Insulated reinforced foam sheathing, reinforced vapor permeable air barrier foam panel and method of making and using same

Abstract

The invention comprises a product. The product comprises a composite panel comprising a foam insulating panel having a first primary surface and an opposite second primary surface, and a first layer of a polymeric elastomeric material on the first primary surface such that at least a portion of a first layer of reinforcing material is at least partially embedded in the polymeric elastomeric material. The composite panel also comprises a fastener for attaching the composite panel to a framing structure, wherein the fastener comprises a washer and wherein at least a portion of the first layer of a polymeric elastomeric material and the first layer of reinforcing material are disposed between the washer and the first primary surface. A method of making and using the composite panel is also disclosed.

1 - 20 . (canceled) 
     
     
         21 . An insulated sheathing product comprising:
 a foam insulating panel having a first primary surface and an opposite second primary surface, wherein the first primary surface defines a single plane;   a first layer of a water-resistant, vapor permeable polymeric material substantially covering the single plane of the first primary surface, wherein the first layer of water-resistant, vapor permeable polymeric material has an elongation factor of approximately 100% to approximately 1,000%, a water vapor transmission rating of at least 1 perm and an air permeance of less than 0.004 cfm/sq. ft. under a pressure differential of 0.3 inches of water, whereby the first layer of water-resistant, vapor permeable polymeric material provides a water-resistant, vapor permeable air barrier; and   a first layer of porous reinforcing material defining a single plane disposed on the single plane of the first primary surface of the foam insulating panel, wherein the first layer of porous reinforcing material is at least partially embedded in the first layer of water-resistant, vapor permeable polymeric material.   
     
     
         22 . The insulated sheathing product of  claim 21  further comprising:
 a second layer of porous reinforcing material defining a single plane disposed on and substantially covering the single plane of the second primary surface of the foam insulating panel; and 
 a second layer of vapor permeable polymeric material disposed on and substantially covering the second layer of porous reinforcing material, wherein the second layer of porous reinforcing material is at least partially embedded in the second layer of vapor permeable polymeric material. 
 
     
     
         23 . The insulated sheathing product of  claim 22 , wherein the foam insulating panel is polystyrene foam. 
     
     
         24 . The insulated sheathing product of  claim 22 , wherein the foam insulating panel is polyurethane foam. 
     
     
         25 . The insulated sheathing product of  claim 22 , wherein the foam insulating panel is polyisocyanurate foam. 
     
     
         26 . The insulated sheathing product of  claim 25 , wherein the first layer of porous reinforcing material is a woven fabric. 
     
     
         27 . The insulated sheathing product of  claim 25 , wherein the first layer of porous reinforcing material is a nonwoven material. 
     
     
         28 . The insulated sheathing product of  claim 25 , wherein the first layer of porous reinforcing material is a fiberglass fabric, matt, web or mesh. 
     
     
         29 . The insulated sheathing product of  claim 25 , wherein the first layer of porous reinforcing material is a fiberglass mesh. 
     
     
         30 . The insulated sheathing product of  claim 26 , wherein the second layer of porous reinforcing material is a woven fabric. 
     
     
         31 . The insulated sheathing product of  claim 27 , wherein the second layer of porous reinforcing material is a nonwoven material. 
     
     
         32 . The insulated sheathing product of  claim 28 , wherein the second layer of porous reinforcing material is a fiberglass fabric, matt, web or mesh. 
     
     
         33 . The insulated sheathing product of  claim 29 , wherein the second layer of porous reinforcing material is a fiberglass mesh. 
     
     
         34 . An insulated sheathing product comprising:
 a foam insulating panel of polyisocyanurate foam, the foam insulating panel having a first primary surface and an opposite second primary surface, wherein the first and second primary surfaces each defines a single plane;   a first layer of porous reinforcing material defining a single plane disposed on, attached to and substantially covering the single plane of the first primary surface of the foam insulating panel;   a first layer of vapor permeable polymeric material disposed on the first layer of porous reinforcing material, wherein the first layer of porous reinforcing material is at least partially embedded in the first layer of vapor permeable polymeric material, wherein the first layer of water-resistant, vapor permeable polymeric material has an elongation factor of approximately 100% to approximately 1,000%, a water vapor transmission rating of at least 1 perm and an air permeance of less than 0.004 cfm/sq. ft. under a pressure differential of 0.3 inches of water, whereby the first layer of water-resistant, vapor permeable polymeric material provides a water-resistant, vapor permeable air barrier;   a second layer of porous reinforcing material defining a single plane disposed on, attached to and substantially covering the single plane of the second primary surface of the foam insulating panel; and   a second layer of vapor permeable polymeric material disposed on the second layer of porous reinforcing material, wherein the second layer of porous reinforcing material is at least partially embedded in the second layer of vapor permeable polymeric material, wherein the second layer of water-resistant, vapor permeable polymeric material has an elongation factor of approximately 100% to approximately 1,000%, a water vapor transmission rating of at least 1 perm and an air permeance of less than 0.004 cfm/sq. ft. under a pressure differential of 0.3 inches of water, whereby the first layer of water-resistant, vapor permeable polymeric material provides a water-resistant, vapor permeable air barrier.   
     
     
         35 . An insulated sheathing product comprising:
 a foam insulating panel having a first primary surface and an opposite second primary surface, wherein the first and second primary surfaces each defines a single plane;   a first layer of porous reinforcing material laminated to the first primary surface of the foam insulating panel; and   a first layer of vapor permeable polymeric elastomeric material disposed on the first layer of porous reinforcing material, wherein the first layer of water-resistant, vapor permeable polymeric material has an elongation factor of approximately 100% to approximately 1,000%, a water vapor transmission rating of at least 1 perm and an air permeance of less than 0.004 cfm/sq. ft. under a pressure differential of 0.3 inches of water, whereby the first layer of water-resistant, vapor permeable polymeric material provides a water-resistant, vapor permeable air barrier.   
     
     
         36 . The insulated sheathing product of  claim 34 , wherein the foam insulating panel is made from polystyrene foam, polyisocyanurate foam or polyurethane foam.