US5345738A — Multi-functional exterior structural foam sheathi…

Claim 1

Independent Claim 78 words

A sheathing panel comprising: a core sheet of a manufactured cellular material having first and second major opposed surfaces; first and second cover sheets secured to the respective first and second major opposed surfaces with the core sheet therebetween, the first and second cover sheets each comprising at least one sheet of cellulosic material impregnated with polyisocyanate within a range of about 8% to 20% by weight of polyisocyanate to cellulosic material with the polyisocyanate being heat cured.

Claim 2

Dependent Claim 78 words

A sheathing panel comprising: a core sheet of a manufactured cellular material having first and second major opposed surfaces; first and second cover sheets secured to the respective first and second major opposed surfaces with the core sheet therebetween, the first and second cover sheets each comprising at least one sheet of cellulosic material impregnated with polyisocyanate within a range of about 8% to 20% by weight of polyisocyanate to cellulosic material with the polyisocyanate being heat cured.

Claim 3

Dependent Claim 27 words

A panel according to claim 1 in which each of the major opposed surfaces of the core sheet is overlayed with a respective blowing agent retaining sheet.

Claim 4

Dependent Claim 19 words

A panel according to claim 2 in which the blowing agent retaining sheets are comprised of a metallic foil.

Claim 5

Dependent Claim 22 words

A panel according to claim 1 in which at least one of the cover sheets is overlayed with a thermal reflective material.

Claim 6

Dependent Claim 16 words

A panel according to claim 4 in which the thermal reflective material comprises a metallic foil.

Claim 7

Dependent Claim 22 words

A panel according to claim 3 in which at least one of the cover sheets is overlayed with a thermal reflective material.

Claim 8

Dependent Claim 17 words

A panel according to claim 1 in which the cover sheets are cellulosic paper or pulp sheets.

Claim 9

Dependent Claim 84 words

A panel according to claim 1 in which the core has a shear strength of from at least about 10 to about 30 psi and a shear modulus of from at least about 500 psi to about 1,000 psi, the cover sheets having a machine direction tensile strength of from about 1.8×10 4 to 2.4×10 4 psi in the major plane of the cover sheets and a Young's modulus in the machine direction of from about 1.8×10 6 psi to about 2.2×10 6 psi.

Claim 10

Dependent Claim 37 words

A panel according to claim 8 in which the core has a thickness of from about 1/8 to 4 inches and a density in the range of from about 1 to about 4 pounds per cubic foot.

Claim 11

Dependent Claim 24 words

A panel according to claim 9 in which the cover sheets have a thickness of from about 8.5×10 -3 inch to about 0.1 inch.

Claim 12

Dependent Claim 19 words

A panel according to claim 10 including a thermal reflective material overlaying at least one of the cover sheets.

Claim 13

Dependent Claim 23 words

A panel according to claim 10 including a respective blowing agent retaining sheet between the core sheet and each of the cover sheets.

Claim 14

Dependent Claim 70 words

A panel according to claim 1 in which the cover sheets comprise cellulosic liner material impregnated with from about 8% to 15% by weight of polyisocyanate to cellulosic material, which is cured to a density of from about sixty-five to about seventy pcf, and having a machine direction linear expansion at from 50% to 90% humidity and 65° F. of less than 0.1 inch per inch in the major direction.

Claim 15

Dependent Claim 55 words

A panel according to claim 1 in which the cover sheets comprise cellulosic liner material impregnated with from about 8% to 15% by weight of polyisocyanate to cellulosic material, which is cured to a density of from about sixty-five to about seventy pcf, and having a water vapor transmission rate of at least 3.5 perms.

Claim 16

Dependent Claim 57 words

A panel according to claim 1 in which the cover sheets comprise cellulosic liner material impregnated with from about 8% to 15% by weight of polyisocyanate to cellulosic material, which is cured to a density of from about sixty-five to about seventy pcf, and having a water absorption at 96 hours of no more than about 6.5%.

Claim 17

Dependent Claim 19 words

A panel according to claim 1 having a thermal conductivity of no more than about 0.134 B.T.U.:in/h.f 2 .°F.

Claim 18

Dependent Claim 21 words

A panel according to claim 1 having a modulus of rupture in the major plane of at least about 800 psi.

Claim 19

Dependent Claim 18 words

A panel according to claim 1 in which the first and second cover sheets are of differing thicknesses.

Claim 20

Dependent Claim 46 words

Plural panels according to claim 1 mounted at least to a corner of a conventional building stud frame without other reinforcing bracing at such corner, the panels being secured to the frame by an adhesive and having a racking shear strength of at least 9,000 lbs.

Claim 21

Dependent Claim 47 words

Plural panels according to claim 1 mounted at least to a corner of a conventional building stud frame without other reinforcing bracing at such corner, the panels being secured to the frame by mechanical fasteners only and having a racking shear strength of at least 2,600 lbs.

Claim 22

Dependent Claim 130 words

A conventional building stud frame having corners with plural sheathing panels mounted at least to a corner of the building stud frame without other reinforcing bracing at such corner, the panels each comprising a core sheet of a manufactured cellular foam material having first and second major opposed surfaces, the core sheet having a thickness of from about 1/8 to 4 inches and a density in the range of from about one to about four pounds per cubic foot, first and second cover sheets at least one of which includes polyisocyanate in the range of about 8 percent to 20 percent by weight of polyisocyanate to cellulosic material, the first and second cover sheets being secured to the respective first and second major opposed surfaces with the core sheet therebetween.

Claim 23

Dependent Claim 130 words

A conventional building stud frame having corners with plural sheathing panels mounted at least to a corner of the building stud frame without other reinforcing bracing at such corner, the panels each comprising a core sheet of a manufactured cellular foam material having first and second major opposed surfaces, the core sheet having a thickness of from about 1/8 to 4 inches and a density in the range of from about one to about four pounds per cubic foot, first and second cover sheets at least one of which includes polyisocyanate in the range of about 8 percent to 20 percent by weight of polyisocyanate to cellulosic material, the first and second cover sheets being secured to the respective first and second major opposed surfaces with the core sheet therebetween.

Claim 24

Dependent Claim 24 words

A conventional building stud frame with mounted plural sheathing panels according to claim 21 with a racking shear strength of at least 2,600 lbs.

Claim 25

Dependent Claim 24 words

A conventional building stud frame with mounted plural sheathing panels according to claim 21 with a racking shear strength of at least 3,500 lbs.

Claim 26

Dependent Claim 24 words

A conventional building stud frame with mounted plural sheathing panels according to claim 21 with a racking shear strength of at least 9,000 lbs.

Claim 27

Dependent Claim 38 words

A conventional building stud frame with mounted plural sheathing panels according to claim 21 and in which the sheathing panels each have a core sheet with the major opposed surfaces overlaid with a respective blowing agent retaining sheet.

Claim 28

Dependent Claim 33 words

A conventional building stud frame with mounted plural sheathing panels according to claim 25 and in which the sheathing panels each have at least one cover sheet overlaid with a thermal reflective material.

Claim 29

Dependent Claim 33 words

A conventional building stud frame with mounted plural sheathing panels according to claim 21 and in which the sheathing panels each have at least one cover sheet overlaid with a thermal reflective material.

Claim 30

Dependent Claim 132 words

A sheathing panel comprising: a core sheet of a manufactured cellular foam material having first and second major opposed surfaces, a thickness of from 1/8 to four inches and a density in the range of from about one to about four pounds per cubic foot; first and second cover sheets secured to the respective first and second major opposed surfaces with the core sheet therebetween, the first and second cover sheets each comprising at least one sheet of cellulosic material with polyisocyanate within a range of about 8 percent to 20 percent by weight of polyisocyanate to cellulosic material; and wherein the core has a shear strength of from at least about 10 to about 30 psi and a shear modulus of from at least about 500 psi to about 1,000 psi.

Claim 31

Dependent Claim 132 words

A sheathing panel comprising: a core sheet of a manufactured cellular foam material having first and second major opposed surfaces, a thickness of from 1/8 to four inches and a density in the range of from about one to about four pounds per cubic foot; first and second cover sheets secured to the respective first and second major opposed surfaces with the core sheet therebetween, the first and second cover sheets each comprising at least one sheet of cellulosic material with polyisocyanate within a range of about 8 percent to 20 percent by weight of polyisocyanate to cellulosic material; and wherein the core has a shear strength of from at least about 10 to about 30 psi and a shear modulus of from at least about 500 psi to about 1,000 psi.

Claim 32

Dependent Claim 19 words

A panel according to claim 28 including a thermal reflective material overlaying at least one of the cover sheets.

Claim 33

Dependent Claim 23 words

A panel according to claim 28 including a respective blowing agent retaining sheet between the core sheet and each of the cover sheets.

Claim 34

Dependent Claim 71 words

A panel according to claim 28 in which the cover sheets comprise cellulosic liner material impregnated with from about 8 percent to 15 percent by weight of polyisocyanate to cellulosic material, having a machine direction linear expansion at from 50 percent to 90 percent humidity and 65° F. of less than 0.1 inch per inch in the major direction, and having a water vapor transmission rate of at least 3.5 perms.

Claim 35

Dependent Claim 23 words

A panel according to claim 28 including a respective blowing agent retaining sheet between the core sheet and each of the cover sheets.

Claim 36

Dependent Claim 19 words

A panel according to claim 28 including a thermal reflective material overlaying at least one of the cover sheets.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1997-09-12	1998-03-14	1998-09-13	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2001-09-12	2002-03-14	2002-09-13	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2005-09-12	2006-03-14	2006-09-13	$7700.00	Window Closed / Lapsed

Multi-functional exterior structural foam sheathing panel

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