Composite insulating building panel and system and method for attaching building panels

• US 8,635,828 B2
• Filed: 01/13/2011
• Issued: 01/28/2014
• Est. Priority Date: 01/13/2010
• Status: Active Grant

• Current Assignee: Pacific Insulated Panel, LLC
• Original Assignee: Pacific Insulated Panel, LLC
• Inventors: Bahnmiller, Jeffrey A.
• Primary Examiner(s): Gilbert, William
• Assistant Examiner(s): FERENCE, JAMES M
• Application Number:
  US13/005,664
• Publication Number:
  US 20110197530A1
• Time in Patent Office: 1,111 Days
• Field of Search: 523/094, 527/62, 524/08, 523/098, 523/099, 523/091.1, 524/74, 524/831, 524/891, 524/892, 524/12, 524/13
• US Class Current: 52/489.1
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 15/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 15/18 comprising iron or steel B32B15/011, B32B15/012 and B32B15/013 take precedence
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2255/06 on metal layer
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/205 Metallic coating
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2262/10 Inorganic fibres layered products comprising a layer of natural mineral fibres B32B19/00
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2266/0228 Aromatic vinyl resin, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 2266/0235 Vinyl halide, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 2266/0278 Polyurethane
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2307/581 Resistant to cut
• CPC Class Codes: B32B 2307/7246 Water vapor barrier
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2419/00 : Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2607/00 : Walls, panels
• CPC Class Codes: B32B 27/12 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/302 : comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
• CPC Class Codes: B32B 27/304 : comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/40 : comprising polyurethanes
• CPC Class Codes: B32B 29/007 : next to a foam layer
• CPC Class Codes: B32B 29/02 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/14 : characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
• CPC Class Codes: B32B 5/18 : characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/245 : another layer next to it being a foam layer
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E04B 1/74 : Heat, sound or noise insulation, absorption, or reflection forms of, or arrangements in, rooms for influencing or directing sound E04B1/99; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls fire protection E04B1/94; elements chiefly adapted for structural purposes E04C1/00 - E04C3/00; chiefly adapted for surface coverings E04F13/00; as underlayers for floor coverings E04F15/18; closures for wall or like openings E06B
• CPC Class Codes: E04B 1/765 : Bottom edge finishing profile
• CPC Class Codes: E04B 1/80 : slab-shaped
• CPC Class Codes: E04C 2/205 : of foamed plastics, or of plastics and foamed plastics, optionally reinforced
• CPC Class Codes: E04C 2/243 : one at least of the material being insulating
• CPC Class Codes: E04D 3/358 : with at least one of the layers being offset with respect to another layer
• CPC Class Codes: E04H 5/10 : Buildings forming part of cooling plants
• CPC Class Codes: Y10T 428/24355 : Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/24785 : including layer embodying mechanically interengaged strands, strand portions or strand-like strips [e.g., weave, knit, etc.]
• CPC Class Codes: Y10T 442/3195 : Three-dimensional weave [e.g., x-y-z planes, multi-planar warps and/or wefts, etc.]
• CPC Class Codes: Y10T 442/3325 : Including a foamed layer or component
• CPC Class Codes: Y10T 442/3333 : Including a free metal or alloy constituent
• CPC Class Codes: Y10T 442/335 : Plural fabric layers

Abstract

An insulation panel includes a foam core with a reinforced and vapor-impervious facing disposed on one or both sides of the core. A portion of the facing extends beyond the core and has an adhesive so that the overhanging portion can be secured to an abutting panel to cover a seam between the abutting panels. A fixture for forming the panel includes two heated platens, preferably provided with a textured surface, held apart by a spacer and between which the facing is mechanically suspended. An installation of the insulation panel includes panel-securing elements attached to frame elements of the building and including first and second flanges spaced apart by the thickness of the panel. A portion of the insulation panel is disposed between the first and second flanges, the first flange is secured to the frame element, and a cover panel disposed over the insulation panel is secured to the second flange.

Claims

1. A cladding assembly for a wall or roof of a building, comprising:

a frame element;

a panel-securing element comprising a first flange, a second flange, and a web securing the first flange with respect to the second flange in a spaced-apart configuration, wherein the first flange is secured to said frame element to attach said panel-securing element to said frame element;

a plurality of insulation panels, each of said plurality of insulation panels having opposed faces defining a thickness therebetween and a first edge abutting or facing against said web of said panel-securing element with said second flange of said panel-securing element disposed over a peripheral portion of one of said opposed faces, wherein a spacing between said first and second flanges of said panel-securing element is at least as large as the thickness of said insulation panel;

each of said plurality of insulation panels comprises a multi-layer facing material forming at least one of said opposed faces;

said facing material includes an overhanging portion extending beyond a second edge of each of said insulation panels and an adhesive material on one side of said overhanging portion to temporarily secure each of said insulation panels adjacent to one another during installation and to form an air, thermal and moisture barrier between each of said adjacent insulation panels; and

a steel cover panel disposed over said insulation panels, wherein each of said cover panels is attached by panel fasteners to said second flange of said panel-securing element to secure said cover panels with respect to said frame element.

2. The cladding assembly of claim 1, wherein said facing material further comprises:

a vapor impervious skin, and

a reinforcing layer, and

wherein each of said insulation panels further comprises a foam core adhered to said facing material.

3. The cladding assembly of claim 2, wherein said facing material further comprises a backing secured to one side of said skin by an adhesive with said reinforcing layer disposed between said skin and said backing.

4. The cladding assembly of claim 2, wherein said reinforcing layer comprises a fiber mesh.

5. The cladding assembly of claim 1, wherein at least one of said opposed faces includes a texture imparted into the surface thereof.

6. The cladding assembly of claim 1, wherein said first and second flanges of said panel-securing element are parallel to one another.

7. The cladding assembly of claim 6, wherein said first and second flanges of said panel-securing element are generally perpendicular to said web and extend in the same direction from said web.

8. The cladding assembly of claim 6, wherein said first flange has a larger dimension in a direction perpendicular to said web than said second flange.

9. The cladding assembly of claim 6, wherein said first and second flanges of said panel-securing element are generally perpendicular to said web and extend in opposite directions from said web.

10. The cladding assembly of claim 1, wherein said panel-securing element is formed from galvanized steel and has a thickness of 10 to 18 gauge.

11. The cladding assembly of claim 1, wherein said panel-securing element is secured to said frame element by screws.

12. The cladding assembly of claim 1, wherein said frame element comprises a girt or a perlin.

13. The cladding assembly of claim 1, wherein each of said cover panels disposed over said insulation panels overlaps an adjacent one of said cover panels and is secured to said second flange of said panel-securing element.

14. The cladding assembly of claim 1, further comprising a thermal isolation material disposed between said cover panels and said second flange of said panel-securing element.

15. The cladding assembly of claim 1, wherein said panel fasteners are screws.

16. The cladding assembly of claim 1, wherein said frame element comprises an eave strut at a transition between the roof and the wall of the building, and wherein said panel-securing element extends beyond the eave strut by a distance corresponding to the thickness of an insulation panel of the wall.