(19)
(11)EP 3 026 186 B1

(12)EUROPEAN PATENT SPECIFICATION

(45)Mention of the grant of the patent:
04.11.2020 Bulletin 2020/45

(21)Application number: 15199603.0

(22)Date of filing:  11.09.2007
(51)International Patent Classification (IPC): 
E04B 5/00(2006.01)

(54)

POLYMER-BASED COMPOSITE STRUCTURAL SHEATHING BOARD AND WALL AND/OR CEILING SYSTEM

STRUKTURELLE VERBUNDVERKLEIDUNGSPLATTE AUF POLYMERBASIS SOWIE WAND UND/ODER DECKENSYSTEM

PANNEAU DE REVÊTEMENT À STRUCTURE COMPOSITE À BASE DE POLYMÈRE ET SYSTÈME DE PAROI ET/OU DE PLAFOND


(84)Designated Contracting States:
AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HU IE IS IT LI LT LU LV MC MT NL PL PT RO SE SI SK TR

(30)Priority: 22.09.2006 US 525746

(43)Date of publication of application:
01.06.2016 Bulletin 2016/22

(62)Application number of the earlier application in accordance with Art. 76 EPC:
07875220.1 / 2079865

(73)Proprietor: Johns Manville
Denver, CO 80202 (US)

(72)Inventor:
  • PARADIS, Duane, R.
    Highlands Ranch, CO Colorado 80126 (US)

(74)Representative: Dörr, Klaus 
Dörr IP Nordring 29
65719 Hofheim
65719 Hofheim (DE)


(56)References cited: : 
WO-A1-2005/105435
US-A- 4 414 265
US-A- 2 999 041
US-A1- 2003 033 775
  
      
    Note: Within nine months from the publication of the mention of the grant of the European patent, any person may give notice to the European Patent Office of opposition to the European patent granted. Notice of opposition shall be filed in a written reasoned statement. It shall not be deemed to have been filed until the opposition fee has been paid. (Art. 99(1) European Patent Convention).


    Description

    BACKGROUND OF THE INVENTION



    [0001] Polymer-based composite structural sheathing boards are known from WO 2005/105435 A1, US 2003/033775 A1 and U.S. Patent No. 4,414,265.

    [0002] The subject invention relates to a wall and/or ceiling polymer-based composite structural sheathing board that has a polymer material or predominantly polymer material core layer and to a wall and/or ceiling system of a building structure that includes a plurality of the polymer-based composite structural sheathing boards overlaying and secured to a structural wall and/or ceiling frame and forming a wall and/or ceiling sheathing layer over the structural frame.

    [0003] In current building wall and ceiling systems, the sheathing layers of the wall and ceiling systems are typically formed of plywood boards, hardboards, particleboards, and/or gypsum boards. While these structural sheathing boards perform satisfactorily, the physical properties of these structural sheathing boards, such as but not limited to their weight, handleablity, cutablity, durability, flame spread rating, water absorption and/or fungus growth characteristics, etc. can present problems during the installation of the sheathing layer and over the anticipated service life of a wall and/or ceiling system. Accordingly, there has remained a need for improved wall and ceiling systems which utilize sheathing layers that are formed by structural sheathing boards that can be relatively light in weight, that are easy to handle, and that are easily cut at the job site to form the sheathing layer. There has also remained a need for improved wall and ceiling systems that include sheathing layers made of structural sheathing boards that are strong and durable, that absorb and retain very little moisture, that are fungus growth resistant, that are flame spread resistant, that have relatively good thermal and acoustical properties, and that have good bonding surfaces for bonding a nonstructural finish layer to an sheathing layer formed by the structural sheathing boards.

    SUMMARY OF THE INVENTION



    [0004] The wall and/or ceiling polymer-based composite structural sheathing boards of the subject invention as defined in claims 1 to 10 provide a solution to the above discussed installation and service related problems of the wall and ceiling sheathing boards of the prior art and the above discussed wall and ceiling system installation and service problems associated with wall and ceiling systems made with the wall and ceiling sheathing boards of the prior art.

    [0005] In first and second embodiments of the wall and/or ceiling polymer-based composite structural sheathing boards according to claim 1, the sheathing boards have a polymer material or predominantly polymer material core layer. A facer overlays at least one of the major surfaces and preferably, facers overlay both of the major surfaces of the core layer of the polymer-based composite structural sheathing boards of the subject invention to reinforce and strengthen the boards and provide the boards with enhanced dimensional stability. To best enhance the integrity, dimensional stability, and fastener pull through strength of the polymer-based composite structural sheathing boards of the subject invention as well as other desired physical and performance characteristics of the polymer based composite structural sheathing boards of the subject invention, a facer of a polymer-based composite structural sheathing board of the subject invention is coextensive with or substantially coextensive with and bonded to the overlaid major surface of the polymer-based composite structural sheathing board.

    [0006] In a third embodiment of the polymer-based composite structural sheathing boards of the subject invention, the sheathing board includes a low density polymer material or predominantly polymer material insulation layer and a polymer material or predominantly polymer material reinforcement layer having a higher density than the insulation layer. The sheathing boards according to the invention include a nonwoven reinforcement mat between the insulation layer and the reinforcement layer, a first facer coextensive with or substantially coextensive with and bonded to a major surface of the reinforcement layer, and/or a second facer coextensive with or substantially coextensive with and bonded to a major surface of the insulation layer.

    [0007] In a fourth embodiment of the polymer-based composite structural sheathing boards of the subject invention, the sheathing board includes a low density polymer material or predominantly polymer material insulation layer that is located intermediate first and second polymer material or predominantly polymer material reinforcement layers having a higher density than the insulation layer. The sheathing board include a nonwoven reinforcement mat between the insulation layer and the first reinforcement layer, a first facer coextensive with or substantially coextensive with and bonded to a major surface of the first reinforcement layer, a nonwoven reinforcement mat between the insulation layer and the second reinforcement layer, and/or a second facer coextensive with or substantially coextensive with and bonded to a major surface of the reinforcement layer.

    [0008] In particular, the polyisocyanurate material or predominantly polyisocyanurate material polymer-based composite structural sheathing boards of the subject invention have good dimensional stability, can be relatively light in weight, are easy to handle, and can be easily cut at the job site to form a wall or ceiling sheathing layer. In addition, these polyisocyanurate material or predominantly polyisocyanurate material wall and/or ceiling polymer-based composite structural sheathing boards exhibit good thermal and acoustical properties, are strong and durable, absorb and retain very little moisture, are fungus growth resistant, are flame spread resistant, and have good bonding surfaces for bonding a nonstructural finish layer (e.g. paint or wall paper) to a wall or ceiling sheathing layer formed by the polymer-based composite structural sheathing sheathing boards. With their excellent physical properties and characteristics, the polymer-based polyisocyanurate material or predominantly polyisocyanurate material composite structural sheathing boards of the subject invention are not only well suited for forming sheathing layers for interior walls and ceilings, but are especially well suited for forming both interior and exterior sheathing layers over the structural framework of exterior building walls.

    BRIEF DESCRIPTION OF THE DRAWINGS



    [0009] 

    Figure 1 is a partial schematic elevation of a wall, with portions broken away, illustrating the use of the polymer-based composite structural sheathing boards of the subject invention in the wall system.

    Figure 2 is a partial schematic vertical cross section through a ceiling illustrating the use of the polymer-based composite structural sheathing boards of the subject invention in the ceiling system.

    Figure 3 is a fragmentary schematic perspective view of a first embodiment of the polymer-based composite structural sheathing boards of the subject invention with portions broken away to better show the layers of composite.

    Figure 4 is a fragmentary schematic perspective view of a second embodiment of the polymer-based composite structural sheathing boards of the subject invention with portions broken away to better show the layers of composite.

    Figure 5 is a fragmentary schematic perspective view of a third embodiment of the polymer-based composite structural sheathing boards of the subject invention with portions broken away to better show the layers of composite.

    Figure 6 is a fragmentary schematic perspective view of a fourth embodiment of the polymer-based composite structural sheathing boards of the subject invention with portions broken away to better show the layers of composite.


    DETAILED DESCRIPTION OF THE INVENTION



    [0010] As schematically shown in Figure 1, a wall system 20 of the subject invention includes wall sheathing formed by the polymer-based composite structural sheathing boards 40, 42, 44, and/or 46 of Figures 3 to 6 and a structural wall frame of studs 22, a floor plate 24, and a ceiling plate 26. As shown, the wall system 20 also includes insulation 28 and may include other structural or nonstructural layers (not shown). Typically, the structural frame members of the structural wall frame are conventional wooden or metal wall studs, floor plates, and ceiling plates. The wall system 20 may be an exterior wall system and the polymer-based composite structural sheathing boards 40, 42, 44, and/or 46 may be used as interior wall sheathing and/or exterior wall sheathing. The wall system 20 may also be an interior wall system and the polymer-based composite structural sheathing boards 40, 42, 44, and/or 46 may be used as wall sheathing on one or both sides of the interior wall system.

    [0011] As schematically shown in Figure 2, a ceiling system 30 of the subject invention includes ceiling sheathing formed by the polymer-based composite structural sheathing boards 40, 42, 44, and/or 46 of Figures 3 to 6 and a structural ceiling frame of ceiling joists 32. As shown, the wall system 20 also includes insulation 34 and may include other structural or nonstructural layers (not shown). Typically, the structural frame members of the structural ceiling frame are conventional wooden or metal ceiling joists.

    [0012] The polymer-based composite structural sheathing board 40 of Figure 3 includes a polymer material or predominantly polymer material core layer 52 and a facer 54 coextensive with or substantially coextensive with and bonded to a first major surface of the core layer 52. The polymer-based composite structural sheathing board 42 of Figure 4 includes a polymer material or predominantly polymer material core layer 52; a first facer 54 coextensive with or substantially coextensive with and bonded to a first major surface of the core layer 52; and a second facer 56 coextensive with or substantially coextensive with and bonded to a second major surface of the core layer 52.

    [0013] The first major surface and the second major surface of the polymer or predominantly polymer material core layer 52 of the polymer-based composite structural sheathing boards 40 and 42 are each defined by the length and the width of the polymer or predominantly polymer material core layer. The polymer or predominantly polymer material core layer 52 and consequently the sheathing boards 40 and 42 typically have a width of about 1.21m (four feet) or greater and a length of about four feet or greater and, preferably, a length of about 2.43m (eight feet).

    [0014] The polymer or predominantly polymer material core layer 52 of the polymer-based composite structural sheathing boards 40 and 42 may be made of various polymer or predominantly polymer materials [e.g. a polyisocyanurate, polyurethane, polystyrene, or phenolic material or a material made of a blend of these materials; a polyisocyanurate, polyurethane, polystyrene, or phenolic foam material or a foam material made of a blend of these materials; a predominantly polyisocyanurate, polyurethane, polystyrene, or phenolic material with up to 40% by weight, but typically between about 1% and about 25% by weight organic and/or inorganic filler(s) or a material made of a blend of these materials with up to 40% by weight, but typically between about 1% and about 25% by weight organic and/or inorganic filler(s); a predominantly polyisocyanurate, polyurethane, polystyrene, or phenolic foam material with up to 40% by weight, but typically between about 1% and about 25% by weight organic and/or inorganic filler(s) or a foam material made of a blend of these materials with up to 40% by weight, but typically between about 1% and about 25% by weight organic and/or inorganic filler(s), a material made of other thermoset matrix polymers; etc.]. However, a preferred material for the core layer 52 is a polyisocyanurate material or foam material or a predominantly polyisocyanurate material or foam material with up to 40% by weight, but typically between about 1% and about 25% by weight organic and/or inorganic filler(s). Examples of various fillers that may be used in the predominantly polymer materials of the core layer 52 include but are not limited to powdered, liquid, and fiber fillers. The polymer or predominantly polymer materials of the core layer 52 may also include fiber reinforcements, fungi growth-inhibiting agents, fire-retardants, and other agents to reduce the cost of and/or modify the properties of the core layer 52, such as but not limited to the compressive strength, the toughness, the flexibility, the friability, and the fire resistance of the core layer. Examples of fillers, which may be used in the predominantly polymer material core layer 52, are fillers such as but not limited to limestone (CaCO3), fiberglass, recycled polyisocyanurate dust, extenders/plasticizers, ground up foam insulation, ground up rubber, wood dust, etc.

    [0015] The first facer 54 of the polymer-based composite structural sheathing board 40 and the first and second facers 54 and 56 of the polymer-based composite structural sheathing board 42 typically overlie the entire or substantially the entire major surface of the core layer 52 of the polymer-based composite structural sheathing board 40 or 42 to which the facer is or facers are bonded. The facers 54 and 56 of the polymer-based composite structural sheathing boards 40 and 42 may be any sheet material that provides suitable first and/or second major surfaces for the polymer-based composite structural sheathing boards 40 and 42, such as but not limited to coated or uncoated paper, foil, coated or uncoated woven or nonwoven mats made of fiberglass and/or other fibers or filaments, coated or uncoated scrims made of fiberglass and/or other fibers or filaments, etc. However, a preferred facer material for the facers 54 and 56 is a coated or uncoated, nonwoven, fiberglass mat or fiberglass scrim. Where a fiberglass scrim material is used, preferably, the scrim material has a tensile strength of at least 47.63kg (105 lbs) per linear 2.54cm (inch), a weight of about 111.1gr/m2 (10 grams/ft2), 8X8 strands per 2.54cm (inch), and utilizes stands having a mean diameter of about 0.05cm (0.019 inches).

    [0016] The polymer-based composite structural sheathing board 44 of Figure 5 includes a low density polymer material or predominantly polymer material foam insulation core layer 60, a polymer material or predominantly polymer material foam reinforcement layer 62 having a higher density than the insulation core layer 60, a reinforcement sheet layer 64 (preferably, a woven or nonwoven reinforcement mat or reinforcement scrim) between the insulation core layer 60 and the reinforcement layer 62, a first facer 66 coextensive with or substantially coextensive with and bonded to a major surface of the reinforcement layer 62, and a second facer 68 coextensive with or substantially coextensive with and bonded to a major surface of the insulation core layer 60. The insulation core layer 60 typically has a density of 64.07 kg/m3 (4 pcf) or less and preferably 40.05 kg/m3 (2.5 pcf) or less. The reinforcement layer 62 typically has a density that is greater than 64.07 kg/m3 (4 pcf) and a thickness less than that of the insulation core layer 60.

    [0017] The major surfaces of the polymer or predominantly polymer material insulation core layer 60 and reinforcement layer 62 of the polymer-based composite structural sheathing board 44 are each defined by the length and the width of the polymer or predominantly polymer material insulation and reinforcement layers. The polymer or predominantly polymer material insulation and reinforcement layers 60 and 62, and consequently the sheathing board 44, typically have a width of about 1.21m (four feet) or greater and a length of about 1.21m (four feet) or greater and, preferably, a length of about 2.43m (eight feet).

    [0018] The polymer-based composite structural sheathing board 46 of Figure 6 includes a low density polymer material or predominantly polymer material foam insulation core layer 70, a first polymer material or predominantly polymer material foam reinforcement layer 72 having a higher density than the insulation core layer 70, a sheet reinforcement layer 74 (being, a nonwoven reinforcement mat) between the insulation core layer 70 and the reinforcement layer 72, a first facer 76 coextensive with or substantially coextensive with and bonded to a major surface of the reinforcement layer 72, a second polymer material or predominantly polymer material foam or solid reinforcement layer 78 having a higher density than the insulation core layer 70, a reinforcement sheet layer 80 (, a nonwoven reinforcement mat) between the insulation core layer 70 and the reinforcement layer 79, and a second facer 82 coextensive with or substantially coextensive with and bonded to a major surface of the reinforcement layer 78. The insulation core layer 70 typically has a density of 64.07 kg/m3 (4 pcf) or less and preferably 40.05 kg/m3 (2.5 pcf) or less. The reinforcement layers 72 and 78 typically have a density that is greater than 64.07 kg/m3 (4 pcf) and a thickness that is less than the thickness of the insulation core layer 70. The densities of the reinforcement layers 72 and 78 may be the same or differ from each other depending on the requirements of a particular application.

    [0019] The major surfaces of the polymer or predominantly polymer material insulation layer 70 and reinforcement layers 72 and 78 of the polymer-based composite structural sheathing board 46 are each defined by the length and the width of the polymer or predominantly polymer material insulation and reinforcement layers. The polymer or predominantly polymer material insulation and reinforcement layers 70, 72, and 78, and consequently the sheathing board 46, typically have a width of about 1.21m (four feet) or greater and a length of about 1.21m (four feet) or greater and, preferably, a length of about 2.43m (eight feet).

    [0020] The polymer or predominantly polymer material insulation layers 60 and 70 and reinforcement layers 62, 72, and 78 of the polymer-based composite structural sheathing boards 44 and 46 may be made of various polymer or predominantly polymer materials [e.g. a polyisocyanurate, polyurethane, polystyrene, or phenolic material or a material made of a blend of these materials; a polyisocyanurate, polyurethane, polystyrene, or phenolic foam material or a foam material made of a blend of these materials; a predominantly polyisocyanurate, polyurethane, polystyrene, or phenolic material with up to 40% by weight, but typically between about 1% and about 25% by weight organic and/or inorganic filler(s) or a material made of a blend of these materials with up to 40% by weight, but typically between about 1% and about 25% by weight organic and/or inorganic filler(s); a predominantly polyisocyanurate, polyurethane, polystyrene, or phenolic foam material with up to 40% by weight, but typically between about 1% and about 25% by weight organic and/or inorganic filler(s) or a foam material made of a blend of these materials with up to 40% by weight, but typically between about 1% and about 25% by weight organic and/or inorganic filler(s), a material made of other thermoset matrix polymers; etc.]. However, a preferred material for the insulation core layers 60 and 70 and the reinforcement layers 62, 72, and 78 is a polyisocyanurate material or foam material or a predominantly polyisocyanurate material or foam material with up to 40% by weight, but typically between about 1% and about 25% by weight organic and/or inorganic filler(s). Examples of various fillers that may be used in the predominantly polymer materials of the insulation core layers 60 and 70 and the reinforcement layers 62, 72, and 78 include but are not limited to powdered, liquid, and fiber fillers. The polymer or predominantly polymer materials of the insulation core layers 60 and 70 and the reinforcement layers 62, 72, and 78 may also include fiber reinforcements, fungi growth-inhibiting agents, fire-retardants, and other agents to reduce the cost of and/or modify the properties of the insulation core layers 60 and 70 and the reinforcement layers 62, 72, and 78, such as but not limited to the compressive strength, the toughness, the flexibility, the friability, and the fire resistance of the layers. Examples of fillers, which may be used in the predominantly polymer material insulation core layers 60 and 70 and the reinforcement layers 62, 72, and 78, are fillers such as but not limited to limestone (CaCO3), fiberglass, recycled polyisocyanurate dust, extenders/plasticizers, ground up foam insulation, ground up rubber, wood dust, etc.

    [0021] The reinforcement sheet layer 64 of the polymer-based composite structural sheathing board 44 and the reinforcement sheet layers 74 and 80 of the polymer-based composite structural sheathing board 46 typically overlie the entire or substantially the entire major surfaces of the polymer or predominantly polymer material insulation layer 70 and reinforcement layer 72 and 78 of the polymer-based composite structural sheathing board 44 or 46 to which the reinforcement sheet layers are bonded. The reinforcement sheet layers 64, 74, and 80 of the polymer-based composite structural sheathing boards 44 and 46 is a sheet material that materially reinforces the polymer-based composite structural sheathing boards 44 and 46, and is a coated or uncoated nonwoven mats made of fiberglass and/or other fibers or filaments, etc. However, a preferred reinforcement material for the reinforcement layers 64, 74, and 80 of the polymer-based composite structural sheathing boards 44 and 46 is a coated or uncoated, nonwoven, fiberglass mat.

    [0022] The facers 66 and 68 of the polymer-based composite structural sheathing board 44 and the facers 76 and 82 of the polymer-based composite structural sheathing board 46 typically overlie the entire or substantially the entire major surface of the insulation core layer 60 or reinforcement layer 62, 72, and 78 of the polymer-based composite structural sheathing board 44 or 46 to which the facer is or facers are bonded. The facers of the polymer-based composite structural sheathing boards 44 and 46 may be any sheet material that provides suitable first and/or second major surfaces for the polymer-based composite structural sheathing boards 44 and 46, such as but not limited to coated or uncoated paper, foil, coated or uncoated woven or nonwoven mats made of fiberglass and/or other fibers or filaments, coated or uncoated scrims made of fiberglass and/or other fibers or filaments, etc. However, a preferred facer material for the facers of the polymer-based composite structural sheathing boards 44 and 46 is a coated or uncoated, nonwoven, fiberglass mat or fiberglass scrim. Where a fiberglass scrim material is used, preferably, the scrim material has a tensile strength of at least 47.63kg (105 lbs) per linear 2.54cm (inch), a weight of about 111.1gr/m2 (10 grams/ft2), 8X8 strands per 2.54cm (inch), and utilizes stands having a mean diameter of about 0.05cm (0.019 inches). It is contemplated that for certain applications, the sheathing board 44 may not include one or both of the facers 66 and 68 and that the sheathing board 46 may not include one or both of the facers 76 and 82, especially where the reinforcement layer 64 or one or both of the reinforcement layers 74 and 80 are utilized in the sheathing boards 44 and 46.

    [0023] The polymer-based composite structural sheathing boards of the subject invention preferably have the following physical properties:
    PropertyRange or MinimumPreferred Range or Minimum
    Thickness 0.38(0.15) to 1.91cm(0.75 inches) 0.64(0.25) to 1.27cm(0.50 inches)
    Density 0.02(1.6) to 0.4g/cm3(25 lbs/ft3) 0.048(3) to 0.16g/cm3(10 lbs/ft3)
    Compressive Strength 172.35 kPa(at least 25 psi) 344.74 kPa(at least 50 psi)
         
    Flexural Strength Modulus of Rigidity (MOR) 2757.9 kPa(at least 400 psi) 10342.125 kPa(at least 1500 psi)
    Load at Yield 88.96 N(at least 20 Ibf) 133.44 N(at least 30 lbf)
    Fastener Pull Through (ASTM Test D1037 effect - June 2006) - in 88.96 N(at least 20 Ibf) 222.4 N(at least 50 lbf)
    Water Absorption by Volume (ASTM Test C209 - in effect - June 2006) 4% or less 2% or less
    Thermal Conductivity R-value of at least 1  
    Flame Spread Rating (ASTM Test E84 - in effect - June 2006) at least 20 at least 25
    Fungus Growth Resistance Does Not Support Fungus Growth



    Claims

    1. A polymer-based composite structural sheathing board for use in the formation of a building wall and/or ceiling system by overlaying and being secured to a structural building wall and/or ceiling frame, comprising:

    (i) a polymer material or predominantly polymer material foam insulation core layer;

    (ii) a first polymer material or predominately polymer material foam reinforcement layer having a higher density than the insulation core layer;

    (iii) the insulation core layer and the first reinforcement layer each having a length, a width, and a thickness;

    (iv) the insulation core layer and the first reinforcement layer each having a first major surface and a second major surface that are defined by the length and the width of the insulation core layer and the first reinforcement layer respectively; and

    (v) a reinforcement sheet located between the insulation core layer and the first reinforcement layer that reinforces, stabilizes, and strengthens the polymer-based composite structural sheathing board and is generally coextensive with and bonded to the major surfaces of the insulation core layer and the first reinforcement layer overlaid by the reinforcement sheet, characterised in that said reinforcement sheet is a nonwoven reinforcement mat.


     
    2. The structural sheathing board according to claim 1, including:

    (i) a second polymer material or predominately polymer material solid or foam reinforcement layer having a higher density than the insulation core layer; the second reinforcement layer having a length, a width, and a thickness;

    (ii) the second reinforcement layer having a first major surface and a second major surface that are defined by the length and the width of the second reinforcement layer; and

    (iii) a second reinforcement sheet located between the insulation core layer and the second reinforcement layer that reinforces, stabilizes, and strengthens the polymer-based composite structural sheathing board and is generally coextensive with and bonded to the major surfaces of the insulation core layer and the second reinforcement layer overlaid by the second reinforcement sheet.


     
    3. The structural sheathing board according to claim 1 or 2, wherein the insulation core has a density of 64.07384 kg/m3 (4 pcf) or less, preferably 40.04615 kg/m3 (2.5 pcf) or less.
     
    4. The structural sheathing board according to claim 1 to 3, wherein the reinforcement layer has a density of greater than 64.07384 kg/m3 (4 pcf) and a thickness less than the insulation core layer.
     
    5. The structural sheathing board according to claim 1 to 4, wherein the polymer material of the insulation core layer and/or the polymer material of the reinforcement layer contains up to 40% by weight inorganic and/or organic filler material.
     
    6. The structural sheathing board according to claim 1 to 5, wherein the polymer material of the insulation core layer and/or the polymer material of the reinforcement layer is polyisocyanurate, polyurethane, polystyrene, phenolic or a blend of such materials
     
    7. The structural sheathing board according to claim 1 to 6, wherein a first facer is bonded coextensive with or substantially coextensive with a major surface of the reinforcement layer and a second facer is bonded coextensive with or substantially coextensive with a major surface of the insulation core layer.
     
    8. The structural sheathing board according to claim 7, wherein the facer is a nonwoven fiberglass scrim or mat.
     
    9. The structural sheathing board according to claim 1 to 8, wherein the polymer-based composite structural sheathing board has a compressive strength of at least 172.37 kPa (25 psi), a flexural strength (MOR) of at least 2757.9 kPa (400 psi) and a fastener pull through strength of at least 88.96N (20 Ibf).
     
    10. The structural sheathing board according to claim 9, wherein the polymer-based composite structural sheathing board has a water absorption rate of 4% by volume or less.
     
    11. A wall and/or ceiling system of a building structure, comprising:

    (i) a plurality of polymer-based composite structural sheathing boards as defined in claims 1 to 10 overlaying and secured to a structural wall and/or ceiling frame,

    (ii) the polymer-based composite structural sheathing boards forming a wall and/or ceiling sheathing layer.


     


    Ansprüche

    1. Strukturelle Verbundverkleidungsplatte auf Polymerbasis zur Verwendung bei der Bildung eines Gebäudewand- und/oder Deckensystems durch Überlagern und Befestigtwerden an einem strukturellen Gebäudewand- und/oder Deckenrahmen, umfassend:

    (i) eine Schaumisolierkernschicht aus Polymermaterial oder vorwiegend aus Polymermaterial;

    (ii) eine erste Schaumverstärkungsschicht aus Polymermaterial oder vorwiegend aus Polymermaterial mit einer höheren Dichte als die Isolierkernschicht;

    (iii) wobei die Isolierkernschicht und die erste Verstärkungsschicht jeweils eine Länge, eine Breite und eine Dicke aufweisen;

    (iv) wobei die Isolierkernschicht und die erste Verstärkungsschicht jeweils eine erste Hauptfläche und eine zweite Hauptfläche aufweisen, die durch die Länge und die Breite der Isolierkernschicht bzw. der ersten Verstärkungsschicht definiert sind; und

    (v) eine Verstärkungsfolie, die zwischen der Isolierkernschicht und der ersten Verstärkungsschicht angeordnet ist und die strukturelle Verbundverkleidungsplatte auf Polymerbasis verstärkt, stabilisiert und stützt und im Allgemeinen mit den Hauptflächen der Isolierkernschicht und der von der Verstärkungsplatte überlagerten ersten Verstärkungsschicht flächengleich und mit diesen verbunden ist, dadurch gekennzeichnet, dass es sich bei der Verstärkungsfolie um eine Vliesverstärkungsmatte handelt.


     
    2. Strukturelle Verkleidungsplatte nach Anspruch 1, einschließlich:

    (i) einer zweiten festen Verstärkungsschicht oder Schaumverstärkungsschicht aus Polymermaterial oder vorwiegend aus Polymermaterial mit einer höheren Dichte als die Isolierkernschicht; wobei die zweite Verstärkungsschicht eine Länge, eine Breite und eine Dicke aufweist;

    (ii) wobei die zweite Verstärkungsschicht eine erste Hauptfläche und eine zweite Hauptfläche aufweist, die durch die Länge und die Breite der zweiten Verstärkungsschicht definiert sind; und

    (iii) einer zweiten Verstärkungsfolie, die zwischen der Isolierkernschicht und der zweiten Verstärkungsschicht angeordnet ist und die strukturelle Verbundverkleidungsplatte auf Polymerbasis verstärkt, stabilisiert und stützt und im Allgemeinen mit den Hauptflächen der Isolierkernschicht und der von der zweiten Verstärkungsfolie überlagerten zweiten Verstärkungsschicht flächengleich und mit diesen verbunden ist.


     
    3. Strukturelle Verkleidungsplatte nach Anspruch 1 oder 2, wobei der Isolierkern eine Dichte von 64,07384 kg/m3 (4 pcf) oder weniger, vorzugsweise von 40,04615 kg/m3 (2,5 pcf) oder weniger, aufweist.
     
    4. Strukturelle Verkleidungsplatte nach Anspruch 1 bis 3, wobei die Verstärkungsschicht eine Dichte von mehr als 64,07384 kg/m3 (4 pcf) und eine Dicke aufweist, die geringer ist als die Isolierkernschicht.
     
    5. Strukturelle Verkleidungsplatte nach Anspruch 1 bis 4, wobei das Polymermaterial der Isolierkernschicht und/oder das Polymermaterial der Verstärkungsschicht bis zu 40 Gew.-% anorganisches und/oder organisches Füllmaterial enthält.
     
    6. Strukturelle Verkleidungsplatte nach Anspruch 1 bis 5, wobei es sich bei dem Polymermaterial der Isolierkernschicht und/oder dem Polymermaterial der Verstärkungsschicht um Polyisocyanurat, Polyurethan, Polystyrol, Phenol oder eine Mischung solcher Materialien handelt.
     
    7. Strukturelle Verkleidungsplatte nach Anspruch 1 bis 6, wobei ein erster Facer flächengleich mit oder im Wesentlichen flächengleich mit einer Hauptfläche der Verstärkungsschicht verbunden ist und ein zweiter Facer flächengleich mit oder im Wesentlichen flächengleich mit einer Hauptfläche der Isolierkernschicht verbunden ist.
     
    8. Strukturelle Verkleidungsplatte nach Anspruch 7, wobei es sich bei dem Facer um einen Glasfaservlies-Gitterstoff oder eine Glasfaservliesmatte handelt.
     
    9. Strukturelle Verkleidungsplatte nach Anspruch 1 bis 8, wobei die strukturelle Verbundverkleidungsplatte auf Polymerbasis eine Druckfestigkeit von mindestens 172,37 kPa (25 psi), eine Biegefestigkeit (MOR) von mindestens 2757,9 kPa (400 psi) und eine Befestigungselement-Durchzugfestigkeit von mindestens 88,96 N (20 lbf) aufweist.
     
    10. Strukturelle Verkleidungsplatte nach Anspruch 9, wobei die strukturelle Verbundverkleidungsplatte auf Polymerbasis eine Wasserabsorptionsrate von 4 Vol.-% oder weniger aufweist.
     
    11. Wand- und/oder Deckensystem einer Gebäudestruktur, umfassend:

    (i) eine Vielzahl von strukturellen Verbundverkleidungsplatten auf Polymerbasis wie in den Ansprüchen 1 bis 10 definiert, welche einen strukturellen Wand- und/oder Deckenrahmen überlagern und daran befestigt sind,

    (ii) wobei die strukturellen Verbundverkleidungsplatten auf Polymerbasis eine Wand- und/oder Deckenverkleidungsschicht bilden.


     


    Revendications

    1. Panneau de revêtement à structure composite à base de polymère pour utilisation dans la formation d'un système de paroi de bâtiment et/ou de plafond superposant et étant fixé à une paroi de bâtiment structurelle et/ou cadre de plafond, comprenant:

    (i) un matériau polymère ou couche d'âme isolante en mousse de façon prédominante en matériau polymère;

    (ii) un premier matériau polymère ou couche de renforcement en mousse de façon prédominante en matériau polymère ayant une densité plus élevée que la couche d'âme isolante;

    (iii) la couche d'âme isolante et la première couche de renforcement ayant chacune une longueur , une largeur, et une épaisseur;

    (iv) la couche d'âme isolante et la première couche de renforcement ayant chacune une première surface principale et une seconde surface principale qui sont définies par la longueur et la largeur de la couche d'âme isolante et respectivement de la première couche de renforcement; et

    (v) une feuille de renforcement logée entre la couche d'âme isolante et la première couche de renforcement qui renforce, stabilise, et fortifie le panneau de revêtement à structure composite à base de polymère et est en général coextensive avec et collée aux surfaces principales de la couche d'âme isolante et de la première couche de renforcement superposée par la feuille de renforcement, caractérisé en ce ce ladite feuille de renforcement est un tapis de renforcement non tissé.


     
    2. Panneau de revêtement à structure composite selon la revendication 1, incluant:

    (i) un second matériau polymère ou solide de façon prédominante en matériau polymère ou couche de renforcement en mousse ayant une densité plus élevée que la couche d'âme isolante, la seconde couche de renforcement ayant une longueur, une largeur, et une épaisseur;

    (ii) la seconde couche de renforcement ayant une première surface principale et une seconde surface principale qui sont définies par la longueur et la largeur de la seconde couche de renforcement; et

    (iii) une seconde feuille de renforcement logée entre la couche d'âme isolante et la seconde couche de renforcement qui renforce, stabilise, et fortifie le panneau de revêtement à structure composite à base de polymère et est en général coextensive avec et collée aux surfaces principales de la couche d'âme isolante et de la seconde couche de renforcement superposée par la seconde feuille de renforcement.


     
    3. Panneau de revêtement à structure composite selon la revendication 1 ou 2, où l'âme isolante présente une densité de 64.07384 kg/m3 (4 pcf) ou moins, préférablement 40.04615 kg/m3 (2,5 pcf) ou moins.
     
    4. Panneau de revêtement à structure composite selon la revendication 1 à 3, où la couche de renforcement présente une densité supérieure à 64.07384 kg/m3 (4 pcf) et une épaisseur moins que la couche d'âme isolante.
     
    5. Panneau de revêtement à structure composite selon la revendication 1 à 4, où le matériau polymère de la couche d'âme isolante et/ou le matériau polymère de la couche de renforcement comprennent jusqu'à 40 % en poids de matériau de remplissage inorganique et/ou organique.
     
    6. Panneau de revêtement à structure composite selon la revendication 1 à 5, où le matériau polymère de la couche d'âme isolante et/ou le matériau polymère de la couche de renforcement est un polyisocyanurate, un polyuréthane, un polystyrène, un phénolique ou un mélange de tels matériaux.
     
    7. Panneau de revêtement à structure composite selon la revendication 1 à 6, où une première face est collée coextensive avec ou substantiellement coextensive avec une surface principale de la couche de renforcement et une seconde face est collée coextensive avec ou substantiellement coextensive avec une surface principale de la couche d'âme isolante.
     
    8. Panneau de revêtement à structure composite selon la revendication 7, où la face est un canevas ou tapis de fibres de verre non tissées.
     
    9. Panneau de revêtement à structure composite selon la revendication 1 à 8, où le panneau de revêtement à structure composite à base de polymère présente une résistance à la compression d'au moins 172.37 kPa (25 psi), une résistance à la flexion (MOR) d'au moins 2757.9 kPa (400 psi) et une force de fixation d'au moins 88.96 N (20 Ibf).
     
    10. Panneau de revêtement à structure composite selon la revendication 9, où le panneau de revêtement à structure composite à base de polymère présente un taux d'absorbtion d'eau de 4 % par volume ou moins.
     
    11. Système de paroi et/ou de plafond d'une structure de bâtiment, comprenant:

    (i) une pluralité de panneaux de revêtement à structure composite à base de polymère tels que définis dans les revendications 1 à 10 superposés et fixés à une paroi structurelle et/ou à un cadre de plafond,

    (ii) les panneaux de revêtement à structure composite à base de polymère formant une paroi et/ou la couche revêtement de plafond.


     




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    Cited references

    REFERENCES CITED IN THE DESCRIPTION



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    Patent documents cited in the description