Methods of providing water protection to wall structures and wall structures formed by the same

Abstract

The present invention relates to methods of providing water protection to exterior and interior wall structures as well as the improved wall structures formed by the methods. The methods comprise providing one or more water resistant wall sheathing panels and installing the wall sheathing panel(s) on a wall structure of a building. Each of the wall sheathing panels comprises a wood sheet product and a nonwoven fabric mat adhered to at least one side of the wood sheet product.

1 . A method of providing water protection to an exterior wall structure of a building comprising the steps of: 
 (a) providing one or more water resistant wall sheathing panels, each panel comprising a wood sheet product and a nonwoven fabric mat adhered to the wood sheet product,    wherein each panel is produced by subjecting a wood sheet product and a “B” stage condition nonwoven fabric mat to sufficient heat and pressure to complete the cure of the binder in the mat and to adhere the mat to the wood sheet product, the “B” stage condition mat comprising fibers bonded together with a resin binder that is only partially cured; and    (b) installing the wall sheathing panel(s) on an exterior wall structure of a building such that the nonwoven mat of each panel faces outwardly from the building.    
   
   
       2 . The method of  claim 1 , wherein the fibers are glass fibers and the mat is a glass fiber nonwoven mat.  
   
   
       3 . The method of  claim 1 , wherein the fibers are polyester fibers and the mat is a polyester fiber nonwoven mat.  
   
   
       4 . The method of  claim 1 , wherein the wood sheet product is selected from the group consisting of OSB, particle board, chip board, plywood, and hardboard.  
   
   
       5 . The method of  claim 1 , wherein the resin binder is selected from the group consisting of a furfuryl alcohol based resin, a phenol formaldehyde resin, a melamine formaldehyde resin, and mixtures thereof.  
   
   
       6 . The method of  claim 1 , wherein each of the one or more wall sheathing panels includes outer edges, the outer edges including self-adhesive tape covered by one or more strips that are removable from the self-adhesive tape.  
   
   
       7 . The method of  claim 6 , wherein step (b) comprises removing the removable strip or strips from the self-adhesive tape of one of the wall sheathing panels and joining the self adhesive tape of the wall sheathing panel with the exterior wall structure or with another wall sheathing panel so as to form a seal.  
   
   
       8 . The method of  claim 1 , wherein each of the one or more wall sheathing panels includes outer edges and wherein step (b) comprises forming a seal between the edges of one of the panels and the exterior wall structure or another wall sheathing panel using epoxy resin.  
   
   
       9 . The method of  claim 1 , further comprising attaching an exterior material to the nonwoven fabric mat of each of the wall sheathing panel(s).  
   
   
       10 . The method of  claim 1 , wherein a fungicide, pesticide, fire retardant, or mixture thereof is included in the nonwoven fabric mat.  
   
   
       11 . An exterior wall structure of a building comprising: 
 (1) a plurality of water resistant wall sheathing panels attached to an exterior wall frame of a building as a base layer, each panel comprising a wood sheet product and a nonwoven fabric mat adhered to the wood sheet product,    wherein each panel is produced by subjecting a wood sheet product and a “B” stage condition nonwoven fabric mat to sufficient heat and pressure to complete the cure of the binder in the mat and to adhere the mat to the wood sheet product, the “B” stage condition mat comprising fibers bonded together with a resin binder that is only partially cured, and    wherein the nonwoven mat of each panel faces outwardly from the building; and    (2) an exterior material attached over the nonwoven fabric mats of the base layer of wall sheathing panels.    
   
   
       12 . A method of providing water protection to an interior wall structure of a building comprising the steps of: 
 (a) providing one or more water resistant wall sheathing panels, each panel comprising a wood sheet product and a nonwoven fabric mat adhered to the wood sheet product,    wherein each panel is produced by subjecting a wood sheet product and a “B” stage condition nonwoven fabric mat to sufficient heat and pressure to complete the cure of the binder in the mat and to adhere the mat to the wood sheet product, the “B” stage condition mat comprising fibers bonded together with a resin binder that is only partially cured; and    (b) installing the wall sheathing panel(s) on an interior wall structure of a building such that the nonwoven mat of each panel faces toward the interior of a room formed by the wall structure, the interior wall structure being exposed to a water source.    
   
   
       13 . The method of  claim 12  wherein the nonwoven fabric mat is selected from the group consisting of a glass fiber nonwoven mat and a polyester fiber nonwoven mat.  
   
   
       14 . The method of  claim 12 , further comprising attaching a decorative material to the nonwoven fabric mat of each of the wall sheathing panel(s).  
   
   
       15 . The method of  claim 14 , wherein the decorative material is tile.  
   
   
       16 . The method of  claim 12 , wherein the water source is selected from the group consisting of a water pipe, a sink, a tub, and a shower.  
   
   
       17 . An interior wall structure of a building comprising: 
 (1) a plurality of water resistant wall sheathing panels attached to an interior wall frame of a building as a base layer, each panel comprising a wood sheet product and a nonwoven fabric mat adhered to the wood sheet product,    wherein each panel is produced by subjecting a wood sheet product and a “B” stage condition nonwoven fabric mat to sufficient heat and pressure to complete the cure of the binder in the mat and to adhere the mat to the wood sheet product, the “B” stage condition mat comprising fibers bonded together with a resin binder that is only partially cured, and    wherein the nonwoven fabric mat of each panel faces toward the interior of a room formed by the wall structure; and    (2) a decorative material attached over the nonwoven fabric mats of the base layer of wall sheathing panels.    
   
   
       18 . A method of providing water protection to an exterior wall structure of a building comprising the steps of: 
 (a) providing one or more water resistant wall sheathing panels, each panel comprising:    a wood sheet product;    a nonwoven fabric mat adhered to the wood sheet product; and    an organic waterproof coating adhered to the nonwoven fabric mat; and    (b) installing the wall sheathing panel(s) on an exterior wall structure of a building such that the coated nonwoven mat of each panel faces outwardly from the building.    
   
   
       19 . The method of  claim 18  wherein the nonwoven fabric mat is selected from the group consisting of a glass fiber nonwoven mat and a polyester fiber nonwoven mat.  
   
   
       20 . The method of  claim 18 , wherein each of the one or more wall sheathing panels includes outer edges, the outer edges including self-adhesive tape covered by one or more strips that are removable from the self-adhesive tape.  
   
   
       21 . The method of  claim 20 , wherein step (b) comprises removing the removable strip or strips from the self-adhesive tape of one of the wall sheathing panels and joining the self adhesive tape of the wall sheathing panel with the exterior wall structure or with another wall sheathing panel so as to form a seal.  
   
   
       22 . The method of  claim 18 , wherein each of the one or more wall sheathing panels includes outer edges and wherein step (b) comprises forming a seal between the edges of one of the panels and the exterior wall structure or another wall sheathing panel using epoxy resin.  
   
   
       23 . The method of  claim 18 , further comprising attaching an exterior material to the coated mat of each of the wall sheathing panels.  
   
   
       24 . The method of  claim 18 , wherein the mat comprises a glass fiber nonwoven mat and the one or more sheathing panels are produced by subjecting a wood sheet product and a “B” stage condition nonwoven fabric mat to sufficient heat and pressure to complete the cure of the binder in the mat and to adhere the mat to the wood sheet product, the “B” stage condition mat comprising fibers bonded together with a resin binder that is only partially cured.  
   
   
       25 . The method of  claim 18 , wherein the mat comprises a glass fiber nonwoven mat comprising glass fibers bonded together with a formaldehyde free binder.  
   
   
       26 . The method of  claim 18 , wherein the mat includes a fungicide, pesticide, fire retardant, or mixture thereof.  
   
   
       27 . The method of  claim 18 , wherein the organic waterproof coating is selected from the group consisting of asphalt, organic silicone, rubber, and polyvinyl chloride.  
   
   
       28 . An exterior wall structure of a building comprising: 
 a plurality of water resistant wall sheathing panels attached to an exterior wall frame of a building as a base layer, each panel comprising a wood sheet product, a nonwoven fabric mat adhered to the wood sheet product, and an organic waterproof coating adhered to the nonwoven fabric mat, wherein the waterproof coating of each panel faces outwardly from the building; and    an exterior material attached over the coated nonwoven fabric mats of the base layer of wall sheathing panels.    
   
   
       29 . A method of providing water protection to an interior wall structure of a building comprising the steps of: 
 (a) providing one or more water resistant wall sheathing panels, each panel comprising:    a wood sheet product;    a nonwoven fabric mat adhered to the wood sheet product; and    an organic waterproof coating adhered to the nonwoven fabric mat; and    (b) installing the wall sheathing panel(s) on an interior wall structure of a building such that the coated nonwoven mat of each panel faces toward the interior of a room formed by the wall structure, the interior wall structure being exposed to a water source.    
   
   
       30 . The method of  claim 29  wherein the nonwoven fabric mat is selected from the group consisting of a glass fiber nonwoven mat and a polyester fiber nonwoven mat.  
   
   
       31 . The method of  claim 29 , further comprising attaching a decorative material to the coated mats of the wall sheathing panel(s).  
   
   
       32 . The method of  claim 31 , wherein the decorative material is tile.  
   
   
       33 . The method of  claim 29 , wherein the water source is selected from the group consisting of a water pipe, a sink, a tub, and a shower.  
   
   
       34 . An interior wall structure of a building comprising: 
 a plurality of water resistant wall sheathing panels attached to an interior wall frame of a building as a base layer, each panel comprising a wood sheet product, a nonwoven fabric mat adhered to the wood sheet product, and an organic waterproof coating adhered to the nonwoven fabric mat, wherein the waterproof coating of each panel faces toward the interior of a room formed by the wall structure; and    a decorative material attached over the coated nonwoven fabric mats of the base layer of wall sheathing panels.    
   
   
       35 . A method of providing water protection to an exterior wall structure of a building comprising the steps of: 
 (a) providing one or more water resistant wall sheathing panels, each panel comprising a wood sheet product and a nonwoven fabric mat adhered to the wood sheet product,    wherein each panel is produced by: 
 (1) forming a composite mat comprising: 
 (i) a mat formed from a furnish comprising wood particles and a binder, the mat having a first face and a second face; and  
 (ii) a nonwoven fabric mat contacting the first face of the mat formed from the furnish; and  
 
 (2) subjecting the composite mat to sufficient heat and pressure to form a wall sheathing panel comprising a wood sheet product having a first face, a second face, and edges with the nonwoven fabric mat adhered to the first face of the wood sheet product; and  
   (b) installing the wall sheathing panel(s) on an exterior wall structure of a building such that the nonwoven mat of each panel faces outwardly from the building.    
   
   
       36 . A method of providing water protection to an interior wall structure of a building comprising the steps of: 
 (a) providing one or more water resistant wall sheathing panels, each panel comprising a wood sheet product and a nonwoven fabric mat adhered to the wood sheet product,    wherein each panel is produced by: 
 (1) forming a composite mat comprising: 
 (i) a mat formed from a furnish comprising wood particles and a binder, the mat having a first face and a second face; and  
 (ii) a nonwoven fabric mat contacting the first face of the mat formed from the furnish; and  
 
 (2) subjecting the composite mat to sufficient heat and pressure to form a wall sheathing panel comprising a wood sheet product having a first face, a second face, and edges with the nonwoven fabric mat adhered to the first face of the wood sheet product; and  
   (b) installing the wall sheathing panel(s) on an interior wall structure of a building such that the nonwoven mat of each panel faces toward the interior of a room formed by the wall structure, the interior wall structure being exposed to a water source.