Polymer-based composite structural sheathing board and wall and/or ceiling system

• US 7,765,761 B2
• Filed: 09/22/2006
• Issued: 08/03/2010
• Est. Priority Date: 09/22/2006
• Status: Active Grant

• Current Assignee: Johns Manville Corporation (Berkshire Hathaway Incorporated)
• Original Assignee: Johns Manville Corporation (Berkshire Hathaway Incorporated)
• Inventors: Paradis, Duane R.
• Primary Examiner(s): Glessner; Brian E
• Assistant Examiner(s): Buckle, Jr.; James J
• Application Number:
  US11/525,746
• Publication Number:
  US 20080120932A1
• Time in Patent Office: 1,411 Days
• Field of Search: 524/08, 524/031, 523/09, 527/471, 523091-3095, 523098-3099, 5230911-30912, 523/091.4, 523/091.7, 524/03, 524/74, 527/821, 527/961, 428/316.6, 428/319.3, 428/319.7
• US Class Current: 52/474
• CPC Class Codes: E04C 2/243 one at least of the material being insulating
• CPC Class Codes: E04C 2/296 composed of insulating material and non-metallic or unspecified sheet-material E04C2/288 takes precedence
• CPC Class Codes: E04C 2/38 with attached ribs, flanges, or the like, e.g. framed panels concerned with attaching to other panels or elements to form a structure, see the places for the relevant structure, e.g. E04B2/00
• CPC Class Codes: E04F 13/18 of organic plastics with or without reinforcements or filling materials of plastic-bound fibres or chips E04F13/16 or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles E04F13/0864 takes precedence
• CPC Class Codes: Y10T 428/249981 Plural void-containing components
• CPC Class Codes: Y10T 428/249991 Synthetic resin or natural rubbers
• CPC Class Codes: Y10T 428/249992 Linear or thermoplastic
• CPC Class Codes: Y10T 442/191 Inorganic fiber-containing scrim
• CPC Class Codes: Y10T 442/60 Nonwoven fabric [i.e., nonwoven strand or fiber material]

Abstract

A wall and/or ceiling polymer-based composite structural sheathing board has a polymer material or predominantly polymer material core layer with a density between 1.6 lbs/ft³ and 25 lbs/ft³. A facer overlays at least one of the major surfaces of the core layer. The facer is generally coextensive with and bonded to the overlaid major surface of the core layer and enhances the integrity and fastener pull through strength of the polymer-based composite structural sheathing board as well as other desired physical and performance characteristics of the polymer based composite structural sheathing board. A wall and/or ceiling system of a building structure includes a plurality of the polymer-based composite structural sheathing boards overlaying and secured to a structural wall and/or ceiling frame and forming a wall and/or ceiling sheathing layer over the structural frame.

Claims

1. A polymer-based composite structural sheathing board for use in the formation of a building wall and/or ceiling system by overlaying and being secured to a structural building wall and/or ceiling frame, comprising:

a polymer material or predominantly polymer material core layer with a density between 1.6 lbs/ft³ and 25 lbs/ft³;

the core layer having a length, a width, and a thickness;

the core layer having a first major surface and a second major surface that are each defined by the length and the width of the core layer;

at least one of the major surfaces of the core layer being overlaid by a facer that reinforces, stabilizes, and strengthens the polymer-based composite structural sheathing board and that is generally coextensive with and bonded to the overlaid major surface of the core layer;

wherein the polymer-based composite structural sheathing board has a compressive strength of at least 25 psi, a flexural strength (MOR) of at least 400 psi, a flexural strength (load at yield) of at least 20 lbf, and a fastener pull through strength of at least 20 lbf.

2. The structural sheathing board according to claim 1, wherein:

the facer is a nonwoven fiberglass scrim or mat.

3. The structural sheathing board according to claim 1, wherein:

the core layer is a predominantly polymer material core layer;

the thickness of the core layer is between about 0.15 inches and about 0.75 inches; and

the polymer material of the core layer is a polyisocyanurate material.

4. The structural sheathing board according to claim 3, wherein:

the predominantly polymer material core layer contains between 1% and 40% by weight inorganic and/or organic filler material.

5. The structural sheathing board according to claim 3, wherein:

the first and second major surfaces of the core layer are each overlaid by a facer that reinforces, stabilizes, and strengthens the polymer-based composite structural sheathing board and that is generally coextensive with and bonded to the overlaid major surface of the core layer.

6. The structural sheathing board according to claim 3, wherein:

the polymer-based composite structural sheathing board has a water absorption rate of 4% by volume or less.

7. The structural sheathing board according to claim 1, wherein:

the core layer is a predominantly polymer foam material core layer;

the thickness of the core layer is between about 0.15 inches and about 0.75 inches; and

the polymer material of the core layer is a polyisocyanurate material.

8. The structural sheathing board according to claim 7, wherein:

the predominantly polymer foam material core layer contains between 1% and 40% by weight inorganic and/or organic filler material.

9. The structural sheathing board according to claim 7, wherein:

the first and second major surfaces of the core layer are each overlaid by a facer that reinforces, stabilizes, and strengthens the polymer-based composite structural sheathing board and that is generally coextensive with and bonded to the overlaid major surface of the core layer.

10. The structural sheathing board according to claim 7, wherein:

the polymer-based composite structural sheathing board has a water absorption rate of 4% by volume or less.

11. A wall and/or ceiling system of a building structure, comprising:

a plurality of polymer-based composite structural sheathing boards overlaying and secured to a structural wall and/or ceiling frame;

each of the polymer-based composite structural sheathing boards having a polymer material or predominantly polymer material core layer with a density between 1.6 lbs/ft³ and 25 lbs/ft³;

the core layer of each of the polymer-based composite structural sheathing boards having a length, a width, and a thickness;

the core layer of each of the polymer-based composite structural sheathing boards having a first major surface and a second major surface that are each defined by the length and the width of the core layer with at least one of the major surfaces being overlaid by a facer that is generally coextensive with and bonded to the overlaid major surface; and

the polymer-based composite structural sheathing boards forming a wall and/or ceiling sheathing layer;

wherein each of the polymer-based composite structural sheathing boards has a compressive strength of at least 25 psi, a flexural strength (MOR) of at least 400 psi, a flexural strength (load at yield) of at least 20 lbf, and a fastener pull through strength of at least 20 lbf.

12. The wall and/or ceiling system of a building structure according to claim 11, wherein:

the first and second major surfaces of the core layer of each of the polymer-based composite structural sheathing boards are each overlaid by a facer that reinforces, stabilizes, and strengthens the polymer-based composite structural sheathing board and that is generally coextensive with and bonded to the overlaid major surface of the core layer of the polymer-based composite structural sheathing board.

13. The wall and/or ceiling system of a building structure according to claim 12, wherein:

the facers of each of the polymer-based composite structural sheathing boards are nonwoven fiberglass mat or fiberglass scrim facers.

14. The wall and/or ceiling system of a building structure according to claim 12, wherein:

the facers of each of the polymer-based composite structural sheathing boards are uncoated nonwoven fiberglass mat or fiberglass scrim facers.

15. The wall and/or ceiling system of a building structure according to claim 11, wherein:

the thickness of the core layer of each of the polymer-based composite structural sheathing boards is between about 0.25 inches and about 0.75 inches; and

the core layer of each of the polymer-based composite structural sheathing boards is a polyisocyanurate polymer material or predominantly polyisocyanurate polymer material core layer.

16. The wall and/or ceiling system of a building structure according to claim 15, wherein:

the core layer of each of the polymer-based composite structural sheathing boards is a predominantly polyisocyanurate polymer material core layer that contains between 1% and 40% by weight inorganic and/or organic filler material.

17. The wall and/or ceiling system of a building structure according to claim 16, wherein:

the filler material includes fibrous fillers.

18. The wall and/or ceiling system of a building structure according to claim 16, wherein:

each of the polymer-based composite structural sheathing boards has a water absorption rate of 4% by volume or less.

19. The wall and/or ceiling system of a building structure according to claim 11, wherein:

the thickness of the core layer of each of the polymer-based composite structural sheathing boards is between about 0.25 inches and about 0.75 inches; and

the core layer of each of the polymer-based composite structural sheathing boards is a predominantly polyisocyanurate polymer material foam core layer.

20. The wall and/or ceiling system of a building structure according to claim 19, wherein:

the foam core layer of each of the polymer-based composite structural sheathing boards contains between 1% and 40% by weight inorganic and/or organic filler material.

21. The wall and/or ceiling system of a building structure according to claim 20, wherein:

the filler material includes fibrous fillers.

22. A wall system of a building structure, comprising:

a plurality of polymer-based composite structural sheathing boards overlaying and secured to a structural wall frame;

each of the polymer-based composite structural sheathing boards having a polymer material or predominantly polymer material core layer with a density between 1.6 lbs/ft³ and 25 lbs/ft³;

the core layer of each of the polymer-based composite structural sheathing boards having a length, a width, and a thickness;

the core layer of each of the polymer-based composite structural sheathing boards having a first major surface and a second major surface that are each defined by the length and the width of the core layer with at least one of the major surfaces being overlaid by a facer that is generally coextensive with and bonded to the overlaid major surface; and

the polymer-based composite structural sheathing boards forming a structural wall sheathing layer;

wherein each of the polymer-based composite structural sheathing boards has a compressive strength of at least 25 psi, a flexural strength (MOR) of at least 400 psi, a flexural strength (load at yield) of at least 20 lbf, and a fastener pull through strength of at least 20 lbf.

23. The wall system of a building structure according to claim 22, wherein:

the first and second major surfaces of the core layer of each of the polymer-based composite structural sheathing boards are each overlaid by a facer that reinforces, stabilizes, and strengthens the polymer-based composite structural sheathing board and that is generally coextensive with and bonded to the overlaid major surface of the core layer of the polymer-based composite structural sheathing board.

24. The wall system of a building structure according to claim 23, wherein:

the wall is an exterior building wall and the structural wall sheathing layer is on an interior side of the structural wall frame.

25. The wall system of a building structure according to claim 23, wherein:

the wall is an exterior building wall and the structural sheathing layer is on an exterior side of the structural wall frame.

26. The wall system of a building structure according to claim 23, wherein:

the thickness of the core layer of each of the polymer-based composite structural sheathing boards is between about 0.25 inches and about 0.75 inches; and

the core layer of each of the polymer-based composite structural sheathing boards is a predominantly polyisocyanurate polymer material core layer.

27. The wall system of a building structure according to claim 26, wherein:

the core layer of each of the polymer-based composite structural sheathing boards contains between 1% and 40% by weight inorganic and/or organic filler material.

28. The wall system of a building structure according to claim 27, wherein:

the filler material includes fibrous fillers.

29. A polymer-based composite structural sheathing board for use in the formation of a building wall and/or ceiling system by overlaying and being secured to a structural building wall and/or ceiling frame, comprising:

a polymer material or predominantly polymer material foam insulation core layer;

a first polymer material or predominately polymer material solid or foam reinforcement layer having a higher density than the insulation core layer;

the insulation core layer and the first reinforcement layer each having a length, a width, and a thickness;

the insulation core layer and the first reinforcement layer each having a first major surface and a second major surface that are defined by the length and the width of the insulation core layer and the first reinforcement layer respectively; and

a reinforcement sheet located between the insulation core layer and the first reinforcement layer that reinforces, stabilizes, and strengthens the polymer-based composite structural sheathing board and is generally coextensive with and bonded to the major surfaces of the insulation core layer and the first reinforcement layer overlaid by the reinforcement sheet;

wherein the polymer-based composite structural sheathing board has a compressive strength of at least 25 psi, a flexural strength (MOR) of at least 400 psi, a flexural strength (load at yield) of at least 20 lbf, and a fastener pull through strength of at least 20 lbf.

30. The structural sheathing board according to claim 29, including:

a second polymer material or predominately polymer material solid or foam reinforcement layer having a higher density than the insulation core layer;

the second reinforcement layer having a length, a width, and a thickness;

the second reinforcement layer having a first major surface and a second major surface that are defined by the length and the width of the second reinforcement layer; and

a second reinforcement sheet located between the insulation core layer and the second reinforcement layer that reinforces, stabilizes, and strengthens the polymer-based composite structural sheathing board and is generally coextensive with and bonded to the major surfaces of the insulation core layer and the second reinforcement layer overlaid by the second reinforcement sheet.

31. A wall and/or ceiling system of a building structure, comprising:

a plurality of polymer-based composite structural sheathing boards overlaying and secured to a structural wall and/or ceiling frame;

each of the polymer-based composite structural sheathing boards having a polymer material or predominantly polymer material foam insulation core layer;

a first polymer material or predominately polymer material solid or foam reinforcement layer having a higher density than the insulation core layer;

the insulation core layer and the first reinforcement layer each having a length, a width, and a thickness;

the insulation core layer and the first reinforcement layer each having a first major surface and a second major surface that are defined by the length and the width of the insulation core layer and the first reinforcement layer respectively; and

a reinforcement sheet located between the insulation core layer and the first reinforcement layer that reinforces, stabilizes, and strengthens the polymer-based composite structural sheathing board and is generally coextensive with and bonded to the major surfaces of the insulation core layer and the first reinforcement layer overlaid by the reinforcement sheet, wherein the polymer-based composite structural sheathing boards have a compressive strength of at least 25 psi, a flexural strength (MOR) of at least 400 psi, a flexural strength (load at yield) of at least 20 lbf, and a fastener pull through strength of at least 20 lbf; and

the polymer-based composite structural sheathing boards forming a wall and/or ceiling sheathing layer.

32. The wall and/or ceiling system of a building structure according to claim 31, wherein:

each of the plurality of polymer-based composite structural sheathing boards has a second polymer material or predominately polymer material solid or foam reinforcement layer having a higher density than the insulation core layer;

the second reinforcement layer having a length, a width, and a thickness;

the second reinforcement layer having a first major surface and a second major surface that are defined by the length and the width of the second reinforcement layer; and

a second reinforcement sheet located between the insulation core layer and the second reinforcement layer that reinforces, stabilizes, and strengthens the polymer-based composite structural sheathing board and is generally coextensive with and bonded to the major surfaces of the insulation core layer and the second reinforcement layer overlaid by the second reinforcement sheet.