Insulated reinforced foam sheathing, reinforced vapor permeable air barrier foam panel and method of making and using same

• US 9,366,023 B2
• Filed: 02/23/2015
• Issued: 06/14/2016
• Est. Priority Date: 03/28/2014
• Status: Active Grant

• Current Assignee: Romeo Ilarian Ciuperca
• Original Assignee: Romeo Ilarian Ciuperca
• Inventors: Ciuperca, Romeo Ilarian
• Primary Examiner(s): KATCHEVES, BASIL S
• Application Number:
  US14/628,805
• Publication Number:
  US 20150275509A1
• Time in Patent Office: 477 Days
• Field of Search: 524/053, 524/071, 523/091.2, 523/091.7
• US Class Current: 1/1
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2305/38 Meshes, lattices or nets
• CPC Class Codes: B32B 2307/724 Permeability to gases, adsorption
• CPC Class Codes: B32B 2307/73 Hydrophobic
• CPC Class Codes: B32B 2325/00 Polymers of vinyl-aromatic compounds, e.g. polystyrene
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 27/40 comprising polyurethanes
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: E04B 1/625 Sheets or foils allowing passage of water vapor but impervious to liquid water; house wraps
• CPC Class Codes: E04B 1/70 Drying or keeping dry, e.g. by air vents using damp-proof courses E04B1/644; using sealings, e.g. sealing masses or foils, E04B1/66; during erection E04G21/28
• CPC Class Codes: E04B 1/7608 comprising a prefabricated insulating layer, disposed between two other layers or panels
• CPC Class Codes: E04B 1/762 Exterior insulation of exterior walls
• CPC Class Codes: E04B 1/7629 Details of the mechanical connection of the insulation to the wall
• CPC Class Codes: E04B 1/78 Heat insulating elements E04B1/7662 takes precedence
• CPC Class Codes: E04B 1/80 slab-shaped
• CPC Class Codes: E04B 2/56 Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members E04B2/74, E04B2/88 take precedence; pillars E04C3/30
• CPC Class Codes: E04B 2/58 with elongated members of metal
• CPC Class Codes: E04B 2/70 with elongated members of wood
• CPC Class Codes: E04B 2/707 obturation by means of panels
• CPC Class Codes: E04B 2002/565 with a brick veneer facing
• CPC Class Codes: E04C 2/296 : composed of insulating material and non-metallic or unspecified sheet-material E04C2/288 takes precedence
• CPC Class Codes: E04F 13/042 : Joint tapes
• CPC Class Codes: E04F 13/045 : Means for fastening plaster-bases to a supporting structure
• CPC Class Codes: E04F 13/047 : Plaster carrying meshes
• CPC Class Codes: E04F 13/142 : with an outer layer of ceramics or clays
• CPC Class Codes: F16B 15/0046 : from the body of the plate
• CPC Class Codes: F16B 43/00 : Washers or equivalent devices; Other devices for supporting bolt-heads or nuts circlips F16B21/18; for indicating tensile load F16B31/02; forming a whole with the bolt or nut F16B33/00; locking bolts or nuts by means of a fixed plate or ring, or washer-like resilient plates F16B39/10, F16B39/24
• CPC Class Codes: Y02A 30/00 : Adapting or protecting infrastructure or their operation
• CPC Class Codes: Y02B 30/90 : Passive houses; Double facade technology

Abstract

The invention comprises a product. The product comprises a composite panel comprising a foam insulating panel having a first primary surface and an opposite second primary surface, and a first layer of a polymeric elastomeric material on the first primary surface such that at least a portion of a first layer of reinforcing material is at least partially embedded in the polymeric elastomeric material. The composite panel also comprises a fastener for attaching the composite panel to a framing structure, wherein the fastener comprises a washer and wherein at least a portion of the first layer of a polymeric elastomeric material and the first layer of reinforcing material are disposed between the washer and the first primary surface. A method of making and using the composite panel is also disclosed.

Claims

1. A method of insulating a framing structure comprising:

attaching a composite panel to the framing structure, the composite panel consisting essentially of;

a foam insulating panel having a first primary surface and an opposite second primary surface, wherein the first primary surface defines a single plane;

a first layer of a water-resistant, vapor permeable polymeric elastomeric adhesive material substantially covering the single plane of the first primary surface, wherein the first layer of water-resistant, vapor permeable polymeric elastomeric adhesive material has an elongation factor of approximately 100% to approximately 1,000%, a water vapor transmission rating of at least 1 perm and an air permeance of less than 0.004 cfm/sq. ft. under a pressure differential of 0.3 inches of water, whereby the first layer of water-resistant, vapor permeable polymeric adhesive material provides a water-resistant, vapor permeable air barrier; and

a first layer of porous reinforcing material defining a single plane disposed on the single plane of the first primary surface of the foam insulating panel, wherein the first layer of porous reinforcing material is at least partially embedded in the first layer of water-resistant, vapor permeable polymeric elastomeric adhesive material.

2. The method of insulating a wall structure of claim 1 further comprising a layer of wood or plywood disposed between the composite panel and the framing structure.

3. The method of insulating a framing structure of claim 1 further comprising a second layer of water-resistant, vapor permeable polymeric elastomeric adhesive material on the second primary surface such that at least a portion of a second layer of porous reinforcing material is at least partially embedded in the second layer of water-resistant, vapor permeable polymeric elastomeric adhesive material.

4. The method of insulating a framing structure of claim 1 further comprising a layer of cementitious material on the first layer of porous reinforcing material.

5. The method of insulating a framing structure of claim 4 further comprising a layer of exterior cladding material attached to the layer of cementitious material.

6. The method of insulating a framing structure of claim 5, wherein the exterior cladding material comprises brick, thin brick, stone, tile, marble, plaster, stucco, cement board, cement siding, wood siding, composite siding, vinyl siding, or aluminum siding.

7. The method of insulating a framing structure of claim 1 further comprising a layer of exterior cladding material attached to the first layer of porous reinforcing material.

8. The method of insulating a framing structure of claim 1, wherein the first layer of porous reinforcing material is a woven fabric.

9. The method of insulating a framing structure of claim 1, wherein the first layer of porous reinforcing material is a nonwoven material.

10. The method of insulating a framing structure of claim 1, wherein the first layer of porous reinforcing material is a fiberglass fabric, matt, web or mesh.

11. The method of insulating a framing structure of claim 1, wherein the first layer of porous reinforcing material is a fiberglass mesh.

12. The method of insulating a wall structure of claim 1, wherein the first layer of a water-resistant, vapor permeable polymeric elastomeric adhesive material has a water vapor transmission rating of at least 5 perm.

13. The method of insulating a wall structure of claim 1, wherein the first layer of a water-resistant, vapor permeable polymeric elastomeric adhesive material has a water vapor transmission rating of at least 10 perm.

14. A method of insulating a wall structure comprising:

attaching a composite panel to a plurality of vertical studs horizontally spaced from each other to form a wall framing structure;

the composite panel consisting essentially of;

a foam insulating panel having a first primary surface and an opposite second primary surface, wherein the second primary surface is disposed adjacent the plurality of wall studs and wherein the first primary surface defines a single plane; and

a layer of a water-resistant, vapor permeable polymeric elastomeric adhesive material substantially covering the single plane of the first primary surface, wherein the layer of water-resistant, vapor permeable polymeric elastomeric adhesive material has an elongation factor of approximately 100% to approximately 1,000%, a water vapor transmission rating of at least 1 perm and an air permeance of less than 0.004 cfm/sq. ft. under a pressure differential of 0.3 inches of water, whereby the layer of water-resistant, vapor permeable polymeric adhesive material provides a water-resistant, vapor permeable air barrier; and

layer of porous reinforcing material defining a single plane disposed on the single plane of the first primary surface of the foam insulating panel, wherein the layer of porous reinforcing material is at least partially embedded in the layer of water-resistant, vapor permeable polymeric elastomeric adhesive material.

15. The method of insulating a wall structure of claim 14 further comprising a layer of cementitious material on the first layer of porous reinforcing material.

16. The method of insulating a wall structure of claim 14 further comprising a layer of wood or plywood disposed between the composite panel and the vertical studs.

17. A method comprising:

a first composite panel consisting essentially of;

attaching a first foam insulating panel to a framing structure, the composite panel having a first primary surface and an opposite second primary surface, wherein the first primary surface defines a single plane;

a first layer of a water-resistant, vapor permeable polymeric elastomeric adhesive material substantially covering the single plane of the first primary surface of the first foam insulating panel, wherein the first layer of water-resistant, vapor permeable polymeric elastomeric adhesive material has an elongation factor of approximately 100% to approximately 1,000%, a water vapor transmission rating of at least 1 perm and an air permeance of less than 0.004 cfm/sq. ft. under a pressure differential of 0.3 inches of water, whereby the first layer of water-resistant, vapor permeable polymeric adhesive material provides a water-resistant, vapor permeable air barrier; and

a first layer of porous reinforcing material defining a single plane disposed on the single plane of the first primary surface of the foam insulating panel, wherein the first layer of fiberglass reinforcing material is at least partially embedded in the first layer of vapor permeable polymeric elastomeric adhesive material; and

attaching a second composite panel to the framing structure adjacent the first composite panel, the second composite panel consisting essentially of;

a second foam insulating panel having a first primary surface and an opposite second primary surface, wherein the first primary surface defines a single plane;

a second layer of a water-resistant, vapor permeable polymeric elastomeric adhesive material substantially covering the single plane of the first primary surface of the second foam insulating panel; and

a second layer of porous reinforcing material forming a single plane disposed on the single plane of the first primary surface of the second foam insulating panel, wherein the second layer of porous reinforcing material is at least partially embedded in the second layer of water-resistant, vapor permeable polymeric elastomeric adhesive material.

18. The method of claim 17 further comprising a third layer of a water-resistant, vapor permeable polymeric elastomeric adhesive material and a third layer of porous reinforcing material at least partially embedded in the third layer of water-resistant, vapor permeable polymeric elastomeric adhesive material disposed on a joint formed between the first and second foam insulating panels.

19. The method of insulating a wall structure of claim 17 further comprising a layer of wood or plywood disposed between the composite panel and the vertical studs.