Continuous Insulation Sheathing for Construction

Abstract

The present invention generally relates to insulation sheathing in interior or exterior wall constructions for residential and business applications. More specifically, the invention pertains to an improved insulation sheathing (IS) system such as a wall sheathing (IWS) system that prevents waterproofing failure, mold, mildew, and wood rot, associated with conventional wall constructions. Particularly, this invention relates to insulation sheathing combined with a weather-resistive barrier that allows for drainage of moisture in wall construction applications. The product may be used as continuous or non-continuous insulation sheathing. In one embodiment, this invention relates to a first IS panel, such as an IWS panel, used for construction purposes, comprising the following layers: an insulation facer layer having an outer surface and an inner surface; a first insulation layer having an outer surface and an inner surface; and a weather-resistive barrier (WRB) layer having an outer surface and an inner surface; wherein the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer; wherein the inner surface of the WRB layer is secured to the outer surface of the first insulation layer through an adhesive layer; wherein, the WRB layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and wherein the extension flap of the WRB layer further comprises a removably attached release-liner attached to the extension flap portion of the WRB layer's inner surface.

1 . A first insulation sheathing (IS) panel, used for construction purposes, comprising the following layers:
 (i) an insulation facer layer having an outer surface and an inner surface; and   (ii) a first insulation layer having an outer surface and an inner surface;   wherein the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;   wherein, the insulation facer layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap;   wherein the extension flap of the insulation facer layer further comprises a removably attached release-liner attached to the insulation facer layer's outer surface; and   wherein the insulation facer layer does not have embossment on its outer surface.   
     
     
         2 . A first IS panel, used for construction purposes, comprising the following layers:
 (i) an insulation facer layer having an outer surface and an inner surface;   (ii) an open-celled insulation layer having an outer surface and an inner surface;   (iii) a first insulation layer having an outer surface and an inner surface; and   (iv) a WRB layer having an outer surface and an inner surface;   wherein the inner surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer, or the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;   wherein the outer surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the first insulation layer;   wherein, the insulation facer layer comprises embossment on its surface;   wherein the inner surface of the WRB layer is secured to the outer surface of the first insulation layer through an adhesive layer;   wherein the WRB layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and   wherein the extension flap of the WRB layer further comprises a removably attached release-liner attached to the extension flap portion of the WRB layer's inner surface.   
     
     
         3 . The first IS panel, as recited in  claim 2 , used for construction purposes, comprising the following layers:
 (i) an insulation facer layer having an outer surface and an inner surface;   (ii) a first insulation layer having an outer surface and an inner surface; and   (iii) a WRB layer having an outer surface and an inner surface;   wherein, the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;   wherein the inner surface of the WRB layer is secured to the outer surface of the first insulation layer through an adhesive layer;   wherein, the WRB layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and   wherein the extension flap of the WRB layer further comprises a removably attached release-liner attached to the extension flap portion of the WRB layer's inner surface.   
     
     
         4 . The first IS panel, as recited in  claim 2 , used for construction purposes, comprising the following layers:
 (i) an insulation facer layer having an outer surface and an inner surface;   (ii) an open-celled insulation layer having an outer surface and an inner surface;   (iii) a first insulation layer having an outer surface and an inner surface; and   (iv) a WRB layer having an outer surface and an inner surface;   wherein the inner surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;   wherein, the outer surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the first insulation layer;   wherein the inner surface of the WRB layer is secured to the outer surface of the first insulation layer through an adhesive layer;   wherein, the WRB layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and   wherein the extension flap of the WRB layer further comprises a removably attached release-liner attached to the extension flap portion of the WRB layer's inner surface.   
     
     
         5 . A first IS panel, used for construction purposes, comprising the following layers:
 (i) an insulation facer layer having an outer surface and an inner surface;   (ii) an open-celled insulation layer having an outer surface and an inner surface;   (iii) first insulation layer having an outer surface and an inner surface; and   (iv) a first WRB layer having an outer surface and an inner surface, or a water-proof intumescent coating fluid applied to the first insulation layer;   wherein the inner surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer, and if not present, the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;   wherein the outer surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the first insulation layer;   wherein the insulation facer layer comprises embossment on its surface;   wherein the inner surface of the WRB layer, if present, is secured to the outer surface of the first insulation layer through an adhesive layer;   wherein, the insulation facer layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and   wherein the extension flap of the insulation facer layer further comprises a removably attached release-liner attached to the extension flap portion of the insulation facer layer's inner surface.   
     
     
         6 . The first IS panel, as recited in  claim 5 , used for construction purposes, comprising the following layers:
 (i) an insulation facer layer having an outer surface and an inner surface;   (ii) an open-celled insulation layer having an outer surface and an inner surface;   (iii) first insulation layer having an outer surface and an inner surface; and   (iv) a first WRB layer having an outer surface and an inner surface;   wherein the inner surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;   wherein the outer surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the first insulation layer;   wherein the inner surface of the WRB layer is secured to the outer surface of the first insulation layer through an adhesive layer;   wherein, the insulation facer layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and   wherein the extension flap of the insulation facer layer further comprises a removably attached release-liner attached to the extension flap portion of the insulation facer layer's inner surface.   
     
     
         7 . The first IS panel, as recited in  claim 5 , used for construction purposes, comprising the following layers:
 (i) an insulation facer layer having an outer surface and an inner surface;   (ii) first insulation layer having an outer surface and an inner surface; and   (iii) a first WRB layer having an outer surface and an inner surface;   wherein the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;   wherein the inner surface of the WRB layer is secured to the outer surface of the first insulation layer through an adhesive layer;   wherein, the insulation facer layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and   wherein the extension flap of the insulation facer layer further comprises a removably attached release-liner attached to the extension flap portion of the insulation facer layer's inner surface.   
     
     
         8 . The first IS panel, as recited in  claim 5 , used for construction purposes, comprising the following layers:
 (i) an insulation facer layer having an outer surface and an inner surface;   (ii) first insulation layer having an outer surface and an inner surface; and   (iii) a water-proof intumescent coating fluid applied to the first insulation layer;   wherein the inner surface of the first insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;   wherein, the insulation facer layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and   wherein the extension flap of the insulation facer layer further comprises a removably attached release-liner attached to the extension flap portion of the insulation facer layer's inner surface.   
     
     
         9 . The first IS panel, as recited in  claim 5 , used for construction purposes, comprising the following layers:
 (i) an insulation facer layer having an outer surface and an inner surface;   (ii) an open-celled insulation layer having an outer surface and an inner surface;   (iii) first insulation layer having an outer surface and an inner surface; and   (iv) a water-proof intumescent coating fluid applied to the first insulation layer;   wherein the inner surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the insulation facer layer;   wherein the outer surface of the open-celled insulation layer is planarly and contactably attached to the inner surface of the first insulation layer;   wherein, the insulation facer layer exceeds the dimension of the first insulation layer from at least one of its edges to create an extension flap; and   wherein the extension flap of the insulation facer layer further comprises a removably attached release-liner attached to the extension flap portion of the insulation facer layer's inner surface.   
     
     
         10 .- 16 . (canceled) 
     
     
         17 . The first IS panel as recited in  claim 2 , comprising a polymeric material. 
     
     
         18 . The first IS panel as recited in  claim 17 , wherein the polymeric material is a thermoplastic resin that is polystyrene, polyisocyanurate, polyolefin, polyurethane foams and beads, GPS, open-celled foam, expanded polystyrene, extruded polystyrene, polyisocyanurate, and combinations thereof. 
     
     
         19 . The first IS panel as recited in  claim 2 , wherein the insulation facer comprises a plastic film, a thin metal foil, a metallized polymeric film, perforated metallized polymeric film, a paper or thin cellulose, a non-woven polymeric fabric, a fiberglass scrim, or combinations of the foregoing. 
     
     
         20 . The first IS panel as recited in  claim 2 , wherein the extension flap extends in length from about 0.5% of the minimum dimension of the first IS panel to about 50% of the length of the maximum dimension of the IS panel. 
     
     
         21 . The first IS panel as recited in  claim 20 , wherein the adhesive on the inner surface of the insulation facer or the WRB layer that adheres to the insulation layer is the same or different as the adhesive on the extension flap having a removably attached release liner. 
     
     
         22 . A first IS panel as recited in  claim 2 , wherein said IS panel is an IWS panel. 
     
     
         23 . An insulation sheathing system comprising at least two IS panels, wherein the two panels are juxtaposed side by side in one plane, wherein each panel comprises an IS panel as recited in  claim 2 . 
     
     
         24 .- 28 . (canceled) 
     
     
         29 . A process for preparing a continuous insulation sheathing as recited in  claim 2 , comprising providing polystyrene for the insulation sheathing process, attaching the insulation facer on to the insulation sheathing, and embossing a design on the insulation facer side of the continuous insulation sheathing,
 wherein the insulation facer comprises a plastic film, a thin metal foil, a metallized polymeric film, a perforated metallized polymeric film, a paper or thin cellulose, a non-woven polymeric fabric, a fiberglass scrim, and combinations of the foregoing.   
     
     
         30 . The process as recited in  claim 29 , comprising a polymeric material. 
     
     
         31 . The process as recited in  claim 30 , wherein the polymeric material is a thermoplastic resin comprising polystyrene, polyisocyanurate, polyolefin, or polyurethane foams and beads. 
     
     
         32 .- 33 . (canceled) 
     
     
         34 . An IS system within an exterior stucco wall construction comprising an insulation sheathing as recited in  claim 2 .