Structural boards having integrated water drainage channels

• US 20090113838A1
• Filed: 10/31/2008
• Published: 05/07/2009
• Est. Priority Date: 11/02/2007
• Status: Abandoned Application

• Current Assignee: Fritz G. Paulsen, John D. Benson
• Original Assignee: Fritz G. Paulsen, John D. Benson
• Inventors: Benson, John D., Paulsen, Fritz G.
• Application Number:
  US12/290,530
• Publication Number:
  US 20090113838A1
• Time in Patent Office: Days
• US Class Current: 52/653.100
• CPC Class Codes: B32B 13/08 of paper or cardboard
• CPC Class Codes: B32B 13/12 of synthetic resin
• CPC Class Codes: B32B 13/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 21/02 the layer being formed of fibres, chips, or particles , e.g. MDF, HDF, OSB, chipboard, particle board, hardboard
• CPC Class Codes: B32B 21/06 of paper or cardboard
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B32B 21/10 Next to a fibrous or filamentary layer
• CPC Class Codes: B32B 21/14 comprising wood board or veneer
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• CPC Class Codes: B32B 2260/028 Paper layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2270/00 Resin or rubber layer containing a blend of at least two different polymers
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2307/73 Hydrophobic
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 comprising polyamides
• CPC Class Codes: B32B 3/263 characterised by a layer having non-uniform thickness
• CPC Class Codes: B32B 3/30 characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 7/05 : the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14
• CPC Class Codes: B32B 9/002 : comprising natural stone or artificial stone
• CPC Class Codes: Y10T 428/24802 : Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• CPC Class Codes: Y10T 428/24934 : including paper layer

Abstract

A water resistant structural board suitable for use in a wall system is disclosed. The structural board has water drainage channels on at least one of its surfaces to drain any water trapped behind the sealed wall system. The water drainage channels may be imparted into the structural board during or applied subsequent to a board production process, and the produced board is shipped to the construction site for a wall installation. When desired, the channeled surface of the structural board may be laminated, coated, or sprayed with a water resistant layer to further enhance the water resistant property of the board. A wall system including the disclosed structural board does not require a layer-by-layer installation of a component having water resistant property and a component having water drainage channel structure at a work site; therefore, labor cost and installation time may be reduced significantly. Examples of structural boards are oriented strand board, plywood, particle board, oriented strand lumber, dimensional lumber, fiberboard, wafer board, chipboard, laminated veneer lumber, and any substantially equivalent wood composite board known in art.

Claims

1. A structural board, comprising:

a. a top edge;

b. a bottom edge; and

c. two opposite outer surfaces, wherein at least one of the outer surfaces has water drainage channels.

2. The board of claim 1, comprising a member selected from the group consisting of oriented strand board, plywood, particle board, oriented strand lumber, dimensional lumber, fiberboard, wafer board, chipboard, laminated veneer lumber, composite board, and combinations thereof.

3. The board of claim 1, wherein the water drainage channel comprises horizontal channels, vertical channels, cross-diagonal channels, non-patterned or patterned textures, and combinations thereof.

4. The board of claim 1, further comprising a water resistant layer sprayed, coated or laminated on the outer surface of the board having the water drainage channels.

5. The board of claim 4, wherein the laminated water resistant layer comprises a member selected from the group consisting of kraft paper, extensible kraft paper, cellulose-based paper, asphalt paper, non-woven fabric, woven fabric, spun-bond or melt-blown thermoplastic material, polyethylene, nylon, polypropylene, emulsified or solvent-based coatings or sprays and combinations thereof.

6. The board of claim 4, wherein the water resistant layer comprises an extensible kraft paper.

7. The board of claim 4, wherein the water resistant layer comprises a thermoplastic resin.

8. The board of claim 4, wherein the water resistant layer comprises a thermoset resin.

9. The board of claim 4, wherein the water resistant layer comprises a material selected from the group consisting of phenolic resin, epoxy resin, rosin-based resin, melamine resin, isocyanate resins, tie-layer thermoplastic, hot melt adhesive, polymeric emulsion-based coatings, and combinations thereof.

10. A wall system including:

(a) a wall frame;

(b) a water resistant structural board of claim 1; and

(c) an exterior finish.

11. The wall system of claim 10 further including an insulation board.

12. The wall system of claim 10 wherein the exterior finish comprises a material selected from the group consisting of concrete block, brick, natural stone, man-made stone, wooden siding, wood-appearing concrete and fiber lap siding, stucco, stucco-look finish, stucco-look finish applied directly over the exterior finish systems, vinyl or aluminum siding, and combinations thereof.

13. A wall system including:

(a) a wall frame;

(b) a water resistant structural board of claim 4;

(c) an exterior finish.

14. The wall system of claim 13, further including an insulation board.

15. The wall system of claim 13,wherein the exterior finish comprises a material selected from the group consisting of concrete block, brick, natural stone, man-made stone, wooden siding, wood-appearing concrete and fiber lap siding, stucco, stucco-look finish, the stucco-look finish applied directly over the exterior finish systems, vinyl or aluminum siding, and combinations thereof.