Insulation board with air/rain barrier covering and water-repellent covering

• US 20060019568A1
• Filed: 07/26/2004
• Published: 01/26/2006
• Est. Priority Date: 07/26/2004
• Status: Abandoned Application

• Current Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Original Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Inventors: Lembo, Michael J., Toas, Murray S., Barefoot, Stephen O.
• Application Number:
  US10/898,740
• Publication Number:
  US 20060019568A1
• Time in Patent Office: Days
• US Class Current: 442/381
• CPC Class Codes: E04B 1/80 slab-shaped
• CPC Class Codes: Y10T 428/1393 Multilayer [continuous layer]
• CPC Class Codes: Y10T 428/232 Encased layer derived from inorganic settable ingredient
• CPC Class Codes: Y10T 428/233 Foamed or expanded material encased
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 442/623 Microfiber is glass
• CPC Class Codes: Y10T 442/659 Including an additional nonwoven fabric
• CPC Class Codes: Y10T 442/674 Nonwoven fabric with a preformed polymeric film or sheet

Abstract

A product comprises: a mineral fiber insulation board which is resistant to liquid water-penetration and has first and second major surfaces, a facing material, which is resistant to air infiltration and liquid water-penetration, laminated to the first major surface of the insulation board, the facing material being permeable to water vapor, and an interior facing laminated to the second surface of the insulation board with an adhesive, so that the second major surface with the interior facing and adhesive thereon is resistant to liquid water-penetration, thereby to form a unitary building exterior envelope product.

Claims

1. A method comprising:

providing a mineral fiber insulation board which is resistant to liquid water-penetration and has first and second major surfaces;

laminating an exterior facing material to the first major surface of the insulation board, the exterior facing material resisting air infiltration and liquid water penetration, the exterior facing material being permeable to water vapor; and

bonding an interior facing to the second major surface of the insulation board with an adhesive, so that the second major surface with the interior facing and adhesive thereon is resistant to liquid water-penetration, thereby to form a section of a unitary building exterior envelope product.

2. The method of claim 1, further comprising:

mounting the section of unitary building exterior envelope product to an exterior side of a plurality of framing members of an exterior wall of a building, so that the interior facing faces the framing members; and

mounting an exterior layer from the group consisting of concrete masonry, ceramic tiles, glass, treated wood panel, siding, shingles, bricks, stucco or stone, to the framing members using a connection device that passes through the section of building envelope product, with the facing material facing the exterior layer, thereby to form the exterior wall.

3. The method of claim 2, wherein the section of unitary building exterior envelope product directly contacts the framing members, and the exterior layer directly contacts the section of unitary building exterior envelope product or faces an air space next to the section of unitary building exterior envelope product.

4. The method of claim 2, wherein the facing material includes a sealing tab on the facing material or on the first surface, the sealing tab being resistant to penetration by liquid water the method further comprising:

mounting a second section of the unitary building exterior envelope product to the exterior side of a plurality of framing members of an exterior wall, with the facing material facing the framing members; and

attaching the sealing tab of the first section of unitary building exterior envelope product to the second section of unitary building exterior envelope product, to form a seal between the first and second sections of unitary building exterior envelope product without applying a separate building wrap or sealing tape.

5. The method of claim 4, wherein the tab has a pressure sensitive adhesive or a double sided adhesive tape thereon.

6. The method of claim 4, wherein the mineral fiber insulation boards of the first and second sections each includes a male and female shiplap edge, the method further comprising joining the male edge of the first section to the female edge of the second section, or joining the male edge of the second section to the female edge of the first section.

7. The method of claim 1, wherein:

the mineral fiber insulation board comprises glass fibers and a binder having a hydrophobic agent therein;

the facing material comprises one of the group consisting of a polymer film, a coextruded polymer film, a polymer film laminate, a nonwoven mat, a coated nonwoven or woven material, a polymer film/nonwoven laminate, a woven polymer film, a woven polymer laminated to a solid polymer film, a polymer film/woven glass laminate, a bituminous coated paper or perforated film, a reflective film or foil that is perforated to permit the passage of water vapor, or a spray applied liquid coating; and

the interior facing is a glass and/or polymer fabric.

8. The method of claim 1, wherein the interior facing is laminated to the second surface, or the fabric is treated to make the fabric resistant to liquid water-penetration during a manufacturing process of the board.

9. The method of claim 1, wherein the exterior facing material has a reflective surface that reflects radiant energy.

10. The method of claim 1, further comprising joining a fire resistant material over the interior facing.

11. The method of claim 1, wherein the exterior facing has a plurality of periodically spaced lines thereon, the method further comprising using the periodically spaced lines as guide marks for placement of fasteners to mount the unitary building exterior envelope product to a framing member.

12. A product comprising:

a mineral fiber insulation board which is resistant to liquid water-penetration and has first and second major surfaces;

an exterior facing material, which resists air infiltration and liquid water penetration, laminated to the first major surface of the insulation board, the facing material being permeable to water vapor; and

an interior facing laminated to the second major surface of the insulation board with an adhesive, so that the second major surface with the interior facing and adhesive thereon is resistant to liquid water-penetration, thereby to form a unitary building exterior envelope product.

13. The product of claim 12, wherein the mineral fiber insulation board comprises glass fibers or stone wool fibers.

14. The product of claim 12, wherein the facing material comprises one of the group consisting of a polymer film, a coextruded polymer film, a polymer film laminate, a nonwoven mat, a coated nonwoven or woven material, a polymer film/nonwoven laminate, a woven polymer film, a woven polymer laminated to a solid polymer film, a polymer film/woven glass laminate, a bituminous coated paper or film, a reflective film or foil that is perforated to permit the passage of water vapor, or a spray applied liquid coating.

15. The product of claim 12, wherein the interior facing is a glass and/or a polymer fabric.

16. The product of claim 12, wherein the facing material includes a sealing tab, and wherein a double-sided tape is adhered to an inside surface of said sealing tab.

17. The product of claim 12, wherein the mineral fiber insulation board includes a male and female shiplap edge.

18. The product of claim 12, wherein:

the mineral fiber insulation board comprises glass fibers or stone wool fibers;

the facing material comprises one of the group consisting of a polymer film, a coextruded polymer film, a polymer film laminate, a nonwoven mat, a coated nonwoven or woven material, a polymer film/nonwoven laminate, a woven polymer film, a woven polymer laminated to a solid polymer film, a polymer film/woven glass laminate, a bituminous coated paper or film, a reflective film or foil that is perforated to permit the passage of water vapor, or a spray applied liquid coating;

the facing material includes a sealing tab, and wherein a double-sided tape is adhered to an inside surface of said sealing tab; and

the mineral fiber insulation board includes a male and female shiplap edge.

19. The product of claim 12, further comprising a fire resistant material over the interior facing.

20. The product of claim 12, wherein the exterior facing has a plurality of periodically spaced lines thereon.

21. A product comprising:

a mineral fiber insulation board which is resistant to liquid water-penetration and has first and second major surfaces;

a facing material, which resists air infiltration and liquid water penetration, laminated to the first surface of the insulation board, the facing material being permeable to water vapor; and

a vapor retarder laminated to the second surface of the insulation board to form a unitary building exterior envelope product.

22. An exterior building wall, comprising:

a plurality of framing members;

a layer of a unitary building envelope material mounted on an exterior side of the framing members, including;

a mineral fiber insulation board which is resistant to liquid water-penetration and has interior and exterior major surfaces;

an exterior facing material, which is resistant to air infiltration and liquid water penetration, laminated to the exterior major surface of the insulation board, the exterior facing material being permeable to water vapor; and

an interior facinglaminated to the interior major surface of the insulation board with an adhesive, so that the second major surface with the interior facing and adhesive thereon is resistant to liquid water-penetration, thereby, the interior major surface facing the framing members; and

an exterior layer from the group consisting of concrete masonry, ceramic tiles, glass, treated wood panel, siding, shingles, bricks, stucco or stone, connected to the framing members using a connection device that passes through the section of building envelope product, with the exterior facing material facing the exterior layer.

23. The wall of claim 22, wherein the mineral fiber insulation board comprises one of the group consisting of glass fibers, stone wool fibers, organic fibers and ceramic fibers.

24. The wall of claim 22, wherein the exterior facing material comprises one of the group consisting of a polymer film, a coextruded polymer film, a polymer film laminate, a nonwoven mat, a coated nonwoven or woven material, a polymer film/nonwoven laminate, a woven polymer film, a woven polymer laminated to a solid polymer film, a polymer film/woven glass laminate, a bituminous coated paper or film, a reflective film or foil, that is perforated to permit the passage of water vapor, or a spray applied liquid coating.

25. The wall of claim 22, wherein the exterior facing material includes a sealing tab, and wherein a double-sided tape is adhered to an inside surface of said sealing tab.

26. The wall of claim 22, wherein the mineral fiber insulation board includes a male and female shiplap edge.

27. The wall of claim 22, wherein the exterior facing has a plurality of periodically spaced lines thereon, and the building envelope material is mounted on the exterior side of the framing members with fasteners that pass through the lines.

28. The wall of claim 22, further comprising a layer of gypsum between the framing members and the layer of a unitary building envelope material.