Vapor-permeable, water-resistant sheathing and methods thereof

Abstract

Embodiments of the present invention generally relate to sheathings generally used for building structures. More specifically, embodiments of the present invention relate to vapor-permeable, water-resistant, surface-treated sheathings having a drainage plane. In one embodiment a sheathing comprises a plurality of core layers, a first and second surface layer, each defining an exterior surface of the sheathing, and a plurality of adhesive layers, each disposed between each of the plurality of core layers, wherein the sheathing comprises a permeability rate of at least about 5 perms, and an absorption rate of less than about 15% water-by-weight.

1 . A sheathing comprising:
 a plurality of core layers;   a first and second surface layer, each defining an exterior surface of the sheathing; and   a plurality of adhesive layers, each disposed between each of the plurality of core layers;   wherein the sheathing comprises a permeability rate of at least about 5 perms, and an absorption rate of less than about 15% water-by-weight.   
     
     
         2 . The sheathing of  claim 1 , having a thickness ranging from about 0.050 inch to about 0.625 inch. 
     
     
         3 . The sheathing of  claim 1 , wherein each of the plurality of core layers comprise at least one of a cellulosic or polymer material. 
     
     
         4 . The sheathing of  claim 3 , wherein each of the plurality of core layers comprise paperboard. 
     
     
         5 . The sheathing of  claim 1 , further comprising at least four core layers. 
     
     
         6 . The sheathing of  claim 1 , wherein the at least an adhesive layer comprises at least one of polyvinyl alcohol, acrylic, thermoplastic hot melt, urea or melamine formaldehyde resin, phenolic, or blends or copolymers thereof. 
     
     
         7 . The sheathing of  claim 6 , wherein the at least an adhesive layer comprises clay impregnated polyvinyl alcohol. 
     
     
         8 . The sheathing of  claim 1 , wherein the first and second surface layers each comprise at least one of a polymer layer or an adhesive layer. 
     
     
         9 . The sheathing of  claim 8 , wherein both the first and second surface layer each comprise a layer of clay impregnated polyvinyl alcohol. 
     
     
         10 . The sheathing of  claim 1 , wherein the first and second surface layers each comprise a drainage plane. 
     
     
         11 . The sheathing of  claim 10 , wherein the drainage plane comprises a plurality of mechanically deformed channels. 
     
     
         12 . The sheathing of  claim 10 , wherein the channels comprise a depth of between about 0.020 inch to about 0.080 inch. 
     
     
         13 . A sheathing comprising:
 at least four core layers comprising a cellulosic or polymeric material;   a first and second surface layer comprising a layer of clay impregnated polyvinyl alcohol; and   a plurality of polyvinyl alcohol adhesive layers, each disposed between each of the core layers;   wherein the sheathing comprises a permeability rate of at least about 5 perms, and an absorption rate of less than about 15% water-by-weight.   
     
     
         14 . The sheathing of  claim 13 , wherein the sheathing comprises a total thickness of between about 0.050 inch to about 0.625 inch. 
     
     
         15 . The sheathing of  claim 13 , wherein the first and second surface layers each comprise a plurality of mechanically deformed channels, defining a drainage plane. 
     
     
         16 . The sheathing of  claim 15 , wherein the channels of the drainage plane are uniformly diamond-shaped. 
     
     
         17 . The sheathing of  claim 16 , wherein the channels comprise a depth of between about 0.020 inch to about 0.080 inch. 
     
     
         18 . The sheathing of  claim 13 , wherein the sheathing comprises a drainage rate of about 90% drainage. 
     
     
         19 . A method of protecting a structure, comprising:
 providing a sheathing comprising:
 a plurality of core layers; 
 a first and second surface layer, each defining an exterior surface of the sheathing; and 
 a plurality of adhesive layers, each disposed between each of the plurality of core layers; 
 wherein the sheathing comprises a permeability rate of at least about 5 perms, and an absorption rate of less than about 15% water-by-weight; and 
   adhering the sheathing to a structural member of the structure using an attachment means.   
     
     
         20 . The method of protecting a structure in  claim 19 , wherein the first and second surface layers of the sheathing each comprise a plurality of mechanically deformed channels, defining a drainage plane.