Methods of forming building wall systems and building wall systems

Abstract

A method of forming a building wall system in the absence of building paper or housewrap that comprises providing a generally flat structural insulating sheathing. The sheathing comprises at least a first layer, a second layer and a third layer. The first and third layers comprises an alkenyl aromatic polymer foam. The second layer comprises paperboard. The insulating sheathing is fastened to the stud wall to form the building wall system such that a seal is formed that inhibits water from penetrating therethrough. The building wall system in the absence of building paper or housewrap passes the test requirements set forth in Section 1403.2 of the 2003 International Building Code.

1 . A method of forming a building wall system in the absence of building paper or housewrap, the method comprising the acts of: 
 providing a generally flat structural insulating sheathing comprising at least a first layer, a second layer and a third layer, the first layer comprising an alkenyl aromatic polymer foam, the second layer comprising paperboard, and the third layer comprising an alkenyl aromatic polymer foam;    providing a stud wall; and    fastening the insulating sheathing to the stud wall to form the building wall system such that a seal is formed that inhibits water from penetrating therethrough,    wherein the building wall system in the absence of building paper or housewrap passes the test requirements set forth in Section 1403.2 of the 2003 International Building Code.    
   
   
       2 . The method of  claim 1 , wherein the stud wall comprises wood.  
   
   
       3 . The method of  claim 1 , wherein the stud wall comprises metal.  
   
   
       4 . The method of  claim 1 , wherein the fastening of the insulating sheathing to the stud wall includes using a plurality of nails.  
   
   
       5 . The method of  claim 4 , wherein each of the plurality of nails includes a head, each of the head of the plurality of nails in its installed position is located near or at the face of the second layer.  
   
   
       6 . The method of  claim 1 , wherein the fastening of the insulating sheathing to the stud wall includes using an adhesive.  
   
   
       7 . The method of  claim 1 , wherein the fastening of the insulating sheathing to the stud wall includes using a plurality of staples.  
   
   
       8 . The method of  claim 1 , wherein the first and third layers comprise a polystyrene foam.  
   
   
       9 . The method of  claim 8 , wherein the first and third layers have a density of from about 1 to about 3 lbs/ft 3 .  
   
   
       10 . The method of  claim 1 , wherein the first and third layers are made of the same alkenyl aromatic polymer.  
   
   
       11 . The method of  claim 1 , wherein the thickness of each of the first and third layers is from about 0.1 to about 1 inch.  
   
   
       12 . The method of  claim 1 , wherein the paperboard is a paperboard laminate.  
   
   
       13 . The method of  claim 1 , wherein the thickness of the second layer is from about 0.05 to about 0.25 inch.  
   
   
       14 . The method of  claim 1 , wherein the insulating sheathing further includes a first laminated surface coating, the first laminated surface coating being attached to the first layer.  
   
   
       15 . The method of  claim 14 , wherein the insulating sheathing further includes a second laminated surface coating, the second laminated surface coating being attached to the third layer.  
   
   
       16 . The method of  claim 1 , wherein the building wall system is formed in the absence of tape and sealants.  
   
   
       17 . A method of forming a building wall system in the absence of building paper or housewrap, the method comprising the acts of: 
 providing a generally flat structural insulating sheathing comprising at least a first foam layer, a second layer and a third foam layer, the first foam layer comprising a polyolefin, polyisocyanurate, polyurethane, polyester, or combinations thereof, the second layer comprising paperboard, and the third foam layer comprising a polyolefin, polyisocyanurate, polyurethane, polyester, or combinations thereof;    providing a stud wall; and    fastening the insulating sheathing to the stud wall to form the building wall system such that a seal is formed that inhibits water from penetrating therethrough,    wherein the building wall system in the absence of building paper or housewrap passes the test requirements set forth in Section 1403.2 of the 2003 International Building Code.    
   
   
       18 . The method of  claim 17 , wherein the fastening of the insulating sheathing to the stud wall includes using a plurality of nails.  
   
   
       19 . The method of  claim 18 , wherein each of the plurality of nails includes a head, each of the head of the plurality of nails in its installed position is located near or at the face of the second layer.  
   
   
       20 . The method of  claim 17 , wherein the fastening of the insulating sheathing to the stud wall includes using an adhesive.  
   
   
       21 . The method of  claim 17 , wherein the fastening of the insulating sheathing to the stud wall includes using a plurality of staples.  
   
   
       22 . The method of  claim 17 , wherein the first and third foam layers are made of the same polyolefin, polyisocyanurate, polyurethane, polyester, or combinations thereof.  
   
   
       23 . The method of  claim 17 , wherein the thickness of each of the first and third layers is from about 0.1 to about 1 inch.  
   
   
       24 . The method of  claim 17 , wherein the paperboard is a paperboard laminate.  
   
   
       25 . The method of  claim 17 , wherein the thickness of the second layer is from about 0.05 to about 0.25 inch.  
   
   
       26 . The method of  claim 17 , wherein the insulating sheathing further includes a first laminated surface coating, the first laminated surface coating being attached to the first layer.  
   
   
       27 . The method of  claim 17 , wherein the building wall system is formed in the absence of tape and sealants.  
   
   
       28 . A building wall system in the absence of building paper or housewrap, comprising: 
 a stud wall; and    a generally flat structural insulating sheathing comprising at least a first layer, a second layer, and a third layer, the first layer comprising an alkenyl aromatic polymer foam, the second layer comprising paperboard, and the third layer comprising an alkenyl aromatic polymer foam, the insulating sheathing being attached to the stud wall such that a seal is formed that inhibits water from penetrating therethrough,    wherein the building wall system in the absence of building paper or housewrap passes the test requirements set forth in Section 1403.2 of the 2003 International Building Code.    
   
   
       29 . The building wall system of  claim 28 , wherein the first and third layers comprise a polystyrene foam.  
   
   
       30 . The building wall system of  claim 28 , wherein the first and third layers have a density of from about 1 to about 3 lbs/ft 3 .  
   
   
       31 . The building wall system of  claim 28 , wherein the thickness of each of the first and third layers is from about 0.1 to about 1 inch.  
   
   
       32 . The building wall system of  claim 28 , wherein the paperboard is a paperboard laminate.  
   
   
       33 . The building wall system of  claim 28 , wherein the thickness of the second layer is from about 0.05 to about 0.25 inch.  
   
   
       34 . A building wall system in the absence of building paper or housewrap, comprising: 
 a stud wall; and    a generally flat structural insulating sheathing comprising at least a first layer, a second layer, and a third layer, the first layer comprising a polyolefin, polyisocyanurate, polyurethane, polyester, or combinations thereof, the second layer comprising paperboard, and the third layer comprising a polyolefin, polyisocyanurate, polyurethane, polyester, or combinations thereof, the insulating sheathing being attached to the stud wall such that a seal is formed that inhibits water from penetrating therethrough,    wherein the building wall system in the absence of building paper or housewrap passes the test requirements set forth in Section 1403.2 of the 2003 International Building Code.    
   
   
       35 . The building wall system of  claim 34 , wherein the first and third foam layers have a density of from about 1 to about 3 lbs/ft 3 .  
   
   
       36 . The building wall system of  claim 34 , wherein the thickness of each of the first and third foam layers is from about 0.1 to about 1 inch.  
   
   
       37 . The building wall system of  claim 34 , wherein the paperboard is a paperboard laminate.  
   
   
       38 . The building wall system of  claim 34 , wherein the thickness of the second layer is from about 0.05 to about 0.25 inch.  
   
   
       39 . A structural insulating sheathing adapted to be used in a building wall system, the insulating sheathing comprising a first layer, a second layer, and a third layer, the first layer comprising an alkenyl aromatic polymer foam, the second layer comprising paperboard, and the third layer comprising an alkenyl aromatic polymer foam, wherein the insulating sheathing has a flexural strength of at least 170 psi as measured in accordance with ASTM C 393, an R-value of at least 2.0 (ft 2 )(° F.)(hr)/(BTU) as measured in accordance with ASTM C 518.  
   
   
       40 . The sheathing of  claim 39 , wherein the insulating sheathing has a flexural strength of at least 225 psi as measured in accordance with ASTM C 393.  
   
   
       41 . The sheathing of  claim 40 , wherein the insulating sheathing has a flexural strength of at least 300 psi as measured in accordance with ASTM C 393.  
   
   
       42 . The sheathing of  claim 39 , wherein the insulating sheathing has an R-value of at least 2.5 as measured in accordance with ASTM C 518.  
   
   
       43 . The sheathing of  claim 39 , wherein the first and third layers have a density of from about 1 to about 3 lbs/ft 3 .  
   
   
       44 . The sheathing of  claim 39 , wherein the thickness of each of the first and third layers is from about 0.1 to about 1 inch.  
   
   
       45 . The sheathing of  claim 39 , wherein the paperboard is a paperboard laminate.  
   
   
       46 . The sheathing of  claim 39 , wherein the thickness of the second layer is from about 0.05 to about 0.25 inch.  
   
   
       47 . A structural insulating sheathing adapted to be used in a building wall system, the insulating sheathing comprising a first foam layer, a second layer, and a third foam layer, the first foam layer comprising a polyolefin, polyisocyanurate, polyurethane, polyester, or combinations thereof, the second layer comprising paperboard, and the third foam layer comprising a polyolefin, polyisocyanurate, polyurethane, polyester, or combinations thereof, wherein the insulating sheathing has a flexural strength of at least 170 psi as measured in accordance with ASTM C 393, an R-value of at least 2.0 (ft 2 )(° F.)(hr)/(BTU) as measured in accordance with ASTM C 518.  
   
   
       48 . The sheathing of  claim 47 , wherein the insulating sheathing has a flexural strength of at least 225 psi as measured in accordance with ASTM C 393.  
   
   
       49 . The sheathing of  claim 47 , wherein the insulating sheathing has a flexural strength of at least 300 psi as measured in accordance with ASTM C 393.  
   
   
       50 . The sheathing of  claim 47 , wherein the insulating sheathing has an R-value of at least 2.5 as measured in accordance with ASTM C 518.  
   
   
       51 . The sheathing of  claim 47 , wherein the first and third foam layers have a density of from about 1 to about 3 lbs/ft 3 .  
   
   
       52 . The sheathing of  claim 47 , wherein the thickness of each of the first and third foam layers is from about 0.1 to about 1 inch.  
   
   
       53 . The sheathing of  claim 47 , wherein the paperboard is a paperboard laminate.  
   
   
       54 . The sheathing of  claim 47 , wherein the thickness of the second layer is from about 0.05 to about 0.25 inch.