Foam board with pre-applied sealing material

Patent metadata

Field	Value
Publication number	US-9476202-B2
Application number	US-201113073170-A
Country	US
Kind code	B2
Filing date	Mar 28, 2011
Priority date	Mar 28, 2011
Publication date	Oct 25, 2016
Grant date	Oct 25, 2016

Abstract

A board with preformed seals. In an exemplary embodiment, a sealing material is applied to at least one edge of a board to form a preformed seal on that edge. The board is configured such that when the board is attached to a frame adjacent to a another board, at least a portion of the sealing material applied to the edge of the board seals against at least a portion of an edge another board. In one exemplary embodiment, the boards are configured to seal against edges of substantially identical boards. A plurality of the sheathing boards may be installed on a building frame to form a sheathing system that provides a moisture and/or gas barrier between and interior and exterior of a building.

First claim

The invention claimed is:

1. A polystyrene board assembly, consisting of:
a polystyrene foam board having front and back polystyrene faces and first, second, third and fourth polystyrene edges;
a compressible foam sealing material pre-applied to and in direct contact with the first polystyrene edge to form a preformed seal, and a protective layer provided over the preformed seal;
wherein the pre-applied compressible foam sealing material contacts only polystyrene and the protective layer over the pre-applied compressible foam sealing material.

2. The polystyrene board assembly of claim 1 wherein said sealing material is cured to the polystyrene foam board to form said preformed seal prior to and remotely from a site where the polystyrene board assembly will be attached to frame members.

3. The polystyrene board assembly of claim 1 wherein the protective layer comprises a film or tape.

4. The polystyrene board assembly of claim 1 wherein the protective layer is removable from the at least one performed seal.

5. A polystyrene board assembly, consisting of:
a polystyrene foam board having front and back polystyrene faces and first, second, third and fourth polystyrene edges;
a compressible foam sealing material pre-applied to and in direct contact with the first polystyrene edge to form a first preformed seal and with the second polystyrene edge to form a second preformed seal, and
a protective layer is provided over the first and second preformed seals;
wherein the pre-applied compressible foam sealing material contacts only polystyrene and the protective layer over the pre-applied compressible foam sealing material.

6. The polystyrene board assembly of claim 5 wherein said sealing material is cured to the polystyrene foam board to form said preformed seal prior to and remotely from a site where the polystyrene board assembly will be attached to frame members.

7. A polystyrene board assembly, consisting of:
a polystyrene foam board having front and back polystyrene faces and first, second, third and fourth polystyrene edges;
a compressible foam sealing material pre-applied to and in direct contact with the first polystyrene edge to form a first preformed seal, with the second polystyrene edge to form a second preformed seal, and with the third polystyrene edge to form a third preformed seal; and
a protective layer is provided over the first, second, and third preformed seals;
wherein the pre-applied compressible foam sealing material contacts only polystyrene and the protective layer over the pre-applied compressible foam sealing material.

8. The polystyrene board assembly of claim 7 wherein said sealing material is cured to the polystyrene foam board to form said preformed seal prior to and remotely from a site where the polystyrene board assembly will be attached to frame members.

9. A polystyrene board assembly, consisting of:
a polystyrene foam board having front and back polystyrene faces and first, second, third and fourth polystyrene edges;
a compressible foam sealing material pre-applied to and in direct contact with the first polystyrene edge to form a first preformed seal, with the second polystyrene edge to form a second preformed seal, with the third polystyrene edge to form a third preformed seal, and with the fourth polystyrene edge to form a fourth preformed seal; and
a protective layer is provided over the first, second, third, and fourth preformed seals;
wherein the pre-applied compressible foam sealing material contacts only polystyrene and the protective layer over the pre-applied compressible foam sealing material.

10. The polystyrene board assembly of claim 9 wherein said sealing material is cured to the polystyrene foam board to form said preformed seal prior to and remotely from a site where the polystyrene board assembly will be attached to frame members.

11. A sheathing system comprising:
a first polystyrene board assembly consisting of a first polystyrene foam board having a front polystyrene face, a back polystyrene face and first, second, third and fourth polystyrene edges and compressible foam sealing material;
wherein the compressible foam sealing material is pre-applied to and in direct contact with one or more of the polystyrene edges of the first polystyrene board to form at least one preformed seal;
a second polystyrene board assembly consisting of a second polystyrene foam board having a front polystyrene face, a back polystyrene face and first, second, third and fourth polystyrene edges and compressible foam sealing material;
wherein the compressible foam sealing material is pre-applied to and in direct contact with one or more of the polystyrene edges of the second polystyrene board to form at least one preformed seal;
wherein the first and second polystyrene board assemblies are attached to frame members such that at least a portion of the compressible foam sealing material applied to the one or more of the polystyrene edges of the first polystyrene foam board seals against a respective said polystyrene edge without the compressible foam sealing material of the second polystyrene foam board;
wherein the pre-applied compressible foam sealing material contacts only polystyrene.

12. The sheathing system of claim 11 wherein said compressible foam sealing material is cured to the polystyrene of the first and second polystyrene foam boards prior to attachment of the first or second polystyrene board assemblies to the frame members.

13. The sheathing system of claim 11 wherein the compressible foam sealing material is pre-applied only to the first and second polystyrene edges of the first and second polystyrene foam boards.

14. The sheathing system of claim 11 wherein the compressible foam sealing material is applied directly to all four edges of the first polystyrene foam board.

15. A sheathing system comprising:
a first polystyrene board assembly consisting of a first polystyrene foam board having a front polystyrene face, a back polystyrene face and first, second, third and fourth polystyrene edges and compressible foam sealing material;
wherein the compressible foam sealing material is pre-applied to and in direct contact with one or more of the polystyrene edges of the first polystyrene foam board to form one or more preformed seals, wherein a protective layer is provided over the one or more preformed seals of the first polystyrene foam board; and
a second polystyrene board assembly consisting of a second polystyrene foam board having a front polystyrene face, a back polystyrene face and first, second, third and fourth polystyrene edges and compressible foam sealing material;
wherein the compressible foam sealing material is pre-applied to and in direct contact with one or more of the polystyrene edges of the second polystyrene foam board to form one or more preformed seals, wherein a protective layer is provided over the one or more preformed seals of the second polystyrene foam board; and
wherein the first and second polystyrene foam boards are attachable to frame members such that at least a portion of the sealing material applied to the one or more of the polystyrene edges of the first polystyrene foam board seals against a respective said polystyrene edge without the compressible foam sealing material of the second polystyrene foam board after each of the protective layers are removed from the first and second polystyrene foam boards;
wherein the pre-applied compressible foam sealing material of the first and second polystyrene foam boards contact only polystyrene after each of the protective layers are removed from the first and second polystyre

Assignees

• Clancy Timothy Robert
• Budinscak Jr John Frank
• Burlingame Lee John
• Owens Corning Intellectual Capital Llc

Inventors

• Clancy Timothy Robert
• Budinscak Jr John Frank
• Burlingame Lee John

Classifications

• E04F13/0803

  with load-supporting elongated furring elements between wall and covering elements · CPC title

• E04B2/7457

  with wallboards attached to the outer faces of the posts, parallel to the partition (E04B2/7459 takes precedence) · CPC title

• E04C2/24

  laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 · CPC title

• B32B2266/0228

  Aromatic vinyl resin, e.g. styrenic (co)polymers · CPC title

• B32B21/02

  the layer being formed} of fibres, chips, or particles {, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard · CPC title