwise, in this specification are incorporated in this specification as if they were fully set forth herein.
In one embodiment, the foam insulation is expanded Polystyrene (EPS), Extruded Polystyrene (XPS), Graphite Polystyrene (GPS), or polyisocyanurate foam insulation.
Expanded Polystyrene Insulation, more commonly referred to as EPS, is a closed cell insulation made commonly with of 98% trapped air and only 2% plastic. In one embodiment, this invention relates to a flat board, a contoured shape, or a combination of flat and contoured shaped EPS.
Extruded Polystyrene, referred to as XPS, is a closed cell insulation product commonly used in remodeling and new construction applications. In one embodiment, this invention relates to a flat board, a contoured shape, or a combination of flat and contoured shaped XPS.
Graphite polystyrene insulation, or GPS, is made from Neopor beads, patented and manufactured by BASF. Neopor gives GPS insulation a dark gray appearance and higher r-value than traditional EPS insulation products. In one embodiment, this invention relates to a flat board, a contoured shape, or a combination of flat and contoured shaped GPS.
Polyisocyanurate foam n boards may include closed-cell polyisocyanurate (polyiso) foam insulation. This is described, for example, in U.S. Pat. No. 10,829,939B2, which is incorporated by reference herein.
In one embodiment, this invention relates to a system of panels described herein, wherein at least one panel comprises EPS, or at least one panel comprises XPS, or at least one panel comprises GPS, or at least one panel comprises polyisocyanurate foam, or at least a combination of two out of the four panels, three of the four panels, or all four panels. In another embodiment, the panels may be organized adjacent each other or separate from each other.
In one embodiment, this invention relates to a insulation sheathing system that comprises two insulation sheathing panels: a first insulation sheathing panel and a second insulation sheathing panel. The two panels are juxtaposed side by side in one plane. Each insulation sheathing panel comprises the insulation foam layer and the fire-proofing layer as described previously.
In one embodiment, this invention relates to a insulation sheathing system that comprises two insulation sheathing panels: a first insulation sheathing panel and a second insulation sheathing panel. The two panels are juxtaposed side by side in one plane. Each insulation sheathing panel comprises the insulation foam layer and the fire-proofing as described previously.
In one embodiment, the panel has more than 2 sides. Stated differently, the present invention envisions a panel comprising, the following sides: 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20.
In one embodiment of the invention, the panel has a curved shape, for example, it is circular, or oblong shaped or a semi-circle shaped. In one embodiment of the invention, the panel has at least one side that is not linear but has a curved shape.
In one embodiment, the multiple-sided panel has all sides that are equal or at least two sides that are equal or no sides that are equal in length.
This invention envisions an insulation sheathing panel system comprising at least two panels wherein a first panel is irregular shaped, but the adjacent juxtaposing second panel neatly fits with the irregular shape of the first panel.
In one embodiment, the insulation panel system comprises more than one square or a rectangular panel, wherein each side of the panel has a tongue or groove configuration.
In one embodiment, the insulation sheathing includes extruded polystyrene, polyisocyanurate, polyolefin, polyurethane, and phenolic foams and beads.

III. Insulation System

In one embodiment, the panel comprises an insulation system. The insulation system comprises at least one insulation layer. In one embodiment, the insulation comprises only one insulation layer, which is made from regular insulation layer or an open-celled insulation layer. In one embodiment, the insulation system comprises two insulation layers, in which the two insulation layers are both regular insulation layers or both open-celled insulation layers.
In one embodiment, the insulation system comprises at least two insulation layers, wherein at least one of the insulation layers is an open-celled foam insulation layer. Stated differently, in one embodiment, the insulation system of the present invention comprises two or more layers, wherein at least one layer is an open-celled foam insulation layer, and one layer is a regular foam insulation layer.
In one embodiment, the regular foam insulation layer and the open-celled foam insulation layer are adjacent each other and are in adhesive contact with each other. But this invention also envisions a system where more than one open-celled foam insulation layers are adhesively stacked to each other and the entire stack is in adhesive contact with one or more of regular insulation foam layers.
If more than one regular foam insulation layer is stacked, in one embodiment, each of the stacked regular foam insulation layers is of the same chemical and/or physical configuration. In another embodiment where more than one regular foam insulation layers are stacked, at least one of the stacked regular foam insulation layers is different physically and/or chemically from at least one other regular foam insulation layers.
In yet another embodiment, where the open-celled insulation foam layers are stacked, at least one of the stacked open-celled insulation foam layers is different physically and/or chemically from at least one other open-celled insulation foam layers.

Regular Insulation Layer

Thermal insulation sheathing offers thermal barrier properties desirable for enclosures having regulated temperatures, including houses, offices, refrigerated containers, and the like. Extruded polymer foam articles such as polystyrene foam boards are thermal insulation materials for use in such enclosures including building and construction applications as well as thermal insulation containers. See for example, WO2018098570A1.
The thermal insulation sheathing that can be cut up into boards are commonly used to enhance insulation of building structures. Relatively thin (about ¼ inch to about 3.0 inches), rectangular panels of foam board are commonly placed between the dry wall and building exteriors such as stone, brick, wood, stucco, and the like. Insulation boards employed in such applications may include, but are not limited to, those utilizing polyisocyanurate foam and extruded polystyrene, polyolefin, and polyurethane foams and beads.
It would be advantageous if such insulation sheathing also provided a weather-resistive barrier that aids in removal of moisture and waterproofing.
The thermal insulation sheathing comprises foams of thermoplastic resins such as, for example, polystyrene and polyethylene, and polyurethane. Foams can be open-celled, close-celled and/or a mixed-cell structure.
In one embodiment, the insulation foams are made of extruded polystyrene, expanded polystyrene, polyethylene, polypropylene, or polyurethane.
They are useful industrial products because of their excellent heat-insulating, cushioning and other properties. These foams have found acceptance over the years in such applications as thermal insulation and cushioning as well as raw material for the fabrication of various shaped articles. The preparation of thermoplastic foams by extruding a heat-plastified mixture of a thermoplastic resin and a blowing agent is well known in the art and is described in U.S. Pat. Nos. 2,740,157; 3,067,147; 3,413,387; 3,413,388; 3,431,163; 3,431,164; 3,954,929 and 3,966,381 and Canadian Pat. No. 451,864. Similarly, various methods of preparing open or close-celled expanded polystyrene and other thermoplastic resins are described in art such as U.S. Pat. Nos. 3,243,485; 3,922,328; 4,399,086; 5,049,328; 5,271,886; and 7,358,280; U.S. Pat. App. Pub. Nos. US20020117769, US20130266766; and EPO patents EP0242191A2 and EP1995273A2. All art cited in this document is incorporated by reference as if fully set forth herein.
Current weather-resistive barriers that claim drainage capability are sheet films that have an external application of adhesive or coating that provides an offset for potential drainage.
In U.S. Pat. No. 6,355,333, granted to Waggoner et al., a Construction Membrane is taught. The membrane is described as resisting liquid and air penetration, being moisture vapor permeable, and being provided with integral drainage channels. The disclosed exterior wall construction which incorporates this membrane may be faced with stucco, siding, brick, or stone.
An Exterior Building Cladding Having Rigid Foam Layer with Drain Channels is shown in U.S. Pat. No. 6,886,301, granted to Schilger. Both the inside and the outside faces of the rigid foam insulation layer are provided with vertical channels 21 to remove moisture by way of thin channels 22. Exterior water penetration drains to the bottom of channels 22, and exits the wall construction by means of a drain wick 28 and flashing 25.
In Published Patent Application No. US 2011/0296781, owned by McCary, an Insulating Finishable Panel is illustrated. This construction employs a rigid-faced foam cored panel, which, in one embodiment includes foam air spacers adhered to the panel's radiant reflective surface. In another arrangement, attached foam air spacers create an air space between the insulation and the radiant reflective surface.
In Published Patent Application No. US 2008/0034690, to Gartz et al., an Underlayment With Improved Drainage is disclosed. The underlayment may include a plurality of vertical channels, and funnels at respective top and bottom edges. The funnels are provided to compensate for misalignment of vertically stacked underlayment panels.
Notwithstanding coats of paint and moisture sealant applied to the exterior layer of a stucco wall, moisture still manages to penetrate the stucco over time, and collect on layers of material within the wall. Known prior art construction methods provide moisture barriers and attempt to allow the drainage of accumulated moisture. However, these methods have proven inadequate, and stucco walls continue to fail from moisture intrusion and accumulation, allowing mold to form and causing wood to rot. The exterior stucco wall construction disclosed herein, provides improved drainage of the moisture which has penetrated the wall and collects therein on materials and structures. Improved longevity and integrity of the stucco wall system is thereby provided.
The insulation layer can comprise any suitable insulation material conventionally known to one of ordinary skill in the art. For example, the insulation layer can comprise a foam polymer insulation, including for example and without limitation, polyisocyanurate foam, polystyrene foam, polyurethane foam, or any combination thereof. In further exemplary aspects, the foam insulation layer comprises polyisocyanurate foam. In still further aspects, the foam insulation layer can comprise a blend or combination of a polyisocyanurate and polyurethane foam.
The foam insulation layer can comprise extruded foam, expanded foam, or a combination thereof. As one of ordinary skill in the art will appreciate, extruded foams can be prepared by melting a suitable polymer material, incorporating a blowing agent to yield a foamed gel, and extruding the foamed gel through a die to form the desired foam layer. Expanded foams can be prepared by subsequent expansion of beads containing a blowing agent, wherein the expanded beads are molded at the time of expansion to form the desired foam layer.
The foam insulation can have any desired density. For example, the foam insulation can have a density of at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or even at least about 20 pounds per cubic feet (pcf) according to ASTM D1622. In further aspects, the foam insulation can have a density in the range of about 1 pcf to about 20 pcf. In still further aspects, the foam insulation density can be any desired value within any range derived from any of the above exemplified values, including, for example, a density in the range from about 2 to about 5 pcf, or from about 1 to about 10 pcf.
The foam insulation can be either closed cell or open cell. Open cell foam is more likely to let water vapor condense inside the cells, thereby reducing the insulation value. Thus, in further exemplary aspect, the foam insulation is closed cell. In a further aspect, the foam insulation is greater than about 50, 60, 70, 80, or even greater than about 90% closed-cell according to ASTM D2856.
Since water can negatively impact thermal performance, the foam insulation preferably exhibits limited or substantially no water absorption. For example, the foam insulation exhibits a water absorption of less than about 10, 9, 8, 7, 6, 5, 4, 3, 2, or even less than about 1% according to ASTM C209. In a further aspect, the foam insulation exhibits a water absorption of less than about 10, 9, 8, 7, 6, 5, 4, 3, 2, or even less than about 1% according to ASTM C2842. In a still further aspect, the foam insulation can exhibit a water absorption in the range of about 10 to about 0%. In a yet further aspect, the water absorption can be any desired value within any range derived from any of the above exemplified values, including, for example, a water absorption in the range from about 0 to about 5%, or from about 1 to about 3.5%.
Moreover, the foam insulation layer can have any desired water vapor permeance (or transmission) value. For example, the water vapor permeance can be about 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, or even about 0 perms according to ASTM E96. In a further aspect, the water vapor permeance can be in the range of about 0 to about 20 perms. In a still further aspect, the water vapor permeance can be any desired value within any range derived from any of the above exemplified values, including, for example, a water vapor permeance in the range from about 0 to about 2 perms, or from about 1 to about 5 perms.
The insulation layer can have any desired thickness (t). This thickness (t) can be customized to fit any particular application and desired thermal resistance. For example, and without limitation, the thickness of the foam insulation layer can be in the range of from about 0.25 in. (¼″) to about 3 in. (3″). In further aspects, the thickness can be from about 0.5 in. to about 1 in. Depending on the intended application, the panel can have any desired thermal resistance value (R-value). For example, the panel can have a R-value of at least about 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25 according to ASTM C1289-02. In a further aspect, the R-value can be in the range of about 1 to about 25. In still further aspects, the R-value can be any desired value within any range derived from any of the above exemplified values, including, for example, R-value in the range from about 1 to about 10, or from about 3 to about 7.
In various aspects, the insulation layer can optionally comprise a membrane layer. The insulation membrane layer can comprise radiant barrier material, such as metal foil, for example, aluminum foil, polymeric film or fabric, paper or cellulosic material, reinforcing scrim, such as fiberglass scrim, or a combination thereof. In some aspects, the membrane layer comprises a single or multi-layered material which can be a laminate in which a backing material is laminated to a foam insulation layer. In other aspects, one or more optional additives can also be incorporated into or otherwise applied to the foam insulation layer. Exemplary and non-limiting additives can include flame retardants, colorants, ultraviolet absorbers, textured coatings, and the like as well as any combinations thereof.
The insulation layer can be secured to the inward facing surface of the panel, for example, by any conventionally used adhesive material known in the art to be compatible for use with foam insulation. For example, according to non-limiting aspects of the invention, the adhesive can be selected from a phenol-formaldehyde resin, hot-melt adhesive, polyvinyl acetate (PVA) resin, or any combination thereof. In still a further aspect, the adhesive can be isocyanate-based.
The insulated panels disclosed herein can exhibit improved physical strength and durability over traditional sheathing panels or foam panels. Thus, in one aspect, the inventive insulated panels can exhibit enhanced structural strength and dimensional stability when compared to a conventional or reference sheathing panel in the absence of the insulation layer when exposed to substantially the same environmental and/or physical forces under substantially similar conditions. To that end, the foam insulation layer can have a dimensional stability of about less than 5, 4, 3, 2, or even less than about 1% according to ASTM D2126. In a further aspect, the dimensional stability is preferably about less than 2%. The foam insulation layer can also have any desired compressive strength. For example, the foam insulation layer can have a desired compressive strength of at least about 1, 5, 10, 15, 20, 25, 30, 35, 40 pounds per square inch (psi) according to ASTM D1621. In a further aspect, the compressive strength can be in the range of about 1 to about 40 psi. In a still further aspect, the compressive strength can be any desired value within any range derived from any of the above exemplified values, including, for example, a compressive strength in the range from about 15 to about 30 psi, or from about 20 to about 25 psi. Likewise, the foam insulation layer can have any desired tensile strength. For example, the foam insulation layer can have a tensile strength of greater than about 300, 400, 500, 600, 700, 800, 900, 1000, 1500, 2000 pounds per cubic foot (pcf) according to ASTM D1623. In a further aspect, the tensile strength can be in the range of about 300 to about 2000 pcf. In a still further aspect, the tensile strength can be any desired value within any range derived from any of the above exemplified values, including, for example, a tensile strength in the range from about 500 to about 1000 pcf, or from about 600 to about 800 pcf.
In further aspects, the structural properties of the disclosed insulated panels make the insulated panels suitable for use in numerous structural applications, while still providing improved thermal performance. For example, in one aspect, the inventive insulated panels can be used as braced wall panels, when used in accordance with 2006 IBC Section 2308.3 and 2006 IRC Section R602.10.1. In another aspect, the inventive insulated panels are considered equivalent to Construction Method 3 described in Section 2308.9.3 of the 2006 IBC and Section R602.10.3 of the 2006 IRC. In another aspects, the inventive insulated panels are suitable for use an alternative to wood structural panels in the construction of wood shear walls, when installed in accordance with 2006 IBC Section 2305.3.
It should be noted that all references cited above, and otherwise, in this specification are incorporated in this specification as if they were fully set forth herein.
In one embodiment, the foam insulation is expanded Polystyrene (EPS), Extruded Polystyrene (XPS), Graphite Polystyrene (GPS), or polyisocyanurate foam insulation.
Expanded Polystyrene Insulation, more commonly referred to as EPS, is a closed cell insulation made commonly with of 98% trapped air and only 2% plastic. In one embodiment, this invention relates to a flat board, a contoured shape, or a combination of flat and contoured shaped EPS.
Extruded Polystyrene, referred to as XPS, is a closed cell insulation product commonly used in remodeling and new construction applications. In one embodiment, this invention relates to a flat board, a contoured shape, or a combination of flat and contoured shaped XPS.
Graphite polystyrene insulation, or GPS, is made from Neopor beads, patented and manufactured by BASF. Neopor gives GPS insulation a dark gray appearance and higher r-value than traditional EPS insulation products. In one embodiment, this invention relates to a flat board, a contoured shape, or a combination of flat and contoured shaped GPS.
Polyisocyanurate foam boards may include closed-cell polyisocyanurate (polyiso) foam insulation. This is described, for example, in U.S. Pat. No. 10,829,939B2, which is incorporated by reference herein.
In one embodiment, this invention relates to a system of panels described herein, wherein at least one panel comprises EPS, or at least one panel comprises XPS, or at least one panel comprises GPS, or at least one panel comprises polyisocyanurate foam, or at least a combination of two out of the four panels, three of the four panels, or all four panels. In another embodiment, the panels may be organized adjacent each other or separate from each other.
In one embodiment, this invention relates to an insulation sheathing system that comprises two insulation sheathing panels: a first insulation sheathing panel and a second insulation sheathing panel. The two panels are juxtaposed side by side in one plane. Each insulation sheathing panel comprises the insulation foam layer and the fire-proofing layer as described previously.
In one embodiment, this invention relates to an insulation sheathing system that comprises two insulation sheathing panels: a first insulation sheathing panel and a second insulation sheathing panel. The two panels are juxtaposed side by side in one plane. Each insulation sheathing panel comprises the insulation foam layer and the fire-proofing as described previously.
In one embodiment, the panel has more than 2 sides. Stated differently, the present invention envisions a panel comprising, the following sides: 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20.
In one embodiment of the invention, the panel has a curved shape, for example, it is circular, or oblong shaped or a semi-circle shaped. In one embodiment of the invention, the panel has at least one side that is not linear, but has a curved shape.
In one embodiment, the multiple-sided panel has all sides that are equal or at least two sides that are equal or no sides that are equal in length.
This invention envisions an insulation sheathing panel system comprising at least two panels wherein a first panel is irregular shaped, but the adjacent juxtaposing second panel neatly fits with the irregular shape of the first panel.
In one embodiment, the insulation panel system comprises more than one square or a rectangular panel, wherein each side of the panel has a tongue or groove configuration.
In one embodiment, the insulation sheathing includes extruded polystyrene, polyisocyanurate, polyolefin, and polyurethane foams and beads.

IIIB. Open-Celled Foam Insulation Layer

The open-celled foam insulation layer as adhesively in contact with the regular foam insulation layer described previously.
In one embodiment, the open-celled foam insulation layer comprises a sprayable foam that is made from polyurethane sprayable foams, polyurea sprayable foams, and combinations thereof. In another embodiment, the sprayable foam may be selected from the group of acrylic foams, latex foams, melamine foams, isocyanurate foams, and silicone foams. When the sprayable foam is the polyurethane sprayable foam, the sprayable foam may be the reaction product of a polyether polyol and an isocyanate. Alternatively, the polyurethane sprayable foam may be the reaction product of a polyester polyol and the isocyanate. The use of the polyester polyol imparts the insulating foam layer with a fire-retardant characteristic. When the sprayable foam is the polyurea sprayable foam, the sprayable foam is the reaction product of a polyamine and an isocyanate. An example of an isocyanate suitable for the sprayable foam is lubrinate. The insulating foam layer may include additives, such as fire retardants, and impact modifiers.
The open-celled spray foam acts as a water barrier that also is not air-permeable. In one embodiment, the open-celled spray foam is an air and water barrier, while still being water vapor permeable.
Polyurethane foam is used as an example to describe the open-celled foam herein.
In one aspect, the open-celled polyurethane with the open cell structure has a density of between 0.60 and 1.5 lb. per cubic foot. In one embodiment, the density of the foamed open cell polyurethane foam is between 0.90 and 1.20 lb. per cubic foot, and in yet another embodiment, between 1.00 and 1.15 lb. per cubic foot.
In one aspect, the open cell structure of the foams of the present invention have a structure wherein the cells are essentially open but include some randomly occurring, solid cell walls.
The term “open-celled, foamed polyurethane” refers to polyurethane materials having a cell structure which is at least partially open, and thus, has few, if any, fully entrained voids (e.g., closed cells) within the polyurethane material. It should be noted that the phrase “open cell” as used herein with reference to foams of the present invention indicates that substantially all cells have at least one cell wall which is at least partially open, or ruptured, so that gas, and in particular, water vapor, may escape from the foam structure. However, the entire foam, as a whole, acts to prevent the passage of liquid water, or the passage of air, and thus acts as a water and air barrier. The open cell structure is also preferably non-shrinking, since the cell structure is not influenced by the expansion and contraction of gas bubbles, as can be seen in some closed cell foam materials.
In one aspect, the open cell structure of the foams is formed by the effect of a surfactant interaction that produces both completely open and at least partially open, cell walls.
If measured by a method such as ASTM D6226, the open cell content of the foams of the first open-celled foam insulation layer of the present invention, in one embodiment is greater than 85%, or 90%, or 95%, or 98%. As such, the level of entrained voids in the foams of the present invention might be as high as 50%, by number, of the total number of cells in the foam. In one embodiment, however, the level of entrained voids in the polyurethane foam is less than 25% by number, or even less than 10%, by number.
The open cell polyurethane foam of the present invention can also include a continuous “skin” portion formed on one or more surfaces of the foam. The skin provides a smooth surface that can prevent ingress of water, and thus can function as a water barrier, and aids initially in causing water to bead off of the surface of the foam. However, the skin is not a solid structure, and should not act to significantly affect the ability of water vapor to pass through the open cell polyurethane foam material.
The size of the cell can vary depending on the materials used, and the amount of blowing agent, and the like that is used. In one embodiment, the foams of the present invention have a cell size of between 0.03 um, and 1.5 um, and more preferably between 0.1 um and 1.0 um. More preferably, the majority of cells have a cell size of 0.8 and 0.3 um.
The insulating ability (for example the “R” value) of the foam is preferably such that the polyurethane foam of the present invention will provide an R value of between 2 and 6 per inch of thickness, and more preferably, between 3 and 5 per inch of thickness. As such, typical “R” values would be between the ranges of 4 and 12 for a 2 inch thickness foam.
In one aspect, the present invention provides a semi-rigid, polyurethane foam, for use in insulating, wherein said sprayed polyurethane foam has an open cell structure and density, as previously described with respect to the present invention.
The general production methods to produce polyurethane foams are well known to the skilled artisan, as is the general chemistry for production thereof. As such, these will not be described in any specific detail Depending upon the type of foam structure that is required by a specific application, the isocyanate and/or polyol resin systems may be selected according to their molecular weight. For example, low molecular weight materials tend to promote the formation of a more rigid material. To achieve a semi-rigid material, typically, a medium molecular weight resin system is typically used. To achieve a flexible foam, a high molecular weight resin system would preferably be used. The types of foam materials are discussed in US20160272772 and CA3045033 and both references are incorporated herein as if they were set forth, here, fully.
Further, as is known in the art, the foam structure of the polyurethane material is provided by a blowing agent which acts to form the voids within the polyurethane as it reacts and solidifies. The nature, types and amounts of blowing agents which are used in polyurethane foam manufacture are well known to those skilled in the art, but can include, for example, water, carbon dioxide, hydrofluorocarbons (HFCs), chlorinated fluorocarbons, hydrofluoro olefins (HFOs), and the like. Typically, water is the preferred blowing agent for formulations of the present invention. Alternatively, other blowing agents can be used, or combined with water, in order to generate a gaseous material during the curing reaction. While carbon dioxide is a preferred gas for generation, other gases such as nitrogen, pentane, HFOs, HFCs, or the like, may be released, or directly used, in order to form a foam with the desired density and cell shape and size. In addition to water, minor amounts of auxiliary blowing agents include: HCFC-22, HFC-134a, HCFC-142b, HFC-245fa, dichloroethylene, hydrocarbons such as n-pentane, isopentane, cyclopentane and the like.
In one embodiment, the foams are 100% water blown foams (both EPS and spray foam) for ultra-low environmental impact.
Additionally, other additives such as catalysts or surfactants, or the like, can be added to the reaction mixture in order to control various properties of the polyurethane foam. Other materials can be included for example, coupling agents, such as silane or titanates, may also be included in the preparation of the composition to improve the physical properties of the material. Where other properties are desired, additional additives may be added to the composition including colorants, dry or liquid inks or pigments, fire and flame retardants, UV absorbers and protectants, antistatic agents, and such other additives as required, and which are known within the industry.

IV. Weather-Resistive Barrier Layer

Weather-resistive barrier layer (“WRB layer”) include the external house-wrap layer that provides barrier properties but may have water vapor permeability. House-wraps are described for example in U.S. Pat. No. 6,901,712. House-wraps include Blueskin® sold by Henry Co. of PA and Tyvek® by DuPont Co. of DE. Other house-wrap materials include Barricade® Wrap Plus, Typar® Building Wrap, CertainTeed CertaWrap™, and HydroGap® Housewrap.
In one embodiment, the WRB layer is a pre-formed sheet air barrier membrane, which is permeable to water vapor, and which can be adhered to a substrate, substantially over its entire area, by virtue of an adhesive deposited on one side of the sheet. In one embodiment of the present invention, the substrate is an insulation layer or the insulation system as described herein.
In another embodiment, the WRB layer provides a pattern for depositing the adhesive on the membrane such that the lateral movement of air between the membrane and the substrate or through lap joints of membrane sections is restricted.
In yet another embodiment, the WRB layer is a water vapor permeable, air barrier sheet membrane which can be installed with or without the use of mechanical fasteners, nails, screws, rivets, mechanical or plastic clamps, or tapes to provide an air barrier system with a continuous plane of air tightness.
In another embodiment, the WRB layer has an adhesive backed water vapor permeable sheet membrane that can perform as a barrier to the infiltration of liquid or bulk water as from wind-driven rain, when used in wall and roof assemblies.
In one embodiment, the WRB layer is a membrane permeable to water vapor, on one side of which is deposited an adhesive in a non-continuous film leaving zones of uncoated membrane, thereby permitting the diffusion of water vapor through the membrane at the uncoated zones.
In another embodiment of the WRB layer, the adhesive is deposited in a pattern on the membrane such that the adhesive intersects or connects in a manner to avoid providing channels through which air can laterally migrate when the membrane is bonded to a substrate.
In another embodiment of the WRB layer, the membrane, although permeable to water vapor, is rendered impermeable to liquid or bulk water and can thus perform as an adhesive backed moisture barrier which is permeable to water vapor.
In another embodiment, the WRB layer is a self-adhering, water vapor permeable, air and moisture barrier sheet for structural surfaces of buildings, comprising (i) an air and moisture barrier membrane which is water vapor permeable, and (ii) has an adhesive applied to one side of the water vapor permeable membrane in a non-continuous film.
In accordance with a particular embodiment of the invention, there is provided a self-adhering sheet for structural surfaces, comprising, (a) an air and moisture barrier membrane having opposed first and second faces, said membrane being water vapor permeable, and (b) an adhesive applied to said second face in a non-continuous film to define a plurality of spaced-apart, non-adhesive-coated zones surrounded by an adhesive coated zone.
In yet another aspect of the invention, WRB layer is an article of manufacture comprising a self-adhering sheet of the invention having a strippable release sheet removably adhered to said second face with a non-continuous adhesive film.
In some embodiments, in addition to the WRB layer, a veneer layer, which is a brick, a ceramic tile, porcelain tile, natural stone, engineered stone, wood, ceramic, plastic, vinyl, or paint.
In another embodiment, for the all the examples and embodiments described above, an intumescent coating that can aid in fireproofing/retarding and ignition proofing/retarding can also be included in place of or in addition to the WRB layer. Intumescent coatings are obtained for example from the NoBurn Co., Wadsworth, OH. Intumescent coatings also include fire retardant coatings and ignition retardant coatings.
In one embodiment, a split liner tape is used that can allow for one or more extension flaps to include the concept of release-liner. Intumescent coatings can be procured from No-Burn.

WRB Layer—Vapor Permeable Membrane

The vapor permeable membrane of the invention is a flexible sheet or film, which is permeable to the passage of water in vapor form. The sheet or film may be microporous, microperforated or some other type of vapor permeable sheet or film.
A microporous sheet or film is a non-perforated continuous microfiber web with microscopic pores large enough for moisture vapor to pass through, but small enough to resist air and liquid water. Microperforated membranes depend on mechanical pin-perforations and/or film laminations to build in properties.
While both of the abovementioned types of sheet or film are permeable to water vapor, a sheet or film of the microporous type is preferred as this type is less permeable to the passage of water or moisture in liquid or bulk form.
Suitable microporous sheets or films are spunbonded or fibrous bonded polyolefin as described in U.S. Pat. Nos. 3,532,589 and 5,972,147, preferred polyolefins are polyethylene and polypropylene, one such microporous sheet is available commercially under the trade-mark Tyvek®; other suitable microporous sheets include oriented polymeric films as described in U.S. Pat. No. 5,317,035, and which comprise ethylene-propylene block copolymers; one such film is commercially available as Aptra®. The sheets or films may be reinforced with several types of scrim materials or may be laminated to other vapor permeable sheets or films, such as non-woven polypropylene or non-woven polyester for the purpose of improving strength and other physical properties.
In general, the membrane will typically have a thickness of 0.001 to 0.04, preferably 0.001 to 0.025 inches.
The WRB layer can extend at one or more edges of the panel as the extension flap, wherein the extension flap comprises a removably attached release-liner on its back side.
In one embodiment, the extension flap, in the direction perpendicular to the edge of the panel, is 0.1% to 50% of the shortest and the longest dimension of the panel, respectively.
In one embodiment, the adhesive on the inner surface of the WRB that adheres to the SS panel, or an insulation layer is the same as the adhesive on the extension flap of the WRB having a removably attached release-liner.
In one embodiment comprising the extension flaps or pre-applied tapes, the overhang is anywhere from 0.1 inches to 12 inches on any one or more edges of the panel. This is advantageous in minimizing or to eliminating the need for labor to tape the seams in the field.

V. Optional Fastener-Gasketing Adhesive

The fastener-gasketing adhesive can be a hot-melt adhesive, solvent based adhesive, water based adhesive or of other types such as UV cured polymer. The applied adhesive is preferably tacky, i.e.—sticky and pressure sensitive. Suitable hot melt adhesives may contain such ingredients as polymers such as butyl rubber, styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SIS), styrene butadiene (SB), styrene-ethylene-butadiene-styrene (SEBS) and ethylene vinyl acetate (EVA); resins such as those of the hydrocarbon and rosin types, natural and petroleum waxes, oils, bitumen and others. Solvent-based adhesives may contain ingredients such as those listed above, dissolved or dispersed in a solvent vehicle. Water based adhesives would normally be based on emulsions of polymeric materials. Suitable polymeric materials would include vinyl acetate and acrylic polymers and copolymers such as vinyl acetate acrylic, ethylene vinyl acetate as well as styrene acrylic, vinyl chloride acrylic, vinyl versatate and others.
From a production standpoint, the preferred adhesives are of the hot melt type which are simply melted for application and need not emit solvent which is an environmental pollutant and may require re-condensation. Water based adhesives have the disadvantage that they generally require the additional use of drying ovens or heat lamps to evaporate the water.
The adhesive may suitably be applied at a thickness of 0.001 inches to 0.1 inch but is preferably applied at a thickness of 0.003 inches to 0.025 inches and most preferably at a thickness of 0.005 inches to 0.02 inches.
The WRB layer is adhered to a wood-composite material layer or a panel, with an adhesive. The WRB layer extends beyond the panel dimensions in one or more directions away from the edges. For example, if the panel is rectangular, with the WRB layer attached to it. The WRB layer will extend at least 0.1 inch over the dimension of the rectangular panel on one or more sides. In these extension flaps of the WRB panel will be attached a release-liner that is attached with an adhesive material, such that when more than one panel is abutted to each other, upon removal of the release-liner the WRB layer adhered directly to the adjacent panel of the assembly, and will seal the gaps between the two panels in the assembly.
Suitable release sheets are paper sheet, having a silicone release surface coating and some treated plastic films.

Adhesive Pattern

To retain an essential level of water vapor permeance in the adhesive coated membrane, the adhesive is applied to the vapor permeable membrane in a non-continuous film in order to leave parts, or spots or zones of the sheet uncoated with adhesive.
In order to prevent the lateral movement of air between the membrane and the substrate to which it is bonded, and through lap joints of the membrane, the adhesive coated areas of the membrane can be made to intersect to isolate the uncoated areas, thereby eliminating channels through which air can laterally move. This can be achieved by any number of patterns, such as intersecting circles with adhesive free centers, intersecting squares or rectangles of adhesive, intersecting strips in a checkered pattern, and the like.
In general, the adhesive film forms an adhesive sea on the membrane surface, with a multitude of membrane islands, surrounded by but not covered by the adhesive sea.
The adhesive may suitably be applied so as to cover 5% to 99% of the area of one side of the membrane, but is preferably applied to cover between 25% and 90% of the area, and most preferably between 50% and 80% of the area, to obtain the optimum balance of adhesion and vapor permeance in the sheet.

VI. Optional Adhesive Layer

The adhesive can be a hot-melt adhesive, solvent based adhesive, water based adhesive or of other types such as UV cured polymer. The applied adhesive is preferably tacky, i.e.—sticky and pressure sensitive. Suitable hot melt adhesives may contain such ingredients as polymers such as butyl rubber, styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SIS), styrene butadiene (SB), styrene-ethylene-butadiene-styrene (SEBS) and ethylene vinyl acetate (EVA); resins such as those of the hydrocarbon and rosin types, natural and petroleum waxes, oils, bitumen and others. Solvent-based adhesives may contain ingredients such as those listed above, dissolved or dispersed in a solvent vehicle. Water based adhesives would normally be based on emulsions of polymeric materials. Suitable polymeric materials would include vinyl acetate and acrylic polymers and copolymers such as vinyl acetate acrylic, ethylene vinyl acetate as well as styrene acrylic, vinyl chloride acrylic, vinyl versatate and others.
From a production standpoint, the preferred adhesives are of the hot melt type which are simply melted for application and need not emit solvent which is an environmental pollutant and may require re-condensation. Water based adhesives have the disadvantage that they generally require the additional use of drying ovens or heat lamps to evaporate the water.
The adhesive may suitably be applied at a thickness of 0.001 inches to 0.1 inch, but is preferably applied at a thickness of 0.003 inches to 0.025 inches and most preferably at a thickness of 0.005 inches to 0.02 inches.
The WRB layer is adhered to a wood-composite material layer or a panel, with an adhesive. The WRB layer extends beyond the panel dimensions in one or more directions away from the edges. For example, if the panel is rectangular, with the WRB layer attached to it. The WRB layer will extend at least 0.1 inch over the dimension of the rectangular panel on one or more sides. In these extension flaps of the WRB panel will be attached a release-liner that is attached with an adhesive material, such that when more than one panel is abutted to each other, upon removal of the release-liner the WRB layer adhered directly to the adjacent panel of the assembly, and will seal the gaps between the two panels in the assembly.
Suitable release sheets are paper sheet, having a silicone release surface coating and some treated plastic films.

Adhesive Pattern

To retain an essential level of water vapor permeance in the adhesive coated membrane, the adhesive is applied to the vapor permeable membrane in a non-continuous film in order to leave parts, or spots or zones of the sheet uncoated with adhesive.
In order to prevent the lateral movement of air between the membrane and the substrate to which it is bonded, and through lap joints of the membrane, the adhesive coated areas of the membrane can be made to intersect to isolate the uncoated areas, thereby eliminating channels through which air can laterally move. This can be achieved by any number of patterns, such as intersecting circles with adhesive free centers, intersecting squares or rectangles of adhesive, intersecting strips in a checkered pattern, and the like.
In general, the adhesive film forms an adhesive sea on the membrane surface, with a multitude of membrane islands, surrounded by but not covered by the adhesive sea.
The adhesive may suitably be applied so as to cover 5% to 99% of the area of one side of the membrane, but is preferably applied to cover between 25% and 90% of the area, and most preferably between 50% and 80% of the area, to obtain the optimum balance of adhesion and vapor permeance in the sheet.
Primer As is common with other types of self-adhering membranes, the use of a liquid primer coating may sometimes be recommended to improve adhesion of the membrane to some substrates such as wood panel. In the case of a vapor permeable membrane, the primer should be selected from certain materials or applied at a reduced rate or in a manner such that the breathability of the assembly is not compromised.

Vapor Impermeable Barrier Sheet

In some embodiments, the vapor permeable membrane sheet of the invention is typically employed in a building structure, especially a wall structure, in conjunction with a vapor impermeable barrier sheet. A preferred sheet is a polyethylene sheet, as known in the art, having a water vapor permeance of not more than 15 ng/Pa·s·m²(ASTM E 96).
Such a sheet may be considered a vapor retarder since it is not completely impermeable to water vapor.
Typically, the barrier sheet has a thickness of 0.001 to 0.008 inches, more usually 0.002 to 0.006 inches.

Insulation Sheathing and WRB Panels

In one embodiment, this invention relates to an insulation sheathing system that comprises two insulation sheathing panels, such as insulation wall-sheathing (IWS) panels: a first IS panel, such as an IWS panel, and a second IS panel, such as an IWS panel. The two panels are juxtaposed side by side in one plane as described previously. In one embodiment, the insulation sheathing system comprises two IS panels, such as IWS panels wherein at least one panel comprises at least one extension flap with a backing of a release liner, on one side of the panel. In another embodiment, the two panels are fitted or attached to each other via the extension flap arrangement, with the release liner now removed and the extension flap extending from one panel to the second panel and providing the joining of the two panels. Multiple panels can be similarly joined.
In one embodiment, the extension flap is continuous along the length of the side of the insulation panel from which it extends outward. In another embodiment, of the invention, the extension flap is discrete, with multiple protrusions which in totality make the extension flap. In one embodiment, there is a gap between the protrusions that form the extension flap. In another embodiment, the protrusions are of the same width or of different widths. See FIG. 4 , generally.

Tongue-and-Groove Arrangement

In an insulation sheathing (IS) panel such as an IWS panel, at least on one side of the panel either a tongue or a groove can be provided for its juxtaposition and attachment to an adjacent panel. By tongue is meant a protrusion along the length of the side of a panel that removably fits within the groove of an adjacent panel. By groove is meant a depression along the length of an insulation wall-sheathing panel which allows for a removable attachment of the side of an adjacent panel that has a tongue along its length.
Generally, separate steps are needed to create a system that is insulative, vapor semi-permeable, a weather resistive barrier, and acts as a drainage plane. The steps may include exterior insulation and a weather-resistive barrier that may or may not meet drainage needs through an outward facing attachment to the film and placing an additional medium to the wall system to promote drainage.
In one embodiment, the tongue and the groove are a continuous feature along the length of a system comprising at least two insulation wall-sheathing panels. In another embodiment of the IS panel, such as an IWS panel, systems, the tongue and the groove arrangement is discrete such each tongue is divided into multiple protrusions along the length of the side of a panel, and the corresponding side of the receiving panel comprises multiple grooves in form of depressed troughs to receive the multiple protrusions. In one system, the tongue is discrete on one sheathing panel, but the receiving groove is continuous.
In one embodiment, this invention relates to an insulation sheathing system that comprises two IS panels, such as two IWS panels,: a first insulation sheathing panel and a second insulation sheathing panel. The two panels are juxtaposed side by side in one plane. In one embodiment, the insulation sheathing system comprises of the two panels wherein each panel comprises either a groove or a tongue at least on one side of the panel. In another embodiment, the two panels are fitted or attached or joined to each other via the tongue-and-groove arrangement. Multiple panels can be similarly joined.
In one embodiment, the tongue and the groove are a continuous feature along the length of a system comprising at least two insulation wall-sheathing panels. In another embodiment of the insulation wall-sheathing panel systems, the tongue and the groove arrangement is discrete such each tongue is divided into multiple protrusions along the length of the side of a panel, and the corresponding side of the receiving panel comprises multiple grooves in form of depressed troughs to receive the multiple protrusions. In one system, the tongue is discrete on one sheathing panel, but the receiving groove is continuous.
In one embodiment, this invention relates to an insulation sheathing system that comprises two insulation sheathing panels: a first insulation sheathing panel and a second insulation sheathing panel. The two panels are juxtaposed side by side in one plane. Each insulation sheathing panel comprises the insulation foam layer and the insulation facer as described previously. In one embodiment, the insulation sheathing system comprises the two panels wherein each panel comprises at least one extension flap with a backing of a release liner, on one side of the panel. In another embodiment, the two panels are fitted or attached to each other via the extension flap arrangement, with the release liner now removed and the extension flap extending from one panel to the second panel and providing the joining of the two panels. Multiple panels can be similarly joined.
In one embodiment, the extension flap is continuous along the length of the side of the insulation panel from which it extends outward. In another embodiment, of the invention, the extension flap is discrete, with multiple protrusions which in totality make the extension flap. In one embodiment, there is a gap between the protrusions that form the extension flap. In another embodiment, the protrusions are of the same width or of different widths.
In one embodiment, the tongue and the groove are a continuous feature along the length of a system comprising at least two insulation sheathing panels. In another embodiment of the insulation sheathing panel systems, the tongue and the groove arrangement is discrete such each tongue is divided into multiple protrusions along the length of the side of a panel, and the corresponding side of the receiving panel comprises multiple grooves in form of depressed troughs to receive the multiple protrusions. In one system, the tongue is discrete on one sheathing panel, but the receiving groove is continuous.
In one embodiment, both the tongue and groove the extension flaps are present, which are used to seal the panels side-by-side.
In one aspect of the invention, the invention relates to an insulation wall-sheathing panel or an insulation sheathing system (i.e., multiple panels), that have panels comprising both the extension flaps and the tongue-and-groove arrangement.
In one embodiment, the insulation wall-sheathing panel has more than 2 sides. Stated differently, the present invention envisions a panel comprising, the following sides:
3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20.
In one embodiment of the invention, the panel has a curved shape, for example, it is circular, or oblong shaped or a semi-circle shaped. In one embodiment of the invention, the panel has at least one side that is not linear, but has a curved shape.
In one embodiment, the multiple-sided panel has all sides that are equal or at least two sides that are equal or no sides that are equal in length.
This invention envisions an insulation wall-sheathing panel system comprising at least two panels wherein a first panel is irregular shaped, but the adjacent juxtaposing second panel neatly fits with the irregular shape of the first panel.
In one embodiment, the insulation panel system comprises more than one square or a rectangular panel, wherein each side of the panel has a tongue or groove configuration, and each side has an extension flap with the releasable liner backing.
In one embodiment, the pattern on the insulation facer will also repeat in the machine direction of the insulation sheath being made. In one embodiment, the embossed design connects with each other for adequate drainage of the moisture. In one embodiment, the embossed design is vertical lines. In one embodiment, the embossed design is crisscross lines or a lattice design. In one embodiment, the design is rhombus or diamond shape. In one embodiment, the entire design is connected to each other. In one embodiment the design is a set of transverse lines. It is to be understood that the designs and/or patterns herein are in plurality and/or in repetition in the vertical or the horizontal (machine) direction.
This invention addresses the above issues of moisture drainage by providing a vapor semi permeable weather resistive drainage product in a single inline process through an embossment technique.
Particularly, in one of its embodiments, it includes a vapor semi-permeable insulation sheathing that provides insulation, a weather-resistive barrier, and an air barrier while simultaneously providing a drainage mechanism on the external surface, which has been engendered through an in-line application of pressure and heat. The patterned embossment on the sheathing provides an avenue for moisture that gets behind the exterior weather barrier a means to escape.
The comprehensive weather resistive barrier that includes an insulation component with an embossed drainage system allows the contractor minimal passes to create all functions while using a planar board that does not exceed the primary dimension of the sheathing. The design uses a polymeric film that is breathable and adhered to an insulative core material through heat lamination on one face that undergoes pressure and heat to create a mechanism to promote drainage when used a s a wall system component. The patterned embossment in the sheathing will provide an avenue for moisture that gets behind the exterior weather barrier a means to escape.
In the present disclosure, insulation sheathing, insulation board, insulation panel, or insulation material is used interchangeably.
As discussed previously, insulation facing laminations are laminates which contain film/foil or metalized films that provide protection for a variety of insulation applications. Often the adhesive possesses fire-retardant properties. Typical applications include ceiling panels and wall insulation.
In another embodiment, for the all the examples and embodiments described above, an intumescent coating that can aid is fireproofing and ignition proofing can also be included in place of the WRB layer.
In one embodiment, the intumescent coating is applied to the surface of the panel in place of the WRB layer. Intumescent coatings are obtained for example form the No-Burn company.
In one embodiment, a split liner tape is used that can allow for one of more extension flaps to include the concept of release liner. Intumescent coatings can be procured from NoBurn Co., Woodsworth OH. Intumescent coatings also include fire retardant coatings and ignition retardant coatings.
In one embodiment, one of the three coatings described above can be used to coat the Insulam® product from Henry Co., Kimberton PA, to provide it the characteristics of intumescence, fire retardation, or ignition retardation.
As discussed previously, the present invention, a vapor semi permeable weather resistive drainage product is created in a single inline process through an embossment technique. Particularly, the present invention provides for a vapor semi-permeable insulation sheathing that provides insulation, a weather resistive barrier and air barrier while providing a drainage mechanism that is formed through pressure and heat. The patterned embossment on the sheathing provides an avenue for moisture that gets behind the exterior weather barrier a means to escape.
In one embodiment, this invention relates to an in-plane, drainable, weather-resistive insulation sheathing, comprising an insulation foam and an insulation facer on at least one side of the insulation sheathing, wherein the insulation facer is adhered to the insulation foam, and wherein the insulation facer comprises an embossed design for moisture drainage.
In one embodiment, this invention relates to a first insulation sheathing panel, comprising:

- (i) an insulation foam layer having an outer surface and an inner surface, and
- (ii) a first insulation facer having an outer surface and an inner surface,
  wherein the inner surface of the first insulation facer is adhered to the inner surface of the insulation foam layer;
  wherein the first insulation facer exceeds the dimension of the insulation foam layer at least at one edge to create an extension flap of the insulation facer,
  wherein the extension flap further comprises a removably attached release liner attached to the insulation facer's inner surface.

In one embodiment, the extension flap of the insulation facer extends in length from about 0.5% of the minimum dimension of the insulation sheathing panel to about 50% of the length of the maximum dimension of the insulation sheathing panel. In one embodiment, the adhesive on the inner surface of the first insulation facer that adheres to the foam layer is the same as the adhesive on the extension flap of the insulation facer having a removably attached release liner.
In one embodiment comprising the extension flaps or pre-applied tapes, the overhang is anywhere from 0.1 inches to 12 inches on any one or more edges of the panel. This is advantageous is minimizing or to eliminating the need for labor to tape the seams in the field.
In one embodiment, the length of the extension flaps or pre-applied tapes can be any one number of the following numbers, or can be a number within a range defined by any two numbers below, including the endpoints of such range, as measured in inches: 0.1, 0.2, 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, and 12.
In one embodiment, the panels are stacked above one on top of the other where the flaps are adhered to shed water.
In one embodiment, this invention relates to an insulation sheathing panel, comprising:

- (iii) an insulation foam layer having an outer surface and an inner surface,
- (iv) a first insulation facer having an outer surface and an inner surface, and optionally,
- (v) a second insulation facer having an outer surface and an inner surface;
  wherein the inner surface of the first insulation facer is adhered to the inner surface of the insulation foam layer;
  wherein the inner surface of the second insulation facer is adhered to the outer surface of the insulation foam layer;
  wherein the first insulation facer exceeds the dimension of the insulation foam layer at least at one edge to create an extension flap of the insulation facer,
  wherein the extension flap further comprises a removably attached release liner attached to the insulation facer's inner surface.

As shown in FIG. 1 , and in one embodiment, the insulation sheathing (1) comprises an insulation foam (2) and an insulation facer (3) laminated on at least one surface of the insulation foam (2).
In one embodiment, such facing materials or insulation facers include plastic film, thin metal foil, metallized polymeric film, perforated metalized polymeric film, paper or thin cellulose, non-woven polymeric fabrics, fiberglass scrims, and combinations of the foregoing.
In one embodiment, the insulation sheathing includes extruded polystyrene, polyisocyanurate, polyolefin, and polyurethane foams and beads.
While this invention relates to unembossed and embossed facers, in one embodiment, the insulation facer comprises an embossed pattern on its surface. The pattern may be geometric, regular, or random. The embossed pattern is such that it aids in draining of the accumulating moisture on the surface of the insulation sheathing.
By geometric pattern is mean vertical lines, horizontal lines, transverse lines, circles, triangles, squares, rectangles, trapezoid, rhombus, pentagons, and other such geometric designs. More than one type of geometric structure may be present on the surface of the insulation facer in an embossed or recessed fashion.
By a regular pattern is meant that the same pattern is repeated in partial or full surface of the insulation facer. In other words, a geometric pattern would be repeated, or an irregular pattern would be repeated.
By irregular pattern is meant the insulation facer has a random design that is not regular.
The pattern will also repeat in the machine direction of the insulation sheath being made.
The embossed design (5) on the insulation sheathing (1) is such that insulation sheathing of the present invention has an advantageous moisture drainage or removal possibility. An embossed design is shown in FIG. 2 .
In one embodiment, this invention relates to an exterior stucco wall construction comprising: a wall frame; sheathing attached to the outer side of the wall frame; a moisture collection channel or the embossed design mounted along the insulation sheathing facer, a second moisture impervious board comprising the insulation sheathing having an inner side insulation facer provided with drain means such as the embossed design described previously to facilitate the downward drainage of moisture.
Turning now to the drawings, and in particular FIG. 3 shows the process of embossing the design on the insulation facer (3). At least one of the rollers (11 & 12) has a design template on its surface. The continuously moving insulation sheathing has an insulation facer (3) on one or both surfaces. The insulation sheathing (with the foam (2) and the facer (3)) moves in the horizontal direction, in one example, and under temperature and/or pressure, the embossed design is imprinted. As shown in FIG. 4 , a design (5) for moisture removal is embossed on the facer (3) of the foam insulation. This embossed design (5) feature provides the maximum discharge of moisture and condensation. Experimentation includes creating a means to emboss the assembly while not deteriorating the weather resistive barrier or air barrier requirements. Further testing includes permeance, wind driven rain, R-Value, compatibility, drainage and pressure testing of the assembly.
FIG. 5 shows an embodiment of a panel (1) with tongue (14) and groove (15). FIG. 6 shows an embodiment of a panel (1) with multiple tongues (14) and multiple grooves (15). FIG. 7 shows a panel (1) with four embodiments of flaps (21).

EXPERIMENTAL

Example 1

In one embodiment, a pattern roller is applied to a rotary press. The sheet of foam which is laminated in line previously enters the roller with ¼″ pinch which creates pressure at a temperature in excess of 220° F. The pressure roller is spinning at 60 feet per minute. The material exits the roll, and the pattern is embossed in the insulation sheathing on the facer side.

Example 2

In this embodiment, the IS panel, such as an IWS panel, comprises of a perforated metalized polymeric facer (MOP) or the insulation facer on the reverse side of an EPS/GPS 4×8 sheet that can vary in thickness and density, the thicknesses are from 9/16″ up to about 3″. The EPS core is produced to meet and exceed the minimum requirements of ASTM C578 Type II. The face of the laminated sheets has a woven polypropylene facer (the WRB layer) that is used in the manufacture for example of Henry Co.'s Blue Skin VP100. This woven polymeric layer or the WRB layer and MOP are laminated to the EPS/GPS insulation core, on their either side, through the application of heat and pressure that activates adhesives that have been pre-applied to the facer materials. The MOP and woven WRB layer use different adhesive technologies however they are contiguous over the entire backside of the film. The woven polymeric WRB layer is positioned on the EPS/GPS core such that the entire face of the insulation layer or the core is covered and a 2″ extension flap is created on the longitudinal edge. A pressure sensitive medium is then applied to this 2″ flap that includes a protective release liner. The trailing edge of the board includes a pre-applied VP100 tape that creates 6″ flap or the woven WRB layer is extended beyond the board to create a 3″ flap that again has a pressure sensitive material with release liner pre-applied.
The perforated MOP insulation facer and the vapor permeable adhesive technology applied to the woven WRB layer allow for the overall sheet to maintain a vapor semi permeable finished product.
n EPS/GPS 4′×8′ panel is prepared as follows. These cores are loaded into aa heat laminator. The MOP is laminated to the reverse side of the EPS/GPS while the woven polymeric film or the WRB layer is applied to the face of the insulation core. The woven polymeric WRB layer is used with a width to create a 2″ overlap extension flap on the longitudinal edge that is contiguous across the face of the insulation core. The lamination techniques utilize heat at levels from 230-350 degrees F. while the product undergoes pressure applied through the rolls. The sheet proceeds downstream where a pressure sensitive medium is applied to the longitudinal overlap and a protective release liner is added to the pressure sensitive medium. Material is then cut to length using flying knives. The 4″ trailing edge has a 6″ wide VP100 tape applied.
The IS panel, such as an IWS panel, is a vapor semi permeable sheathing material for wall applications. The product will act as an air and weather resistive barrier (WRB) while providing code required continuous insulation requirements. It is applied in a horizontal fashion with joints seamed as the product is installed.

Claims

1. A first insulation sheathing (IS) panel, used for construction purposes, comprising the following layers:

(i) an insulation facer layer having an outer surface and an inner surface; and

(ii) a first insulation layer having an outer surface and an inner surface;

wherein the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;

wherein, the insulation facer layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap;

wherein the extension flap of the insulation facer layer further comprises a removably attached release-liner attached to the insulation facer layer's outer surface; and

wherein the insulation facer layer does not have embossment on its outer surface.

2. A first IS panel, used for construction purposes, comprising the following layers:

(i) an insulation facer layer having an outer surface and an inner surface;

(ii) an open-celled insulation layer having an outer surface and an inner surface;

(iii) a first insulation layer having an outer surface and an inner surface; and

(iv) a WRB layer having an outer surface and an inner surface;

wherein the inner surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer, or the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;

wherein the outer surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the first insulation layer;

wherein, the insulation facer layer comprises embossment on its surface;

wherein the inner surface of the WRB layer is secured to the outer surface of the first insulation layer through an adhesive layer;

wherein the WRB layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and

wherein the extension flap of the WRB layer further comprises a removably attached release-liner attached to the extension flap portion of the WRB layer's inner surface.

3. The first IS panel, as recited in claim 2, used for construction purposes, comprising the following layers:

(i) an insulation facer layer having an outer surface and an inner surface;

(ii) a first insulation layer having an outer surface and an inner surface; and

(iii) a WRB layer having an outer surface and an inner surface;

wherein, the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;

wherein, the WRB layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and

4. The first IS panel, as recited in claim 2, used for construction purposes, comprising the following layers:

(i) an insulation facer layer having an outer surface and an inner surface;

(iv) a WRB layer having an outer surface and an inner surface;

wherein the inner surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;

wherein, the outer surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the first insulation layer;

5. A first IS panel, used for construction purposes, comprising the following layers:

(i) an insulation facer layer having an outer surface and an inner surface;

(iii) first insulation layer having an outer surface and an inner surface; and

(iv) a first WRB layer having an outer surface and an inner surface, or a water-proof intumescent coating fluid applied to the first insulation layer;

wherein the inner surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer, and if not present, the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;

wherein the insulation facer layer comprises embossment on its surface;

wherein the inner surface of the WRB layer, if present, is secured to the outer surface of the first insulation layer through an adhesive layer;

wherein, the insulation facer layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and

wherein the extension flap of the insulation facer layer further comprises a removably attached release-liner attached to the extension flap portion of the insulation facer layer's inner surface.

6. The first IS panel, as recited in claim 5, used for construction purposes, comprising the following layers:

(i) an insulation facer layer having an outer surface and an inner surface;

(iii) first insulation layer having an outer surface and an inner surface; and

(iv) a first WRB layer having an outer surface and an inner surface;

7. The first IS panel, as recited in claim 5, used for construction purposes, comprising the following layers:

(i) an insulation facer layer having an outer surface and an inner surface;

(ii) first insulation layer having an outer surface and an inner surface; and

(iii) a first WRB layer having an outer surface and an inner surface;

8. The first IS panel, as recited in claim 5, used for construction purposes, comprising the following layers:

(i) an insulation facer layer having an outer surface and an inner surface;

(ii) first insulation layer having an outer surface and an inner surface; and

(iii) a water-proof intumescent coating fluid applied to the first insulation layer;

9. The first IS panel, as recited in claim 5, used for construction purposes, comprising the following layers:

(i) an insulation facer layer having an outer surface and an inner surface;

(iii) first insulation layer having an outer surface and an inner surface; and

(iv) a water-proof intumescent coating fluid applied to the first insulation layer;

10.-16. (canceled)

17. The first IS panel as recited in claim 2, comprising a polymeric material.

18. The first IS panel as recited in claim 17, wherein the polymeric material is a thermoplastic resin that is polystyrene, polyisocyanurate, polyolefin, polyurethane foams and beads, GPS, open-celled foam, expanded polystyrene, extruded polystyrene, polyisocyanurate, and combinations thereof.

19. The first IS panel as recited in claim 2, wherein the insulation facer comprises a plastic film, a thin metal foil, a metallized polymeric film, perforated metallized polymeric film, a paper or thin cellulose, a non-woven polymeric fabric, a fiberglass scrim, or combinations of the foregoing.

20. The first IS panel as recited in claim 2, wherein the extension flap extends in length from about 0.5% of the minimum dimension of the first IS panel to about 50% of the length of the maximum dimension of the IS panel.

21. The first IS panel as recited in claim 20, wherein the adhesive on the inner surface of the insulation facer or the WRB layer that adheres to the insulation layer is the same or different as the adhesive on the extension flap having a removably attached release liner.

22. A first IS panel as recited in claim 2, wherein said IS panel is an IWS panel.

23. An insulation sheathing system comprising at least two IS panels, wherein the two panels are juxtaposed side by side in one plane, wherein each panel comprises an IS panel as recited in claim 2.

24.-28. (canceled)

29. A process for preparing a continuous insulation sheathing as recited in claim 2, comprising providing polystyrene for the insulation sheathing process, attaching the insulation facer on to the insulation sheathing, and embossing a design on the insulation facer side of the continuous insulation sheathing,

wherein the insulation facer comprises a plastic film, a thin metal foil, a metallized polymeric film, a perforated metallized polymeric film, a paper or thin cellulose, a non-woven polymeric fabric, a fiberglass scrim, and combinations of the foregoing.

30. The process as recited in claim 29, comprising a polymeric material.

31. The process as recited in claim 30, wherein the polymeric material is a thermoplastic resin comprising polystyrene, polyisocyanurate, polyolefin, or polyurethane foams and beads.

32.-33. (canceled)

34. An IS system within an exterior stucco wall construction comprising an insulation sheathing as recited in claim 2.