Wall panel system and method

Abstract

The water resistive barrier system may include a foam panel coupled to a frame of a building. The system may include a membrane above the foam panel. The system may include a scratch layer above the membrane. The system may include an exterior layer above the scratch layer. The system wherein the foam panel has a thickness between two and eight inches may have a structural tensile strength of 50 psi. In some embodiments, a method of manufacturing the water resistive barrier system may include providing a foam panel. The method may include coupling a membrane above the foam panel. The foam panel and the membrane can be manufactured as one panel. The method may include providing a scratch layer material for further coupling above the membrane during an installation. The method may include providing an exterior layer material for further coupling above a scratch layer during the installation.

What is claimed is: 
     
         1 . A water resistive barrier system, comprising:
 a foam panel coupled to a frame of a building structure;   a membrane overlaying above the foam panel;   a scratch layer overlaying above the membrane; and   an exterior layer overlaying above the scratch layer;   wherein the system has a structural tensile strength of approximately 50 psi for the foam panel having a thickness between one and eight inches.   
     
     
         2 . The system of  claim 1 , further comprising:
 a shield layer overlaying the exterior layer applied for additional water-resistance of the system.   
     
     
         3 . The system of  claim 2 , wherein the membrane and the shield layer comprise two layers providing a water-resistive barrier of the system. 
     
     
         4 . The system of  claim 1 , wherein the system is breathable. 
     
     
         5 . The system of  claim 1 , wherein a pH content of the system can be equal or greater than 8.0. 
     
     
         6 . The system of  claim 1 , wherein the system is erosion-resistant. 
     
     
         7 . The system of  claim 1 , wherein the system comprises integral UV resistant pigments. 
     
     
         8 . The system of  claim 1 , wherein the system is weather resistant. 
     
     
         9 . The system of  claim 1 , wherein a thickness of the foam panel is in a range between one and twelve inches and the system has an R value in a range between four and 60 ft 2 *h*° F./Btu. 
     
     
         10 . The system of  claim 1 , wherein the membrane further comprises:
 a laminate layer at least partially adhered to the foam panel.   
     
     
         11 . The system of  claim 10 , wherein the laminate membrane is formed at least partially of a recycled material. 
     
     
         12 . The system of  claim 10 , wherein the laminate membrane has a surface energy in a range between 200 and 300 psi/ft 2  to facilitate an adherence of other materials to the laminate membrane. 
     
     
         13 . The system of  claim 1 , wherein a total weight of the system is between 5.5 and 9.5 lbs. per square foot. 
     
     
         14 . The system of  claim 1 , wherein the system is used in building structures having a height up to or equal to 30 feet without an additional support. 
     
     
         15 . The system of  claim 1 , wherein the system is resistant to at least one of a flame spread above 40 feet or does not require bracing substantially every 30 feet. 
     
     
         16 . The system of  claim 1 , wherein the foam panel is applied directly to the frame of the building structure. 
     
     
         17 . The system of  claim 1 , wherein the system provides a continuous insulation outside of a building envelope. 
     
     
         18 . A water resistive barrier system, comprising only:
 a foam panel coupled to a frame of a building structure;   a membrane overlaying above the foam panel;   a scratch layer overlaying above the membrane; and   an exterior layer overlaying above the scratch layer.   
     
     
         19 . Method of manufacturing a water resistive barrier system, the method comprising:
 providing a foam panel;   coupling a membrane above the foam panel;   providing a scratch layer material for further coupling above the membrane during an installation; and   providing an exterior layer material for further coupling above a scratch layer during the installation;   wherein the foam panel and the membrane are manufactured as one panel.   
     
     
         20 . Method of installing a water resistive barrier system, the method comprising:
 providing a frame;   coupling a foam panel and a membrane to the frame;   applying a scratch layer above the membrane; and   applying an exterior layer above the scratch layer.   
     
     
         21 . The method of  claim 20 , further comprising:
 applying an additional shield layer for an additional water-resistance of the system.