Gypsum wood fiber structural insulated panel arrangement

Abstract

A generally planar, structural insulated panel for building construction includes a pair of outer facings disposed on opposed surfaces of a plastic foam core. Both of the outer facings are gypsum cellulose fiber board such as gypsum wood fiber board. Disposed on the exterior surface of the gypsum wood fiber board on the exterior surface and between another expanded polystyrene insulation panel is a weather resistant barrier that is fastened to the gypsum wood fiber board. The exterior surface of the second insulation panel is fastened to the gypsum wood fiber board by mechanical fasteners. The insulation panels are then coated with a basecoat which has an embedded mesh reinforcement and then a finishing coat is applied to the base coating. Vinyl or aluminum metal siding can be fastened to the structural assembly by G screw fasteners or other mechanical fasteners.

1 . A reinforced structural insulated panel arrangement for building construction, said panel arrangement comprising:
 a generally flat insulating core of an expanded plastic foam;   first and second facings attached to opposed lateral surfaces of said insulating core, wherein said first and second outer facings are respectively each gypsum wood fiber board;   a first sheet of weather resistant barrier attached to the exterior surface of one of the facings that is on the side of the panel arrangement that will be used on exterior sides of a building;   a layer of expanded plastic foam insulation panels over said weather resistant barrier layer which is attached to a building frame by corrosion resistant mechanical fasteners through the weather resistant barrier to the gypsum wood fiber board facing;   a basecoat with an embedded reinforcing mesh applied across the outer surface of the foam insulation panel; and   a finishing coat applied over the basecoat.   
   
   
       2 . The panel of  claim 1 , wherein the expanded foam insulation is selected from expanded polystyrene foam and extruded polystyrene foam. 
   
   
       3 . The panel arrangement of  claim 1 , further including a siding attached to the exterior surface of the panel arrangement by the use of corrosion resistant gypsum mechanical fasteners. 
   
   
       4 . The panel arrangement of  claim 2 , wherein the insulation core is about 31.78 kg./m 3  (2 lbs/ft 3 ) expanded polystyrene foam. 
   
   
       5 . The panel arrangement of  claim 1 , further comprising an adhesive layer disposed between said insulating core and said first and second outer facings for bonding said facings to said insulating core. 
   
   
       6 . The panel arrangement of  claim 1 , wherein the weather resistant barrier is a very fine high density polypropylene fiber or spun bonded polyethylene. 
   
   
       7 . The panel arrangement of  claim 2 , wherein the gypsum wood fiber boards are glued to the surfaces of the insulation core. 
   
   
       8 . The panel of  claim 1 , wherein the weather resistant barrier is stapled to the gypsum wood fiber board panel. 
   
   
       9 . The panel assembly of  claim 2 , wherein the exterior polystyrene panel is about 1.27 cm. (0.5 in.) to about 10.16 cm. (4.0 in.) thick. 
   
   
       10 . The panel assembly of  claim 2 , wherein the exterior polystyrene panel is about 2.54 to 3.81 cm. (1.0 to 1.50 in.) thick.