Panel for sheathing system and method

• US 9,382,713 B2
• Filed: 03/13/2015
• Issued: 07/05/2016
• Est. Priority Date: 02/23/2004
• Status: Active Grant

• Current Assignee: Huber Engineered Woods LLC
• Original Assignee: Huber Engineered Woods LLC
• Inventors: Bennett, John L., Barker, Joel F., Jordan, Rick D., Schuman, Thomas L., Ou, Nian, Swiacki, Neil C., Flaherty, Kelly R.
• Primary Examiner(s): STEPHAN, BETH A
• Application Number:
  US14/656,999
• Publication Number:
  US 20150184382A1
• Time in Patent Office: 480 Days
• Field of Search: 524/08, 524/10, 527/414, 524/59, 521/77, 524/17, 527/981, 525/18, 525/881, 428/141, 428/156, 428/292.4, 428/292.7, 428/105, 428/107
• US Class Current: 1/1
• CPC Class Codes: B32B 21/00 Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
• 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 21/14 comprising wood board or veneer
• CPC Class Codes: B32B 2307/7265 Non-permeable
• CPC Class Codes: B32B 2307/744 Non-slip, anti-slip
• CPC Class Codes: B32B 2419/06 Roofs, roof membranes
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 3/06 for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• 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 1/64 for making damp-proof; Protection against corrosion sealings E04B1/66
• CPC Class Codes: E04B 1/665 Sheets or foils impervious to water and water vapor
• CPC Class Codes: E04B 1/68 of joints, e.g. expansion joints packing for joints in roads or airfields E01C11/02; expansion joints for bridges E01D19/06; sealing joints between foundation piles E02D5/14; joints in foundation structures E02D29/16; devices for sealing the spaces or joints between roof-covering elements E04D1/36; sealing joints between roof-covering elements E04D3/38; construction of joints for flooring or floor layers composed of a number of similar elements E04F15/02005; construction of joints for flooring or floor layers made of masses in situ E04F15/14
• CPC Class Codes: E04B 1/6803 Joint covers E04B1/6815 takes precedence
• CPC Class Codes: E04B 1/762 Exterior insulation of exterior walls
• 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 2103/04 of plastics, fibrous material or wood
• CPC Class Codes: E04B 7/00 Roofs; Roof construction with regard to insulation structures for roofs as well as for floors E04B5/00; ceilings E04B9/00; greenhouses A01G9/14; large containers having floating covers B65D88/34; roof trusses, truss-like structures, joists E04C3/02; roof coverings E04D
• CPC Class Codes: E04B 7/22 the slabs having insulating properties, e.g. laminated with layers of insulating material
• CPC Class Codes: E04C 2/02 characterised by specified materials translucent E04C2/54
• CPC Class Codes: E04C 2/24 : laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
• CPC Class Codes: E04C 2/246 : combinations of materials fully covered by E04C2/16 and E04C2/20
• 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: E04C 2/46 : specially adapted for making walls E04C2/52, E04C2/54 take precedence; structure of slab-shaped elements E04B1/02; walls of elements of relatively thin form E04B2/72
• CPC Class Codes: E04D 12/00 : Non-structural supports for roofing materials, e.g. battens, boards E04D11/02 and E04D13/16 take precedence; self-supporting slabs with non-structural supports for roofing materials E04B7/205
• CPC Class Codes: E04D 13/1618 : with means for fixing the insulating material between the roof covering and the upper surface of the roof purlins or rafters
• CPC Class Codes: E04D 3/35 : Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation self-supporting roofing slabs laminated with layers of insulating material E04B7/22; insulating devices or arrangements in the roof covering E04D13/16; connecting, fastening of double roof covering E04D3/3608
• CPC Class Codes: E04D 3/351 : at least one of the layers being composed of insulating material, e.g. fibre or foam material
• CPC Class Codes: E04D 3/355 : the insulating layers of adjacent slabs having cooperating edges
• CPC Class Codes: Y10T 29/49629 : Panel
• CPC Class Codes: Y10T 428/24355 : Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/249982 : With component specified as adhesive or bonding agent

Abstract

The panel includes a water resistant barrier layer secured atop its outward facing surface. The water resistant barrier layer includes a skid resistant surface. The panels are made of lignocellulosic material. The water resistant and skid resistant surface may include indicia for aligning strips of tape or for aligning fasteners. A method for manufacturing the water resistant building panels is also disclosed and includes the steps of feeding paper onto a forming belt, depositing lignocellulosic material and the binding agent onto the forming belt so as to form a lignocellulosic mat, applying heat and pressure so as to impart the skid resistant surface on the paper, and cutting panels to predetermined sizes.

Claims

1. A panel system to externally envelope a structure, the system comprising:

at least two adjacent lignocellulosic panels, each panel including an outer surface, an inner surface, and at least one edge extending therebetween, wherein each panel is aligned with its at least one edge proximate to the at least one edge of the adjacent panel to define a longitudinal joint between the two adjacent panels, and wherein the edges of the adjacent panels are substantially parallel to each other;

a barrier layer secured to the outer surface or the inner surface of each panel, the barrier layer being substantially bulk water resistant and substantially water vapor permeable, the barrier layer having an outer surface that is textured; and

a bulk water resistant edge sealant sealing the joint between the proximate edges of the two adjacent panels, wherein the edge sealant includes strips of water-resistant tape having an adhesive layer and a backing, wherein the panel includes alignment guides for positioning of the water-resistant tape during installation,

wherein the assembled panel system forms a sealed wall or roof of the structure without applying a separate moisture barrier layer of house wrap or felt paper.

2. The system of claim 1, wherein each panel and barrier layer has a water vapor transmission rate from about 0.7 to about 7 grams/m²/24 hrs as determined by ASTM E96 procedure A (at 73°

F.—

50% RH) and a liquid water transmission rate from about 1 to about 28 grams/100 in²/24 hrs via Cobb ring according to the test method described in ASTM D5795.

3. The system of claim 1, wherein the tape backing includes a polyolefin material.

4. The system of claim 1, wherein the tape includes a water vapor permeance of greater than 1.0 perm as determined by via ASTM E96 procedure B (at 73°

F.—

50% RH).

5. The system of claim 1, wherein the edge of one of the panels is a tongue and the edge of the adjacent panel is a groove.

6. The system of claim 1, wherein the textured outer surface provides a wet coefficient of friction in a range of about 0.8 to about 1.1 (English XL Tribometer) and a dry coefficient of friction of at least about 0.8 (English XL Tribometer).

7. The system of claim 1, wherein the edge sealant includes a liquid sealant.

8. A panel system to externally envelope a structure, the system comprising:

at least two adjacent lignocellulosic panels, each panel including an outer surface, an inner surface, and at least one edge extending therebetween, wherein each panel is aligned with its at least one edge proximate to the at least one edge of the adjacent panel to define a longitudinal joint between the two adjacent panels, and wherein the edges of the adjacent panels are substantially parallel to each other;

a barrier layer secured to the outer surface or the inner surface of each panel, the barrier layer being substantially bulk water resistant and substantially water vapor permeable, wherein the barrier layer includes a resin-impregnated paper substantially covering the outer surface of the panel, the resin-impregnated paper having a paper basis weight of 21.772 kg (48 lbs.) to about 102.058 kg (225 lbs.) per ream and a resin content of less than 80% by dry weight, and wherein the barrier layer has an outer surface that is textured; and

a bulk water resistant edge sealant sealing the joint between the proximate edges of the two adjacent panels, wherein the edge sealant includes strips of water-resistant tape having an adhesive layer and a backing, wherein the panel includes alignment guides for positioning of the water-resistant tape during installation,

wherein the assembled panel system forms a sealed wall or roof of the structure without applying a separate moisture barrier layer of house wrap or felt paper.

9. A method of externally sheathing a building structure, the method comprising:

obtaining at least two panel assemblies, each panel assembly including

a lignocellulosic panel including

an outer surface;

an inner surface;

and at least one edge; and

a barrier layer secured to the outer surface of each panel, the barrier layer being substantially bulk water resistant and substantially water vapor permeable, and the barrier layer having an outer surface that is textured;

positioning the panel assemblies adjacent to each other such that the respective edges are proximate and substantially parallel to each other to define a longitudinal joint therebetween and such that the respective inner surfaces contact the structure;

fastening each panel assembly to the structure; and

sealing the longitudinal joint between the edges of the adjacent panels by applying strips of adhesive-backed water-resistant tape to one of the panel outer surface and the barrier-layer outer surface, including removing a backing of the water-resistant tape to expose an adhesive layer of the water-resistant tape, positioning the water-resistant tape using alignment guides of the adjacent panels, and applying the adhesive layer to the adjacent panels covering the longitudinal joint,

wherein the resulting assembled sealed panel system forms a sealed wall or roof of the structure without applying a separate moisture barrier layer of house wrap or felt paper.

10. The method of claim 9, wherein the barrier layer includes a resin-impregnated paper substantially covering the outer surface of the panel, the resin-impregnated paper having a paper basis weight of 21.772 kg (48 lbs.) to about 102.058 kg (225 lbs.) per ream and a resin content of less than 80% by dry weight.

11. The method of claim 9, wherein each panel assembly has a water vapor transmission rate from about 0.7 to about 7 grams/m²/24 hrs as determined by ASTM E96 procedure A (at 73°

F.—

50% RH) and a liquid water transmission rate from about 1 to about 28 grams/100 in²/24 hrs via Cobb ring according to the test method described in ASTM D5795.

12. The method of claim 9, wherein the edge of one of the panels includes a tongue, the edge of the adjacent panel includes a groove, and the step of positioning each panel along the structure includes positioning the tongue proximate the groove.

13. The method of claim 9, the step of positioning each panel along the structure includes positioning the edge of one of the panels a distance away from the edge of the adjacent panel to allow for expansion and contraction of each panel.

14. The method of claim 9, wherein sealing the joint between the edges of the panels includes applying a liquid sealant to one of the outer surface and the barrier layer.