US 12,247,397 B2
Insulated sheathing panel and methods for use and manufacture thereof
Allen Sealock, Jefferson, GA (US); Joel Barker, Townville, SC (US); and Terry Liles, Jefferson, GA (US)
Assigned to Huber Engineered Woods LLC, Charlotte, NC (US)
Filed by HUBER ENGINEERED WOODS LLC, Charlotte, NC (US)
Filed on Jan. 31, 2022, as Appl. No. 17/588,628.
Application 14/982,780 is a division of application No. 13/907,628, filed on May 31, 2013, granted, now 9,234,355, issued on Jan. 12, 2016.
Application 17/588,628 is a continuation of application No. 16/794,568, filed on Feb. 19, 2020, granted, now 11,414,865.
Application 16/794,568 is a continuation of application No. 14/982,780, filed on Dec. 29, 2015, granted, now 10,570,616, issued on Feb. 25, 2020.
Claims priority of provisional application 61/654,064, filed on May 31, 2012.
Prior Publication US 2022/0154466 A1, May 19, 2022
Int. Cl. E04C 2/24 (2006.01); B32B 9/02 (2006.01); B32B 9/04 (2006.01); B32B 9/06 (2006.01); E04B 1/76 (2006.01); E04B 1/80 (2006.01); E04B 2/00 (2006.01); E04B 5/02 (2006.01); E04C 2/00 (2006.01); E04C 2/16 (2006.01); E04C 2/20 (2006.01); E04C 2/38 (2006.01); E04F 13/08 (2006.01)
CPC E04C 2/243 (2013.01) [B32B 9/02 (2013.01); B32B 9/046 (2013.01); B32B 9/06 (2013.01); E04B 1/762 (2013.01); E04B 1/80 (2013.01); E04C 2/00 (2013.01); E04C 2/16 (2013.01); E04C 2/205 (2013.01); E04C 2/246 (2013.01); E04C 2/38 (2013.01); E04C 2/46 (2013.01); E04C 2/50 (2013.01); E04F 13/08 (2013.01); B32B 2307/724 (2013.01); B32B 2307/7265 (2013.01); E04B 2001/7691 (2013.01); Y10T 428/233 (2015.01); Y10T 428/239 (2015.01)] 9 Claims
OG exemplary drawing
 
1. A sheathing and insulating structural wall panel for use in a panelized sheathing and insulating system for a building having a structural frame, the system also including an adjacent sheathing and insulating structural wall panel and a seam sealant, the wall panel consisting essentially of:
a structural layer made of an oriented strand board and having an outer surface, an inner surface, and at least one edge extending therebetween, wherein the structural layer is a structural-use panel that is structural-rated according to the PS-2-92 performance standard;
a barrier layer secured to the outer surface of the structural layer prior to installation of the wall panel on the structural frame of the building; and
an insulation layer having an outer surface secured to the inner surface of the structural layer prior to installation of the wall panel on the structural frame of the building and having an inner surface that is opposite the insulation layer outer surface, wherein the insulation layer:
has a density in the range of about 1 to about 20 pounds per cubic feet (pcf) according to ASTM D1622,
has a compressive strength of at least about 5 pounds per square inch (psi) according to ASTM D1621,
has a tensile strength of greater than about 300 pounds per cubic foot (pcf) according to ASTM D1623,
has a dimensional stability of about less than 5% according to ASTM D2126,
has a water vapor permeance from about 0.1 to about 20 perms as determined according to ASTM E96,
has a thickness of about 0.25 in. to about 3 in, and
is secured to the structural layer by an adhesive selected from a phenol-formaldehyde resin, hot-melt adhesive, polyvinyl acetate (PVA) resin, or a combination thereof,
wherein the insulation layer, the structural layer, and the barrier layer form an integral three-layer arrangement configured so that with the wall panel placed external to the structural frame, with the barrier layer facing outward, with the insulation layer facing inward and the insulation layer inner surface contacting the structural frame, and with the three-layer wall panel fastened securely in place to the structural frame by fasteners extending all the way through the three-layer wall panel and into the structural frame, the three-layer wall panel forms a structural insulated wall deck, without any additional structural bracing, to which an exterior wall finish can be directly applied,
wherein, with the wall panel fastened to the structural frame, the wall panel exhibits at least the minimum allowable shear capacity (pounds per linear feet (plf)) for braced wall panels constructed according to method 3 described in 2006 International Building Code (IBC) Section 2308.9.3, and as determined in accordance with 2006 IBC and International Code Council Evaluation Service (ICC-ES) Acceptance Criteria 269 (AC269),
wherein in use the wall panel is fastened to the structural frame with the at least one edge adjacent to at least one edge of the adjacent wall panel to define a longitudinal seam between the two adjacent wall panels so that the seam sealant can be applied to the two wall panels to cover the seam to form the panelized sheathing and insulating system.