US20240344321A1

US20240344321A1 - Wall panel system and method

Info

Publication number: US20240344321A1
Application number: US18/299,457
Authority: US
Inventors: Joseph Mrak, III; Ralph W Bush, JR.
Original assignee: Stonecoat International Inc
Current assignee: Stonecoat International Inc
Priority date: 2023-04-12
Filing date: 2023-04-12
Publication date: 2024-10-17
Also published as: WO2024215611A1

Abstract

The water resistive barrier system may include a foam panel coupled to a frame of a building. The system may include a membrane above the foam panel. The system may include a scratch layer above the membrane. The system may include an exterior layer above the scratch layer. The system wherein the foam panel has a thickness between two and eight inches may have a structural tensile strength of 50 psi. In some embodiments, a method of manufacturing the water resistive barrier system may include providing a foam panel. The method may include coupling a membrane above the foam panel. The foam panel and the membrane can be manufactured as one panel. The method may include providing a scratch layer material for further coupling above the membrane during an installation. The method may include providing an exterior layer material for further coupling above a scratch layer during the installation.

Description

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application is related to and incorporates by reference, in their entireties and for all purposes, each of U.S. Pat. No. 10,315,956, issued May 22, 2019, and U.S. Patent Application No. 61/949,659, filed Mar. 7, 2014.

TECHNICAL FIELD

This disclosure relates generally to the field of wall insulation structures and more specifically to water-resistant systems.

BACKGROUND

Typically, a wall panel can be a multi-layered system that can include at least an insulation board, an adhesive layer, a base coat (or base layer), a reinforcing mesh layer, and a finish coat (or finish layer). The insulation board (or insulation panel) is typically formed of a polystyrene material that can be coupled to an exterior wall structure with an adhesive layer. Afterwards, the base coat is applied above the insulation board, and a reinforcing mesh is embedded into the base coat. A finish coat that can include a range of materials such as acrylic, synthetic stucco, or brick is applied above the reinforcement mesh. For example, the typical wall panel system may include the following layers: a Dens-Glass and/or OSB sheathing (described below), water proofing, adhesive and mechanical fasteners, insulation board, a fiber mesh, a base coat, and a finish coat (that can be, for example, acrylic).
The wall panel systems provide an energy-efficient building envelope through reduction of air infiltration and increases in thermal resistance. The wall panel also provides a seamless and continuous layer of insulation, which facilitates elimination of thermal bridging and reduction of heat loss. Additionally, the wall panel can provide a design flexibility, as it can be customized to achieve various finishes, textures, and colors. However, the wall panel can be susceptible to moisture intrusion if not properly installed or maintained, which can lead to problems such as mold growth, rot, or structural damage.
Therefore, a need exists for such a wall panel system structure that can facilitate a more efficient installation and maintenance procedures to ensure the long-term performance of the wall panel system.

SUMMARY OF THE INVENTION

One embodiment of the present disclosure relates to a water resistive barrier system that may include a foam panel coupled to a frame of a building structure. The water resistive barrier system may also include a membrane overlaying the foam panel. The system may furthermore include a scratch layer overlaying the membrane. The system may in addition include an exterior layer overlaying the scratch layer. The system may include a structural tensile strength of approximately 50 psi for a foam panel having a thickness between two and eight inches.
Some embodiments may include a shield layer applied for additional water-resistance of the system. The system having the membrane and the shield layer may include two layers providing a water-resistive barrier of the system. The system can be breathable. The system can be at least one of mold or rot resistant. The system can be erosion resistant. The system can have such ultra-violet (UV) properties that the system is fade-resistant. The system can be weather resistant. The system where a thickness of the foam panel is approximately in a range between one and twelve inches can have an R value of in a range between four and 60 ft²*h*° F./Btu. The system can include the laminate membrane that is formed of a plastic material recycled from oil and gas industry. In some embodiments, the material used for forming a laminate membrane 14 can be at least partially a post-consumption fiber. In some embodiments, the laminate membrane 14 can be formed of a laminate material having a Class A Fire Rating. It should be understood that the laminate may be otherwise formed.
The system can substantially sustain at least one of a high velocity object, shear load, lateral load, or pressure. The system having the laminate membrane has a high surface energy (for example, in a range between 200 and 300 psi/ft²) to facilitate an adherence to the laminate membrane. The system may have a total weight between 5.5 and 9.5 lbs. per square foot. The system can be used in building structures having a height up to or equal to 30 feet without an additional support. The system can be resistant to at least one of a flame spread above 40 feet or does not require bracing substantially every 30 feet. The system can include the foam panel that is applied directly to the frame of the building structure. The system can provide a substantially continuous insulation outside of a building envelope.
In one general aspect, a method of manufacturing a water-resistant system may include providing a foam panel. The method may also include coupling a membrane above the foam panel. The method may furthermore include providing a scratch layer material for further coupling above the membrane during an installation. The method may in addition include providing an exterior layer material for further coupling above the scratch layer during the installation. The method may moreover include manufacturing the foam panel and the membrane that are as one panel.
In another aspect, there is provided a method of installing a water-resistant system that includes providing a frame. The method may also include coupling a foam panel and a membrane to the frame. The method may furthermore include applying a scratch layer above the membrane. The method may in addition include applying an exterior layer above the scratch layer. The installation method may include applying an additional shield layer for an additional water-resistance of the system.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, is best be obtained by referring to the detailed description and claims when considered in connection with the drawing figures, wherein like numerals denote like elements.

FIG. 1 illustrates a perspective view of a water-resistant system.

FIG. 2 illustrates a cross-sectional view of the water-resistant system taken along line A-A of FIG. 1 .

FIG. 3A illustrates a perspective view of a sheathing assembly of the water-resistant system illustrated in FIG. 1 .

FIG. 3B illustrates a section view of the sheathing assembly of FIG. 3A taken along the line B-B of FIG. 3A.

FIG. 3C illustrates a section view of a sheathing assembly having a double-sided membrane.

FIG. 4 illustrates a cross-sectional view of a water-resistant system installed in a building structure.

DETAILED DESCRIPTION

The present embodiments will now be described in detail with reference to the drawings, which are provided as illustrative examples of the embodiments so as to enable those skilled in the art to practice the embodiments and alternatives apparent to those skilled in the art. Notably, the figures and examples below are not meant to limit the scope of the present embodiments to a single embodiment, but other embodiments are possible by way of interchange of some or all of the described or illustrated elements. Moreover, where certain elements of the present embodiments can be partially or fully implemented using known components, only those portions of such known components that are necessary for an understanding of the present embodiments will be described, and detailed descriptions of other portions of such known components will be omitted so as not to obscure the present embodiments. In the present specification, an embodiment showing a singular component should not be considered limiting; rather, the present disclosure is intended to encompass other embodiments including a plurality of the same component, and vice-versa, unless explicitly stated otherwise herein. Moreover, applicants do not intend for any term in the specification or claims to be ascribed an uncommon or special meaning unless explicitly set forth as such. Further, the present embodiments encompass present and future known equivalents to the known components referred to herein by way of illustration.
FIGS. 1 and 2 are illustrations, not to scale, of a water-resistant system 10 in which multiple layers are employed to advantage. In the embodiment illustrated, for example, in FIG. 1 , the water-resistant system 10 is supported and secured to frame 30 and includes an exterior layer 18, a scratch layer 16, and a sheathing assembly 11.
Typically, sheathing is one or more layers of materials that are applied to the exterior or interior surface of the building frame. Oftentimes, sheathing is used to provide structural support and/or rigidity to a building and incudes a base for the installation of other building components, such as insulation, exterior siding, and/or interior finishing layers. Generally, sheathing facilitates a structural integrity and overall performance of a building, providing stability to a building to withstand forces of wind, gravity, and other external factors.
Typically, sheathing materials used in the exterior wall structures are plywood, oriented strand board (OSB), and/or foam insulation board. These materials can provide a durable and stable surface for the attachment of the exterior cladding and a barrier against air and water infiltration. In interior walls and ceilings, sheathing is used to provide a smooth surface for installation of finish layers such as drywall or plaster. The typical interior sheathing materials can include a gypsum board, a plywood, and a fiberboard.
FIGS. 3A and 3B illustrate, not to scale, a perspective view and a side view, respectively, of a sheathing assembly 11 of the water-resistant system 10 illustrated in FIG. 1 . As illustrated in FIGS. 3A and 3C, the sheathing assembly 11 includes a foam panel 12 and a high tensile strength membrane 14. Furthermore, in the embodiment illustrated in FIGS. 3A and 3B, the sheathing assembly 11 includes an adhesive layer 24. According to some embodiments, the adhesive layer 24 can be a urethane adhesive BETAFUSE 533™, such as those supplied by DuPont of Wilmington, U.S.A.
According to embodiments disclosed herein, the sheathing assembly 11 can be preassembled off-site or on-site and can be installed onto studs of the frame 30 (FIG. 1 ). After secured to the frame 30 (or the desired structure), the sheathing assembly 11 is taped at seams between adjacent panels of the sheathing assembly 11. The scratch layer 16 and exterior layer 18 are applied on-site once the sheathing assembly 11 is installed and taped. In some embodiments, at least one layer of the scratch coat 16 (or scratch layer) and one exterior layer 18 is applied. According to some embodiments, the scratch layer 16 and/or exterior layer 18 can be formed of a limestone material; however, it should be understood that any similar performing material can be used.
According to some embodiments, the exterior layer 18 can have a smooth and/or carve surfaces. The exterior layer 18 can be a stucco product that offers the same or greater flexibility of installation and finishes as traditional stucco. In some embodiments, the smooth exterior layer 18 can be formed of a breathable, waterproof and/or mold-proof material. The smooth exterior layer 18 can be compatible with most traditional stucco substrate systems. In some embodiments, the exterior layer 18 can be formed of a limestone material; however, it should be understood that any similar performing material can be used. In some embodiments, the smooth exterior layer 18 can be applied directly to an existing surface, such as brick or cement block.
According to some embodiments, the carve exterior layer 18 can be a lightweight stone veneer system that is suitable for exterior and interior applications. In some embodiments, the carve exterior layer 18 can result in space reduction, more efficient installation time, and/or cost savings when compared to conventionally installed quarried stone masonry veneer, manufactured stone (cementitious) veneer, and/or traditional stone alternatives. In some embodiments, the carve exterior layer 18 can include a wide variety of custom finishes. The carve exterior layer 18 can adhere to many materials used in the building industry, for example, drywall, concrete, metal, wood, and/or brick.
According to some embodiments, an additional waterproofing layer or a shield layer (not illustrated) can be optionally applied to overlay the exterior layer 18. The shield layer can be formed of an eco-friendly, clear, filmless, penetrating water repellant material that can be used for a wide variety of vertical concrete masonry and vertical and/or horizontal installations of natural stone.
As previously described, in some embodiments the sheathing assembly 11 of the water-resistant system 10 can include the foam panel 12 that can be formed of various expanded materials. In some embodiments, for example, the foam panel 12 can be formed of an expanded polystyrene (EPS). As used herein, the term EPS can, for example, refer to a lightweight, rigid, closed-cell foam plastic that can be used as an insulation material in construction. EPS can be formed by expanding relatively small beads of polystyrene with steam, and then molding the expanded material into various shapes or sizes. In some embodiments, EPS has a relatively high thermal resistance, which facilitates its use as an effective insulation material for building structures. In some embodiments, EPS has a low moisture absorption rate, which facilitates prevention of water damage and mold growth in building structures. Additionally, EPS can used as insulation in walls, roofs, foundations, and/or in concrete forms and under concrete slabs. It can also be used as a lightweight fill material in civil engineering applications, such as road construction and bridge abutments.
In addition to or in lieu of EPS, other rigid foam insulation boards, such as extruded polystyrene (XPS) and/or polyisocyanurate (ISO), can be used for insulation purposes and more specifically, to form the foam panel 12. For example, the foam panel 12 of the sheathing assembly 11 that is formed of extruded polystyrene (XPS) may have a thickness of four inches that has an R-value of 20. In some embodiments, the thickness of the foam panel can be in a range between one and twelve inches. For example, the R-value of the XPS material can be 5 and the R-value of the EPS material can be 4. In some embodiments, the R-value for the XPS material can be in a range between 5 and 60. In some embodiments, the R-value for the EPS material can be in a range between 4 and 48.
According to some embodiments, each foam panel 12 can have a thermal resistance that is typically measured by an R-value. As used herein, the term “R-value” can, for example, refer to a measure of the thermal resistance of a material, such as insulation, that indicates resistance of the material to a heat flow. Typically, the higher the R-value of a material, the more efficiently the material can prevent or substantially reduce a heat transfer. The R-value can be calculated based on the thickness and thermal conductivity of the material. A material with a higher R-value has a lower thermal conductivity, e.g., such material is more resistant to the heat flow. R-values are typically measured per inch of thickness, so a material with a higher R-value per inch can provide more thermal resistance in a given space.
Typically, R-values are used in a building industry to specify a required amount of insulation for a particular building application and to compare performance of different insulation materials. Building codes and energy standards typically require a minimum R-value for different areas of a building, depending on the climate in a specific geographic region and other factors. An actual thermal performance of a building assembly, such as a wall or roof, is affected by various factors in addition to an R-value of the insulation. For example, such factors can include a type and thickness of other building materials, air leaks, and thermal bridging. Therefore, typically, an overall building design and construction are considered when evaluating an energy efficiency and thermal performance of the building.
In some embodiments, the water-resistant system 10 can include the foam panel 12 that substantially contributes to the total R-value from the foam material and is designed to exceed a typical R-value found in a traditional wall panel that can be in a range between 4.5 and 6. For example, the foam panel 12 having a thickness of two inches can provide an R-value of about 10. The foam panel 12 can have the thickness in a range between one and eight inches, thus providing the R-value in range between five and 40 depending on a depth where an R-value is measured.
In the embodiment illustrated in FIGS. 3 a and 3 b , the sheathing assembly 11 includes the structural laminate membrane 14 that is adhered to a foam panel 12. In some embodiments, the laminate membrane 14 can be formed of a plastic material that is at least partially recycled from materials used in oil and gas applications. In some embodiments, the material from which the laminate membrane 14 is formed may have little to no lumber or other wood content. In some embodiments, the structural laminate membrane 14 has a relatively high surface energy to facilitate its adherence to various building products and systems. For example, in some embodiments, the surface energy of the laminate membrane 14 can be in a range between 200 and 300 psi/ft². In other embodiments, the surface energy of the laminate membrane 14 can be 260 psi/ft². Additionally, the laminate membrane 14 has high tensile properties that provides high performance against high velocity objects and better structural capabilities with respect to resisting to shear loads, lateral loads, and pressures. The laminate membrane 14 also has a low permeability rating that facilitates the laminate membrane 14 functioning as the primary water-resistive barrier (WRB) for the water-resistant system 10 that is described below, by way of example. For example, the water-resistant system 10 performs functions of water/moisture management by eliminating exterior moisture intrusion through a primary WRB and secondary WRB that are exterior to the continuous insulation (CI) that is described further below. The water-resistant system 10 is specifically designed to allow moisture that reaches the primary WRB to evaporate out of the water-resistant system 10 during the heating/cooling cycles of the day.
The water-resistant system 10 in the embodiment of FIGS. 3A-3B, not to scale, includes a singular membrane 14 (e.g., disposed on one side of the foam panel 12 substantially between the scratch layer 16 and the foam panel 12). In some embodiments, as illustrated in FIG. 3C, not to scale, the water-resistant system 10 may include double- sided membranes 14 a and 14 b (that can be, for example, disposed on both sides of the foam panel 12). In some embodiments, the double-sided water-resistant system 10 may have a tensile strength that has approximately a double value of the single-sided water-resistant system 10. In some embodiments, the water-resistant system 10 can have any number of the membranes 14 on one or more sides of the foam panel 12. For example, in some embodiments, the water-resistant system 10 can include one membrane 14 a on the first side of the foam panel 12 and two membranes 14 b on the second side of the foam panel 12.
FIG. 4 illustrates, not to scale, a cross-sectional view of the water-resistant system 10 installed in connection with a building structure. For example, in some embodiments, the building structure is erected above a concrete slab 36. The concrete slab 36 may have a void 32 that is formed under the concrete slab 36 to capture excessive moisture or water gathered between the layers of the wall structure of the building. The frame 30 is erected above the concrete slab 36 and can be formed in various configurations. For example, in some embodiments, the studs of the frame 30 (FIG. 1 ) can be formed of metal or wood materials. In some embodiments, rafters can be used instead of or in combination with the studs. In some embodiments, Z-girts 34 and/or C-channels can be employed to provide a structural support for a building. For example, the Z-girts 34 having a length of eight inches can be installed to support the water-resistant system 10 as illustrated in FIG. 4 . In some embodiments, a separate panel can be installed above the Z-girts 34, C-channels, and/or the studs of frame 30. Such separate panel can be formed, for example, of metal.
As used herein, the term “Z-girt” can, for example, refer to a type of metal framing component used in construction to attach exterior cladding materials, such as, for example, metal panels, fiber cement, and/or high-pressure laminate panels, to a structural frame of a building. The Z-girt can be, for example, a cold-formed, galvanized steel member shaped as a letter “Z”. At least one flange of the Z-girt can be attached to the structural framing of the building whereas at least one other flange of the Z-girt can be used to secure the cladding panels. Z-girts are used as an alternative to traditional wood or metal stud framing and can be used in commercial and industrial building construction. They are configured to create a cavity between the cladding and the structural framing, which facilitates for ventilation and drainage of any moisture that may penetrate the cladding system. The use of Z-girts can provide an increased energy efficiency by improving the thermal performance of the building envelope, reduced maintenance and repair costs, and improved resistance to wind and seismic forces. Z-girts are also relatively lightweight and easy to install, which can result in a faster construction process and lower labor costs.
In exterior walls, sheathing assembly 11 is typically applied above the frame 30 and beneath exterior cladding material (that can be, for example, a siding and/or stucco). The water-resistant system 10 can include the base scratch layer 16 and the exterior layer 18. An interior panel 42 is disposed on the inner side of the building structure, e.g., spaced apart from the exterior side of the building by the wall structure. The wall structure may include furring channels 44 (that can have, for example, a depth of ⅞ inches) for holding insulation material 40 therewithin. The furring channels 44 facilitate a substantially equidistant coupling of inner panel 42 to the frame 30 allowing a more straight vertical wall structure on the inner side of the building. The Z-girts 34 can support the interior panel 42. The interior panel can be for example a gypsum board having a thickness of ⅝ inches. The insulation layer 40 can include double liners with an interior liner having the R-value at least 19 ft²*h*° F./Btu.
A reference is now made to a method of manufacturing a water resistive barrier system, as described herein. For example, the process may include providing a foam panel 12. In some embodiments, the manufacturing method may include coupling or otherwise attaching a membrane 14 over the foam panel 12, as described herein. The manufacturing method may include providing a material for scratch layer 16 for further coupling over the membrane 14 during an installation, as described herein. The manufacturing method may include providing a material for an exterior layer 18 for its further coupling above or otherwise over the scratch layer 16 during the installation, as described herein. The manufacturing method may include manufacturing of the foam panel 12 and the membrane 14 where the foam panel 12 and the membrane 14 are manufactured as one panel, as described herein.
In some embodiments, the membrane 14 can be formed as a laminate layer. The membrane 14 can have a tensile strength of approximately 50 psi for the sheathing assembly 11 that has a thickness between two and eight inches where the sheathing thickness primarily comprises a thickness of the foam panel 12. For example, the membrane 14 can have a strength of 50 psi for a sheathing assembly 11 having a thickness of 2 inches. The strength of the membrane is greater than a strength of Dens-Glass and/or OSB materials (that are described below). Therefore, using the water-resistant system 10 eliminates or substantially reduces a need for any additional sheathing on the studs of the frame 30 (besides the sheathing assembly 11 included in the water-resistant system 10). Thus, for example, the OSB/Dens-Glass layer in a typical wood/steel stud framing can be eliminated or substantially reduced when the water-resistant system 10 is utilized. Put another way, aspects of the present disclosure allow the elimination of the Dens-Glass and/or OSB sheathing, waterproofing barrier(s), and metal lath (or mesh layer) and still retain water resistance properties.
Although the above manufacturing method is described using example steps, in some embodiments, the process may include additional steps, fewer steps, different steps, or differently arranged steps than those described above. Additionally, or alternatively, two or more of the steps of the manufacturing method may be performed in parallel.
A reference is now made to a method of installing a water resistive barrier system 10. For example, the installation method may include providing a frame 30. As discussed herein, the water-resistant system 10 in a disassembled state may include four components: a foam panel 12, an engineered thin membrane 14, a scratch layer or coat 16, and a final coat or exterior layer 18. The installation method may include coupling the foam panel 12 and the membrane 14 to the frame 30, as described herein. For example, using liquid nails and screws, the water-resistant system 10 can be applied directly to the studs (that can be metal or wood) of the frame 30 or an exterior metal panel of a building structure. For example, the sheathing assembly 11 can be directly applied to the studs of the frame 30 while the water-resistant system 10 provides an equal or improved structural tensile strength as compared to a traditional wall panel.
To install a water-resistant system 10, a user may apply relatively small spheres of a liquid nail substance having a diameter of ¼ inches to the frame 30 and/or a metal panel of the building structure at a distance 24 inches (on center) along horizontal and vertical axes. Within an open time of the liquid nail application, a user can install and attach the sheathing assembly 11 using, for example, the metal screws coupling the sheathing assembly 11 to the frame 30 at a distance 24 inches (on center) along horizontal and vertical axes. Such coupling with liquid and metal screws can sustain a dead load greater than 10 pounds per square foot (psf). Then, all or substantially all joint seams in the sheathing assembly 11 are taped.
The installation method may include applying a scratch layer 16 above or otherwise over the membrane 14, as described herein. The membrane 14 and the shield layer, if present, provide two layers of a water-resistive barrier (WRB). The installation method may include applying an exterior layer 18 above the scratch layer 16, as described herein. The exterior layer 18 can have a carve or smooth finish depending on a desired preference of a user. For example, the veneer surface of the exterior layer 18 can have a stone appearance and/or stucco appearance.
The exterior layer 18 of the water-resistant system 10 can be applied by trowel or dispersed by an air pressure directly onto the panel membrane 14. For example, the exterior layer 18 can be applied using the traditional trowel method. Such method is relatively easy to apply and comparable to other installation methods of residential stucco. The traditional trowel method is widely available and well understood technique of applying the stucco material. The exterior layer 18 can be dispersed by an air pressure directly onto the panel membrane 14 by a wall mortar spray hopper. Such installation method is relatively easy to apply since it is a known installation technique for applying a cement mortar. During the installation technique utilizing the wall mortar spray hopper, a faster speed of application the materials can be achieved and it requires additional equipment and training to achieve a desired finished product.
The method of installing the water resistive barrier 10 may include additional embodiments, such as any single embodiment or any combination of embodiments described below and/or in connection with one or more other methods described elsewhere herein. In some embodiments, the installation method further includes applying an additional shield layer for an additional water-resistance of the system. For example, optionally, the shield layer of liquid may be applied for a stronger water-proofing capacity of the water-resistant system 10.
A relative simplicity in the design of the water-resistant system 10 facilitates labor savings and efficient application of the water-resistant system 10 to the frame 30 of the building structure. For example, the exterior layer 18 can be applied substantially by the same team that couples the sheathing assembly 11 on the studs and the scratch layer 16. The installation process for the water-resistant system 10 is relatively straightforward making building process relatively simpler and more efficient than installation of the traditional wall panel systems. In some embodiments, the labor and/or cost savings can be equal or greater than 30% when compared to traditional EIFS alternatives.
Although example steps of the installation method, in some embodiments, the process may include additional steps, fewer steps, different steps, or differently arranged steps than those described herein. Additionally, or alternatively, two or more of the steps of the installation method may be performed in parallel.
As described below, the water-resistant system 10 meets new standards of the 2021 Energy Code including Continuous Insulation (CI) requirements, as well as the Building Code and the Fire Code. At the same time, the water-resistant system 10 eliminates or substantially reduces several layers of the exterior building process while providing an R-value that is equal to or greater than traditional wall panel systems can provide.
As used herein, the term “water-resistive barrier” (WRB) can, for example, refer to any material that is installed on the exterior wall of a building to facilitate protection of the building from a water intrusion. The purpose of the WRB is to provide a secondary layer of protection behind the exterior cladding of the building (for example, behind siding or stucco) if the water penetrates the cladding. The WRB is typically made of a moisture-resistant material, such as a house wrap, a building paper, or a specialized WRB membrane. Typically, the WRB is installed beneath the exterior cladding and over the exterior sheathing, which is typically made of plywood, OSB, or a foam insulation.
The WRB facilitates prevention of water entering the building by providing a barrier that directs the water away from the building interior. The WRB allows any water that penetrates the exterior cladding to drain and/or evaporate, rather than being absorbed by the building framing or insulation. In addition, the WRB can facilitate reduction of a risk of mold growth and other moisture-related problems that can be caused by water infiltration.
Reference is now made to a continuous insulation (CI). As used herein, the term “CI” can, for example, refer to any type of a thermal insulation that is installed continuously across the exterior walls of a building, substantially without any thermal bridging. CI is installed on the exterior side of the building sheathing and is intended to create a continuous thermal barrier that facilitates prevention of a heat transfer between the inside and outside sides of the building. One of the purpose of CI is to increase the energy efficiency of a building by reducing thermal bridging. The thermal bridging is the transfer of heat through structural components of the building that have a lower R-value than the insulation material. Thermal bridging can cause substantial heat loss, reduce the effectiveness of insulation, and result in higher energy costs.
CI is typically made of rigid foam insulation board, such as expanded polystyrene (EPS), extruded polystyrene (XPS), or polyisocyanurate (ISO), and is installed on the exterior side of the building sheathing, beneath the exterior cladding. In addition to improving energy efficiency, CI can also facilitate reduction of a risk for problems related to condensation and moisture by providing a continuous thermal barrier. Continuous insulation is required by most building codes and energy standards, including the International Energy Conservation Code (IECC) and the American Society of Heating, Refrigerating, and Air-Conditioning Engineers 90.1 (ASHRAE 90.1) standard, which establish minimum energy efficiency requirements for buildings. Proper installation of CI prevents or substantially reduces moisture problems.
A reference is now made to tensile strength that is a measure of the maximum stress that a material can withstand before breaking or deforming permanently under tension. The tensile strength is an important mechanical property of materials and is used to determine the suitability of a material for a particular application. The tensile strength of a material is typically expressed in units of force per unit of cross-sectional area, such as pounds per square inch (psi) or newtons per square meter (N/m²).
The tensile strength of a material is affected by several factors, including the type and composition of the material, a manufacturing process of the material, and any defects or imperfections in the material. For example, materials with high tensile strength are typically used in applications that require high load-bearing capacity, such as structural components of buildings, bridges, and vehicles. The tensile strength of a material can be determined through various testing methods, such as a tensile test, which involves applying a gradually increasing load to a material until it breaks. This test allows engineers and manufacturers to evaluate the strength and reliability of materials and to design products that are safe and durable.
A reference is now made to attributes of the water-resistant system 10 related to “green” factors, sustainability, and/or environment. The water-resistant system 10 completed a Lifecycle Analysis (LCA) and Environmental Product Declaration (EPD), which showed that the water-resistant system 10 provides 90% fewer carbon emission when compared to other cement-based siding options, for example, a Portland cement-based stucco or manufactured stone. In some embodiments, the R-value and energy efficiency of the sheathing assembly 11 facilitate the overall product evaluation approaching a net zero or better performance of the greenhouse gas emission. For example, in some embodiments, a further green factor may be provided by the membrane 14 that can be formed of recycled plastics from the oil and gas industry. Furthermore, the elimination of the Dens-Glass and/or OSB sheathing, waterproofing barrier(s), and metal lath (or mesh layer) can be incorporated into analysis of the sustainable attributes of the water-resistant system 10. For example, the water-resistant system 10 can eliminate or substantially reduce non-sustainable materials, waste, energy used for delivery (e.g., gasoline and the like) and labor. The water-resistant system 10 is relatively lightweight which can reduce foundation requirements and therefore reduce the amount of cement and/or steel used in construction of the foundation.
The water-resistant system 10 is a cost-effective solution relative to traditional exterior wall systems. For example, the system at scale can cost less in materials and can eliminate or substantially reduce several layers of wall panel and associated labor. Depending on the user preferences for a finish look and appearance, a wide variety of the design options for the exterior layer 18 can eliminate or substantially reduce a need for a subsequent painting.
Being a sustainable veneer with a high R-value for energy efficiency, a structure of the water-resistant system 10 provides both eco-friendly building materials and high energy efficiency. The characteristics of the water-resistant system 10 allows to achieve LEED credits (that are described below) as part of an overall building design and accreditation.
As used herein, the term “Exterior Insulation and Finish System” (EIFS) includes an exterior cladding system used in commercial and residential construction. Typically, EIFS may include OSB and/or Dens-Glass.
As used herein, the term “Oriented Strand Board” (OSB) can, for example, refer to any type of an engineered wood panel that is formed by compressing layers of wood strands and/or flakes with adhesive under high pressure and temperature. The wood strands can be arranged in a cross-oriented pattern that facilitates strength and dimensional stability of the panel. The OSB is used in construction industry as, for example, a substitute for plywood or other types of wood panels. It can be used as sheathing, subflooring, and/or roof decking in residential and commercial buildings. OSB can be used in furniture and packaging industries. OSB can be employed advantageously due to its cost-effectiveness compared to other typical wood panels. OSB can also have a relatively high strength, durability, and moisture resistance characteristics. On the other hand, OSB may have a coarse appearance, susceptibility to swelling in relatively high humidity conditions, and vulnerability to edge swelling if not being properly sealed during installation.
As used herein, the term “Dens-Glass” can, for example, refer to a type of gypsum fiberglass mat sheathing, such as those supplied by Georgia-Pacific Gypsum LLC of Atlanta, U.S.A. Dens-Glass can be formed as a panel by bonding a moisture-resistant gypsum core with fiberglass mats on both sides of the gypsum core panel. This bonding facilitates strength and durability of the bonded panel. The panels can be used as an exterior sheathing material in construction industry for commercial and residential buildings. Dens-Glass sheathing is often used as a substrate for stucco and/or other components of the EIFS and the like systems. Dens-Glass can also be used as a base layer for air and water barriers. The Dens-Glass panels may include a noncombustible core and can be resistant to mold, moisture, and/or fire. The Dens-Glass panels may have a relatively high dimensional stability that can facilitate their use for geographical areas with extreme temperature fluctuations.
As discussed herein, the water-resistant system 10 eliminates or substantially reduces a need for Dens-Glass and/or OSB sheathing to be applied to the studs, a primary (and secondary) water-resistive barrier, and metal lath (or mesh layer). For example, in a traditional EIFS, even if a cement board is coupled to the foam panel, such system would still require a Dens-Glass and/or OSB sheathing to be applied to the studs and it will require a primary water-resistive barrier. The reduction of building envelope layers provides a significant saving in material cost and labor and reduces waste.
As used herein, the term “acrylic coat” or “acrylic stucco finish” can, for example, refer to a type of finish coat that is applied over a base coat of a traditional cement-based stucco. The acrylic coat is a mixture of acrylic resins, cement, and other additives that provide durability, flexibility, and weather resistance. The acrylic stucco finishes are used in the building industry because they offer several advantages over traditional stucco finishes. For example, the acrylic stucco finishes can be tinted to a wide range of colors, they are less prone to cracking, and are more resistant to water penetration and fading. Additionally, the acrylic stucco finishes can be formed having various textures and patterns to deliver a relatively wider range of architectural styles and designs.
The acrylic stucco finishes are typically applied in multiple coats, when each coat needs to dry and cure before the next coat is applied. The finish coat is usually troweled or sprayed onto the surface and can be smoothed or textured as desired. Proper installation of the acrylic stucco finish is important to facilitate its long-term durability and weather resistance. The base coat needs to be applied properly and cured before the acrylic coat is applied. The substrate surface on which the acrylic stucco finish is applied must be clean, dry, and substantially free of defects. The proper mixing and applying of the acrylic finish, including the recommended thickness, coverage rate, and curing time are needed. Using the relatively simpler water-resistant system 10 described herein facilitates a more effective building process.
The acrylic finish coat can be susceptible to UV fading, mold, and reapplication. Unlike the acrylic final coat, the exterior layer 18 of the water-resistant system 10 is less susceptible to the UV fading, weather, mold, and reapplication. For example, to make a rehabilitation and/or remodeling of the building where the water-resistant system 10 is utilized, there may be no need for demolition and/or procedures related to preparation for rehabilitation and/or remodeling. In some embodiments, the water-resistant system 10 can include integral UV resistant pigments that make the system 10 resistant to fading such that substantially no fading or no fading at all occurs when the water-resistant system 10 is exposed to the UV light. This results in the water-resistant system 10 that does not need a level of maintenance (or does not require any maintenance at all) that the traditional wall panel typically requires. Having a relatively high pH content that can be equal or greater than 8.0, the water-resistant system 10 can substantially or completely mitigate a mold risk.
As used herein, the term “metal lath” can, for example, refer to a type of building materials that are used as a base for plaster or stucco finishes on interior and exterior walls. The metal lath is typically made of galvanized steel or the like metals and can be formed into a sheet of small openings that can be diamond-shaped, square-shaped, and the like, with relatively small ridges between the openings. The metal lath can be used as a reinforcement for plaster or stucco finishes because it provides a strong, stable base that helps the plaster or stucco adhere to the wall surface. The small diamond-shaped openings in the lath allow the plaster or stucco to key into the metal, creating a mechanical bond that facilitates prevention of the finish layer from cracking or separating from the wall.
The metal lath can be formed in different sizes and thicknesses, depending on a specific application and the type of finish layer that is applied thereto. The metal lath can be installed above various types of wall surfaces, including wood framing, masonry, and/or concrete. Generally, the metal lath allows coupling (e.g., fastening) cement-based materials to framing structures formed of wood, metal and the like materials. In addition to providing a base for the plaster or stucco finish layers, the metal lath can also be used for other applications, providing a base for finish layers that include tiles or stones. The metal lath needs to be properly installed to achieve its desired effectiveness and to prevent cracking and/or separation of the finish layer. For example, the metal lath needs to be securely fastened to the wall surface and the edges and joints need to be properly lapped and fastened.
A reference is now made to the relevance of the water-resistant system 10 to several regulatory codes and certification programs. For example, the 2021 Energy Code refers to the most recent revision of the International Energy Conservation Code (IECC), a model code that sets minimum standards for energy efficiency in buildings. The IECC is developed by the International Code Council (ICC) and is adopted in whole or in part by many state and local jurisdictions in the United States.
The 2021 revision of the IECC includes several updates and changes aimed at improving the energy efficiency of buildings. Some of the new modifications include increased insulation requirements for walls, roofs, and floors; improved air sealing requirements to reduce air leakage and energy loss; updated requirements for fenestration, including increased minimum energy performance ratings for windows and doors; new requirements for lighting and electrical systems, including the use of high-efficiency lighting and controls; and expanded requirements for renewable energy systems, such as solar photovoltaic (PV) systems. The efficient singular water-resistant system 10 meets the requirements of the 2021 IECC and other related energy codes.
The 2021 Energy Code aims to improve the energy efficiency of buildings and reduce an environmental impact of the buildings and their construction. By setting higher standards for insulation, air sealing, lighting, and renewable energy, the 2021 Energy Code aims to promote the construction of more sustainable and energy-efficient buildings. This in turn can facilitate reduction of energy costs, improvement of indoor comfort, and reducing greenhouse gas emissions.
The 2021 Energy Code affects the building industry by, for example, requiring enhanced R-values and continuous insulation outside of a building envelope. As described herein the foam panel 12 of the water-resistant system 10 has a relatively high R-value. Also, the laminate membrane 14 has a high surface energy, high tensile properties, and the low permeability rating. These properties of the water-resistant system 10 allow the panel to serve several functions fulfilling the 2021 Energy Code requirements using one lightweight panel of the water-resistant system 10 while also addressing the structural sheathing requirements, WRB requirements, and the surface energy thresholds necessary to adhere thin veneers.
For example, the water-resistant system 10 can be used instead of adding expanded polystyrene (EPS) to the front or back side of the existing wall structures, for example, on one or both sides of the sheathing assembly 11. Also, in cementitious nonstructural systems the water-resistant system 10 can be used instead of adding additional EPS layers to the inside of the cementitious systems. Thus, using the water-resistant system 10 can substantially reduce or eliminate the added material cost and layers to the wall structure. Therefore, the water-resistant system 10 does not require a larger building footprint that is required by one or more of the additional insulative layers in a traditional wall panel.
A reference is now made to the 2021 International Building Code (IBC). The IBC modifications created market conditions where thin-veneer cladding systems have gained a substantial market share. However, the thin-veneer systems are generally more expensive than traditional load-bearing veneers. In a construction industry, it is considered that only one pass is performed when a second layer (for example, a scratch layer 16) is wrapped around the building within one hour of a first layer (e.g., the foam panel 12 together with the laminate membrane 14) being wrapped around the building. Using the water-resistant system 10 facilitates reduction of the total number of steps for installing thin-veneer systems. For example, the water-resistant system 10 reduces several tasks of the building process (such as, sheathing, WRB, CI, and/or lathing) into one assembly that requires only one or two passes around the building versus up to six passes when traditional thin-veneer systems are used.
As discussed herein, the water-resistant system 10 is an environmentally conscious system that can be based on a breathable limestone material. At the same time, the water-resistant system 10 is a structural system that can meet various design requirements for finish, color, and/or texture based on user preferences. In some embodiments, the water-resistant system 10 does not substantially incorporate any building materials that are prone to rot or rust. For example, in some embodiments, no organic materials are used for forming the water-resistant system 10, e.g., carbon that can be used for forming the laminate membrane 14 substantially does not rot. The water-resistant system 10 is a lightweight, long-lasting, substantially maintenance-free, carbon friendly building system.
A reference is now made to the 2021 Fire Code. The 2021 Fire Code references the National Fire Protection Association 285 (NFPA-285) testing standard that increased testing requirements for EIFS and other thin-veneer systems. Under the new standard, the EPS foam systems used in traditional EIFS systems may not be able meet the NFPA-285 requirements. A carbon laminate membrane 14 and detailing paired with limestone veneer of the scratch layer 16 has created a system that exceeds the testing requirements of NFPA-285. In some embodiments, the water-resistant system 10 having the exterior layer 18 added above the scratch layer 16 exceeds the testing requirements of NFPA-285. Additionally, the weight/square feet ratio of the water-resistant system 10 can be in a range between 5.5 and 9.5 lbs./ft².
In some embodiments, the weight of the water-resistant system 10 having ⅝″ thickness can be around 6 lbs. depending on a veneer type, the weight saving can be in a range between 50% and 70% when compared to traditional Stucco materials. A typical wall system that includes a load bearing masonry (e.g., having a thickness of three inches) is supported by the foundation of the building. Such typical continuous insulation material requires a bracing support every 30 feet. Having a relatively light weight, the water-resistant system 10 is supported by the structure of the building rather than by the foundation of the building. The lightweight nature allows traditional framing systems to support the water-resistant system 10 without requiring an additional bracing support substantially every 30 feet, by way of example.
In some embodiments, the laminate membrane 14 can be formed of a laminate material having a Class A fire rating. The foam panel 12 that can be formed of the XPS material or the EPS material being exposed to high temperature of fire may melt but does not substantially combust or spreads the flame. The water-resistant system 10 having the laminate membrane 14 (that is formed of a material having a Class A fire rating) and the foam panel 12 prevents or substantially reduces a flame spread. This allows a single system to be installed to the maximum allowable height without a typical Fire Code restriction for the flame spread above 40 feet.
The reference is now made to Leadership in Energy and Environmental Design (LEED) that is a green building certification program that was developed by the U.S. Green Building Council (USGBC). LEED is a globally recognized program that provides a framework for the design, construction, operation, and maintenance of sustainable buildings. The LEED rating system awards points for various sustainable design and construction practices, such as energy efficiency, water conservation, indoor air quality, selection of materials, and sustainable site development. Building structures that achieve a certain number of points are awarded an LEED certification, which indicates that the building has met certain environmental and sustainability criteria.
LEED certifications are available for various types of buildings, including commercial, residential, and institutional buildings. In addition to the building certifications, LEED offers certifications for interior design and construction, neighborhood development, and building operations and maintenance. LEED certifications are based on a rigorous third-party verification process, which includes a review of the building design and construction documents, an on-site inspection, and ongoing monitoring to ensure that the building continues to meet the sustainability criteria. LEED certifications represent the quality and sustainability in the building industry and can provide a variety of benefits, such as energy savings, improved indoor air quality, and enhanced marketability for building owners and tenants.
Although preferred embodiments of the present invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the spirit of the invention as set forth and defined by the following claims.
In the foregoing description of certain embodiments, specific terminology has been resorted to for the sake of clarity. However, the disclosure is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes other technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as “left” and right”, “front” and “rear”, “above” and “below” and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.
In this specification, the word “comprising” is to be understood in its “open” sense, that is, in the sense of “including”, and thus not limited to its “closed” sense, that is the sense of “consisting only of”. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear.
In addition, the foregoing describes only some embodiments of the invention(s), and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive.
Furthermore, invention(s) have been described in connection with what are presently considered to be the most practical and preferred embodiments and it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention(s). Also, the various embodiments described above may be implemented in conjunction with other embodiments, e.g., aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment.

Claims

What is claimed is:

1. A water resistive barrier system, comprising:

a foam panel coupled to a frame of a building structure;

a membrane overlaying above the foam panel;

a scratch layer overlaying above the membrane; and

an exterior layer overlaying above the scratch layer;

wherein the system has a structural tensile strength of approximately 50 psi for the foam panel having a thickness between one and eight inches.

2. The system of claim 1, further comprising:

a shield layer overlaying the exterior layer applied for additional water-resistance of the system.

3. The system of claim 2, wherein the membrane and the shield layer comprise two layers providing a water-resistive barrier of the system.

4. The system of claim 1, wherein the system is breathable.

5. The system of claim 1, wherein a pH content of the system can be equal or greater than 8.0.

6. The system of claim 1, wherein the system is erosion-resistant.

7. The system of claim 1, wherein the system comprises integral UV resistant pigments.

8. The system of claim 1, wherein the system is weather resistant.

9. The system of claim 1, wherein a thickness of the foam panel is in a range between one and twelve inches and the system has an R value in a range between four and 60 ft²*h*° F./Btu.

10. The system of claim 1, wherein the membrane further comprises:

a laminate layer at least partially adhered to the foam panel.

11. The system of claim 10, wherein the laminate membrane is formed at least partially of a recycled material.

12. The system of claim 10, wherein the laminate membrane has a surface energy in a range between 200 and 300 psi/ft²to facilitate an adherence of other materials to the laminate membrane.

13. The system of claim 1, wherein a total weight of the system is between 5.5 and 9.5 lbs. per square foot.

14. The system of claim 1, wherein the system is used in building structures having a height up to or equal to 30 feet without an additional support.

15. The system of claim 1, wherein the system is resistant to at least one of a flame spread above 40 feet or does not require bracing substantially every 30 feet.

16. The system of claim 1, wherein the foam panel is applied directly to the frame of the building structure.

17. The system of claim 1, wherein the system provides a continuous insulation outside of a building envelope.

18. A water resistive barrier system, comprising only:

a foam panel coupled to a frame of a building structure;

a membrane overlaying above the foam panel;

a scratch layer overlaying above the membrane; and

an exterior layer overlaying above the scratch layer.

19. Method of manufacturing a water resistive barrier system, the method comprising:

providing a foam panel;

coupling a membrane above the foam panel;

providing a scratch layer material for further coupling above the membrane during an installation; and

providing an exterior layer material for further coupling above a scratch layer during the installation;

wherein the foam panel and the membrane are manufactured as one panel.

20. Method of installing a water resistive barrier system, the method comprising:

providing a frame;

coupling a foam panel and a membrane to the frame;

applying a scratch layer above the membrane; and

applying an exterior layer above the scratch layer.

21. The method of claim 20, further comprising:

applying an additional shield layer for an additional water-resistance of the system.