Structural insulation sheathing

Abstract

Structural insulation sheathing (SIS), preferably in the form of a panel, comprises a structural member and an insulation member. The structural member and insulation members are in intimate, planar contact with one another, and the SIS structure meets both the structural (that is, AC 269) and insulation (R>2) requirements for the North American residential market. The structural 23 member of the SIS structure is multi-layer laminated paperboard. The insulation member of the SIS is a foamed sheet of a thermoplastic material such as polyisocyanurate.

1 . Structural insulation sheathing (SIS) comprising a structural member and an insulation member in intimate, planar contact with one another, the SIS comprising (i) a structural member comprising at least one layer of water resistant paperboard; and (ii) a foamed insulation member comprising a foam that has been formed from a foamable composition that is dispensed as a liquid, spray or froth onto the structural member to form a foam on such structural member. 
     
     
         2 . The SIS structure of  claim 1 , wherein the structural member comprises a plurality of superposed water resistant paperboard layers, said layers being adhered together by layers of an adhesive positioned intermediate and contacting adjacent said layers of water resistant paperboard. 
     
     
         3 . The SIS of  claim 1  characterized in that it is capable of tolerating a load in a small scale racking test, without failure, of equal to or greater than 875 pounds at a deflection of 0.6 inches, and having an insulation value, R, equal to or greater than about 2.5. 
     
     
         4 . The SIS of  claim 1  in which the combined thickness of the structural member and insulation member in intimate planar contact with one another is between about 7/16 and about 9/16 inch. 
     
     
         5 . The SIS of  claim 3  characterized as having an insulation value, R, equal to or greater than about 2.7. 
     
     
         6 . The SIS of  claim 3  characterized as having an insulation value, R, equal to or greater than about 2.8. 
     
     
         7 . The SIS of  claim 1  characterized in that its properties pass the structural performance criteria for the North American residential market set forth at ICC-ES Acceptance Criteria 269 (AC 269) “Acceptance Criteria for Racking Shear-Evaluation of Proprietary Sheathing Materials Used as Braced Wall Panels”. 
     
     
         8 . The SIS of  claim 1  in which the foamed insulation member comprises rigid polyisocyanurate or rigid or semi-rigid polyurethane foam. 
     
     
         9 . The SIS of  claim 8  in which the face of the foamed insulation member opposite the face of the foamed insulation member in contact with the structural member is in intimate, planar contact with the outer layer of the insulation member (OL-IM). 
     
     
         10 . The SIS of  claim 9  in which the OL-IM comprises at least one of fiber, paper, plastic, and aluminum foil. 
     
     
         11 . The SIS of  claim 1  in which the thickness of the structural member is between about 0.0625 and 0.250 inches. 
     
     
         12 . The SIS of  claim 1  made by an on-line polyisocyanurate liquid foaming process. 
     
     
         13 . The SIS of any of the preceding claims attached to a building wall. 
     
     
         14 . A building wall comprising at least two SIS of  claim 13 , wherein the two SIS are placed adjacent to each other and are sealed together with a weather resistant sealing material. 
     
     
         15 . The wall structure of  claim 14 , wherein the wall structure meets the criteria for a Weather Resistant Barrier. 
     
     
         16 . A process for making a SIS panel comprising the steps of
 a) feeding a sheet of structural member to a continuous foaming line;   b) dispensing liquid, sprays, or froths of a foamable composition onto the surface of the structural member; and   c) allowing the foamable composition to expand and cure.   
     
     
         17 . The process of  claim 16  comprising the additional step of feeding a separate outer layer onto the surface of the foamable composition such that the outer layer adheres to the foam layer of the insulating member. 
     
     
         18 . The process of  claim 17  wherein the outer layer is a barrier material for inhibiting egress of cell gas from the insulating member.