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

• US 9,574,341 B2
• Filed: 09/08/2015
• Issued: 02/21/2017
• Est. Priority Date: 09/09/2014
• Status: Active Grant

• Current Assignee: Romeo Ilarian Ciuperca
• Original Assignee: Romeo Ilarian Ciuperca
• Inventors: Ciuperca, Romeo Ilarian
• Primary Examiner(s): Maestri, Patrick
• Application Number:
  US14/847,152
• Publication Number:
  US 20160069067A1
• Time in Patent Office: 532 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: E04B 1/4178 Masonry wall ties with insulation-layer locating devices E04B1/7616; replacing or adding wall ties E04G23/0222
• 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 1/66 Sealings damp-proof courses E04B1/644; fire-proof sealings E04B1/948; additions of anti-leak properties to plaster C04B; bituminous sealing masses C08L95/00; sealings for hydraulic engineering work in general E02B3/16; against ground humidity or ground water E02D31/02; coverings against rain or other precipitations of the atmosphere E04D; composition of material or manufacture of sealing foils, see the relevant classes for these foils
• CPC Class Codes: E04B 1/7612 in combination with an air space
• CPC Class Codes: E04B 1/7629 Details of the mechanical connection of the insulation to the wall
• CPC Class Codes: E04B 1/7633 Dowels with enlarged insulation retaining head
• CPC Class Codes: E04B 1/80 slab-shaped
• CPC Class Codes: E04B 2/04 Walls having neither cavities between, nor in, the solid elements
• CPC Class Codes: E04B 2/58 with elongated members of metal
• CPC Class Codes: E04B 2/706 with supporting function
• CPC Class Codes: E04B 2002/565 with a brick veneer facing
• CPC Class Codes: E04B 2002/7477 Details of connections using screws or nails
• CPC Class Codes: E04C 2/284 at least one of the materials being insulating
• CPC Class Codes: E04C 2/34 composed of two or more spaced sheet-like parts E04C2/32 takes precedence; spacers for cavity walls E04B2/44

Abstract

The invention comprises a product. The product comprises a first foam panel having an edge, a first primary surface and an opposite second primary surface and a second foam panel having an edge, a first primary surface and an opposite second primary surface, wherein the first and second foam panels are disposed such that their edges are adjacent each other and define a joint therebetween. The product also comprises an elongate metal strip having a body portion and a projection extending outwardly from the body portion, the metal strip being disposed such that at least a portion of the projection is disposed in the joint between the foam panels and at least a portion of the body portion covers a portion of the second primary surface of the first foam panel and a portion of the second primary surface of the second foam panel. A method of making and using the composite panel is also disclosed.

Claims

1. A wall structure comprising:

a plurality of vertical stud members horizontally spaced from each other to form a wall framing structure;

an elongate metal strip having a body member and a projection extending outwardly from the body member, the metal strip being attached to at least two adjacent vertical stud members;

a first sheathing panel having an edge;

a second sheathing panel having an edge, wherein the first and second sheathing panels are disposed such that the edges of the first and second sheathing panels are adjacent each other and define a joint therebetween, wherein the metal strip is disposed such that at least a portion of the projection is disposed in the joint between the first and second sheathing panels, and

wherein each of the first and second sheathing panels consist essentially of;

a vapor permeable insulating panel having a primary surface opposite the plurality of vertical stud members;

a layer of porous reinforcing material substantially covering and adhered to the primary surface of the vapor permeable insulating panel; and

wherein the layer of reinforcing material is adhered to the primary surface of the vapor permeable insulating panel with and at least partially embedded in a water-resistant, polymeric elastomeric material that is a vapor permeable air barrier material having 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.

3. The wall structure of claim 1, wherein the layer of reinforcing material is a porous fabric, a web, a mesh or a lath.

4. The wall structure of claim 1, wherein the layer of reinforcing material is a nonwoven plastic sheet, a nonwoven fiberglass mat, a nonwoven fiberglass mesh or a nonwoven fiberglass grid.

7. The wall structure of claim 1, wherein the insulating panel is made from polystyrene foam, polyisocyanurate foam or polyurethane foam.

2. A method of insulating a structure comprising:

securing an elongate metal strip to adjacent wall studs, the elongate metal strip having a body member and a projection extending outwardly from the body member;

securing a sheathing panel to a portion of the elongate metal strip, wherein the sheathing panel has an edge, a first primary surface and an opposite second primary surface, wherein the sheathing panel is disposed such that the projection is adjacent the edge of the sheathing panel and at least a portion of the second primary surface covers at least a portion of the body member;

wherein the sheathing panel consist essentially of;

a vapor permeable insulating panel having a primary surface opposite the plurality of vertical stud members;

a layer of reinforcing material substantially covering and adhered to the primary surface of the vapor permeable insulating panel; and

wherein the layer of porous reinforcing material is adhered to the primary surface of the vapor permeable insulating panel with and at least partially embedded in a water-resistant, polymeric elastomeric material that is a vapor permeable air barrier material having 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.

5. The method of insulating a structure of claim 2, wherein the layer of reinforcing material is a porous fabric, a web, a mesh or a lath.

6. The method of insulating a structure of claim 2, wherein the layer of reinforcing material is a nonwoven plastic sheet, a nonwoven fiberglass mat, a nonwoven fiberglass mesh or a nonwoven fiberglass grid.

8. The method of insulating a structure of claim 2, wherein the insulating panel is made from polystyrene foam, polyisocyanurate foam or polyurethane foam.