Patent Application
20240391219
There is a need in the residential and commercial construction markets for an improved wall sheathing product.
The present disclosure will be more readily understood from a detailed description of some example embodiments taken in conjunction with the following figures:
Various non-limiting embodiments of the present disclosure will now be described to provide an overall understanding of the principles of the structure, function, and use of the composite structural insulation panels as disclosed herein. One or more examples of these non-limiting embodiments are illustrated in the accompanying drawings. Those of ordinary skill in the art will understand that systems and methods specifically described herein and illustrated in the accompanying drawings are non-limiting embodiments. The features illustrated or described in connection with one non-limiting embodiment may be combined with the features of other non-limiting embodiments. Such modifications and variations are intended to be included within the scope of the present disclosure.
Reference throughout the specification to “various embodiments,” “some embodiments,” “one embodiment,” “some example embodiments,” “one example embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with any embodiment is included in at least one embodiment. Thus, appearances of the phrases “in various embodiments,” “in some embodiments,” “in one embodiment,” “some example embodiments,” “one example embodiment, or “in an embodiment” in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
The examples discussed herein are examples only and are provided to assist in the explanation of the composite structural insulation panels and methods described herein. None of the features or components shown in the drawings or discussed below should be taken as mandatory for any specific implementation of any of these composite structural insulation panels and methods unless specifically designated as mandatory. For ease of reading and clarity, certain components, modules, or methods may be described solely in connection with a specific figure. Any failure to specifically describe a combination or sub-combination of components should not be understood as an indication that any combination or sub-combination is not possible.
There is a need in the residential and commercial construction markets for a wall sheathing product that offers various functional values, such as structural, weather barrier, continuous insulation, construction site durability, and fire control. While conventional sheathing products may provide one or more of these properties, such products have value limiting challenges. Example composite structural insulation panels in accordance with the present disclosure, however, can add new value in several economically beneficial ways. By way of non-limiting examples, composite structural insulation panel in accordance with the present disclosure can eliminate the need to embed mechanical fasteners into the foam insulation, as this type of structural nailing requirement harms the panels weather barrier effectiveness and limits structural performance. Additionally, the presently disclosed composite structural insulation panel can eliminate one or more steps in the manufacturing process. Furthermore, example composite structural insulation panels can provide improved fastener holding capability, improved structural performance, improved jobsite durability, and improved fire control.
The sheathing component 200 can be, for example, an engineered fiberboard laminate which is a composite material formed from multiple layers of paperboard made from wood fibers or other cellulosic materials that are bonded together using various techniques and bonding agents to create a strong, stable, and durable panel. The bonding agents may include extruded polymer, adhesive, or a combination thereof. In some embodiments, the extruded polymer can be a thermoplastic or thermoset material that is applied to the paperboard layers through an extrusion coating process. The adhesive can be any suitable type of adhesive, such as a moisture-resistant or water-resistant adhesive, that is compatible with the paperboard layers and provides adequate bonding strength. In some embodiments, one or more of the paperboard layers within the engineered fiberboard laminate may be extrusion coated with a polymer material to enhance the moisture resistance, durability, or other properties of the sheathing layer. Alternatively, or in addition, one or more of the paperboard layers of the sheathing component 200 may be laminated to a plastic film or foil to provide additional barrier properties, such as water resistance, vapor resistance, or gas impermeability. The plastic film can be made from various polymeric materials, such as polyethylene, polypropylene, polyester, or nylon, while the foil can be an aluminum foil or other metallic foil that provides a high level of barrier protection.
The insulation component 300 utilized in the composite structural insulation panels 100 can be selected from a wide range of options. By way of example, the insulation component 300 can comprise expanded polystyrene, extruded expanded polystyrene, among other types of rigid, closed-cell foam materials. Other example types of foam insulation include polyisocyanurate materials, polyurethane materials, and phenolic materials. In some embodiments, the insulation component 300 can include a phase change material (PCM) insulation material.
Referring now to
The laminated configurations described herein can beneficially eliminate the need to drive the head of panel fasteners through or as deep into the insulation component thereby improving the panel's weather barrier properties. Additionally, incorporating two relatively thin structural components in thicknesses, such as Dryline® TSX, can support in-line lamination of the sheathing component(s) 200 and the insulation component(s) 300 during the composite insulation component manufacturing process.
Moreover, some insulation board products use facer materials such as films, matts, or foils to facilitate their manufacturing process and/or add weather barrier properties. By replacing these facer materials with a Dryline® TSX or similar products the cost of the current facer materials and the need for one or more secondary manufacturing processes may be eliminated.
As shown in
The use of one or more of these layers 400, non-limiting examples of which are shown in
Moreover, some composite structural insulation panels can include a fiberglass, polymer, or metal sheet, film, fiber, mat, and/or fabric layer (i.e., layer 400) and also incorporate one or more fiberglass, polymer, or metal fabricated, molded, or stamped parts onto the surface of the structural or insulation component(s) or between the insulation and structural components(s). As provided above, such approach can help to prevent fastener pull through, improve structural performance, improved fastener holding capability, improve fire control, and allow the use of thinner structural components to achieve design compliant structural values at lower manufacturing costs. Additionally, this approach can also facilitate the use of thinner structural components to achieve design compliant structural values and the lowest manufacturing cost.
Composite structural insulation panels 100 in accordance with the present disclosure can incorporate full coverage adhesive between all or some of the components to improve cohesive structural performance of the composite. In some embodiments, fire resistant or retarding coatings or components like gypsum or magnesium can be provided in or between layers to provide fire control capabilities. Moreover, moisture vapor permeable coatings, components, or discontinuous adhesive application processes can be incorporated to add moisture vapor control capability within the composite.
The foregoing description of embodiments and examples has been presented for purposes of illustration and description. It is not intended to be exhaustive or limiting to the forms described. Numerous modifications are possible in light of the above teachings. Some of those modifications have been discussed, and others will be understood by those skilled in the art. The embodiments were chosen and described in order to best illustrate principles of various embodiments as are suited to particular uses contemplated. The scope is, of course, not limited to the examples set forth herein, but can be employed in any number of applications and equivalent devices by those of ordinary skill in the art. Rather it is hereby intended the scope of the invention to be defined by the claims appended hereto.
This application claims the benefit of U.S. Patent Application Ser. No. 63/469,005, filed on May 25, 2023 and is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63469005 | May 2023 | US |
