Construct a wall assembly by: (a) providing a support structure with spaced apart structural members; (b) affixing a thermally insulating layer of polymeric foam boards to the structural members, the foam boards achieving a Class A rating according to ASTM E-84; (c) covering seams between polymeric
Construct a wall assembly by: (a) providing a support structure with spaced apart structural members; (b) affixing a thermally insulating layer of polymeric foam boards to the structural members, the foam boards achieving a Class A rating according to ASTM E-84; (c) covering seams between polymeric foam boards with a sealing tape; (d) affixing a plurality of fasteners through the thermally insulating layer to structural members with the fasteners extending beyond the outside surface of the thermally insulating layer; (e) attaching a façade selected from metal panel, metal-composite-metal panels, fiber reinforced cementitious siding veneer and materials having a thickness of at least 1.9 centimeters (0.75 inches) that qualify as “non-combustible” according to ASTM E136 to the fasteners and within five centimeters of the thermally insulating layer; and desirably (f) applying a spray polyurethane foam material to seal gaps through the thermally insulating layer; the process being free of applying gypsum sheathing layer or wood-based sheathing between structural members and the thermally insulating layer.
대표청구항▼
1. A process for assembling a continuously insulated wall assembly comprising the following steps: (a) providing a support structure comprising structural members spaced apart from one another so as to define a cavity between structural members;(b) providing a thermally insulating layer comprising a
1. A process for assembling a continuously insulated wall assembly comprising the following steps: (a) providing a support structure comprising structural members spaced apart from one another so as to define a cavity between structural members;(b) providing a thermally insulating layer comprising a plurality of polymeric foam boards each having a polyurethane foam core and having opposing inside and outside surfaces with the inside surfaces attached to two or more of the structural members so as to create a cavity defined by structural members and the thermally insulating layer, the polymeric boards abutting one another with seams where the boards abut and characterized by achieving a Class A rating according to ASTM E-84 test procedures and by having an R-value of greater than 28 meters*Kelvin per Watt (4 hour*square foot*degrees Fahrenheit per British Thermal Unit*inch);(c) providing a sealing tape that contains butyl rubber, rubberized asphalt, or both and covering the seams between polymeric foam boards with the sealing tape;(d) providing a plurality of fasteners and affixing them all the way through the thermally insulating layer to structural members such that the fasteners extend beyond the outside surface of the thermally insulating layer; and(e) attaching a façade to one or more than one of the plurality of fasteners and within five centimeters of the thermally insulating layer such that the thermally insulating layer and sealing tape are between the structural members and the façade, the façade being selected from a group consisting of metal panel veneer, metal-composite-metal panels, fiber reinforced cementitious siding veneer and materials having a thickness of at least 1.9 centimeters that qualify as “non-combustible” according to ASTM E136;(f) applying a polyurethane foam sealant within the cavity defined by the structural members and thermally insulating layer in a manner that seals air gaps having an opening of less than 25 square millimeters between the inside and outside surface of the thermally insulating layer; the process further characterized by being free of application of a gypsum sheathing layer or wood-based sheathing layer between the structural members and thermally insulating layer. 2. The process of claim 1, wherein the façade is selected from a group consisting of man-made stone, brick, terra-cotta, limestone, stucco, granite and cementitious materials where the materials of the group have a thickness of at least 1.9 centimeters. 3. The process of claim 1, wherein the polymeric foam boards of the thermally insulating layer have as an outside surface a facer selected from facers comprising one or more of the following: a metal sheet layer and a coated glass fiber mat where the coating comprise a polymeric binder filled with inorganic filler such that 90-95 wt % of the coated glass fiber mat is a combination of glass and inorganic filler. 4. The process of claim 1, further comprising fastening the thermally insulating layer to the support structure using a plurality of second mechanical fasteners. 5. A continuously insulated wall assembly comprising the following elements: (a) a support structure comprising structural members spaced apart from one another and defining a cavity between any two structural members;(b) a thermally insulating layer comprising a plurality of polymeric foam boards each having a polyurethane foam core and having opposing inside and outside surfaces with the inside surfaces attached to two or more of the structural members so as to create a cavity defined by structural members and the thermally insulating layer, the polymeric boards abutting one another with seams where the boards abut and characterized by achieving a Class A rating according to ASTM E-84 test procedures and by having an R-value of greater than 28 meters*Kelvin per Watt (4 hour*square foot*degrees Fahrenheit per British Thermal Unit*inch);(c) sealing tape covering seams where the polymeric foam boards abut one another;(d) a plurality of fasteners that are affixed to structural members and all the way through the thermally insulating layer and that extend beyond the outside surface of the thermally insulating layer;(e) a façade attached to one or more of the plurality of fasteners and located within five centimeters of the thermally insulating layer such that the thermally insulating layer and the sealing tape are between the façade and support structure; the façade being selected from a group consisting of metal panel veneer, metal-composite-metal panels, fiber reinforced cementitious siding veneer and materials having a thickness of at least 1.9 centimeters that qualify as “non-combustible” according to ASTM E136; and(f) a polyurethane foam sealant within the cavity defined by the structural members and thermally insulating layer that seals air gaps having an opening of less than 25 square millimeters between the inside and outside surface of the thermally insulating layer wherein the continuously insulated wall assembly is free of any gypsum sheathing layer or wood-based sheathing layer between the support structure and the thermally insulating layer. 6. The continuously insulated wall assembly of claim 5, wherein the façade is selected from a group consisting of man-made stone, brick, terra-cotta, limestone, stucco, granite and cementitious materials where the materials of the group have a thickness of at least 1.9 centimeters. 7. The continuously insulated wall assembly of claim 1, wherein the polyurethane foam sealant covers all portions of the thermally insulating layer, sealing tape and plurality of fasteners that would otherwise be exposed within the cavity defined by the support structure and the thermally insulating layer. 8. The continuously insulated wall assembly of claim 1, wherein the polyurethane foam sealant forms a layer over the thermally insulating layer that has an average thickness of 2.54 to 5.08 centimeters thick. 9. The continuously insulated wall assembly of claim 1, further characterized by the polymeric foam boards of the thermally insulating layer having as an outside surface a facer selected from facers comprising one or more of the following: a metal sheet layer and a coated glass fiber mat where the coating comprise a polymeric binder filled with inorganic filler such that 90-95 wt % of the coated glass fiber mat is a combination of glass and inorganic filler. 10. The continuously insulated wall assembly of claim 1, further characterized as being free of any gypsum sheathing layer that covers 50% or more of the area covered by the thermally insulating layer and on the same side of the support structure as the thermally insulating layer and sealing tape. 11. The continuously insulated wall assembly of claim 1, further characterized as being free of any gypsum sheathing layer on the same side of the support structure as the thermally insulating layer and sealing tape. 12. The continuously insulated wall assembly of claim 1, further characterized as being free of vertical drainage channels on the inside surface, outside surface or both inside and outside surface of the thermally insulating layer. 13. The continuously insulated wall assembly of claim 1, further characterized by the sealing tape extending over less than an entire polymeric foam board in contact with the sealing tape. 14. The continuously insulated wall assembly of claim 1, further characterized by a space of 2.5-5 centimeters between the thermally insulating layer and the façade. 15. The continuously insulated wall assembly of claim 1, further comprising a gypsum board layer on a side of the structural members opposite the thermally insulating layer such that the gypsum board serves to further enclose a cavity defined by the support structure and the thermally insulating layer. 16. The continuously insulated wall assembly of any of claims 5-6 and 7-15, further comprising a plurality of second mechanical fasteners that attach the thermally insulating layer to the support structure.
Messenger, Harold G.; Harmon, Thomas G.; Baur, Kenneth; Graziano, Gary C.; Lorah, Douglas L., Insulative concrete building panel with carbon fiber and steel reinforcement.
Bennett, John L.; Barker, Joel F.; Jordan, Rick D.; Schuman, Thomas L.; Ou, Nian; Swiacki, Neil C.; Flaherty, Kelly R., Wall sheathing system and method of installation.
Steppan, David D.; Baily, David M.; Palmosina, II, Michael F., Methods for making pre-fabricated insulated wall structures and apparatus for use in such methods.
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