Composite structural insulation panels and methods of manufacture
AssigneeNational Shelter Products, Inc.
InventorJohn W. Cahill
Life of this patent
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Abstract
Composite structural insulation panels are provided that can eliminate the need to embed mechanical fasteners into foam insulation, as this type of structural nailing requirement harms the panels weather barrier effectiveness and limits structural performance. The composite structural insulation panels can also provide improved fastener holding capability, improved structural performance, improved jobsite durability, and improved fire control.
Claims20
A structural insulation panel, comprising:
- an insulation core comprising a single, continuous layer of extruded expanded polystyrene;
- a first structural sheathing layer disposed on and bonded to a first side of the insulation core, wherein the first structural sheathing layer comprises a polymer;
- and
- a second structural sheathing layer disposed on and bonded to a second, opposing side of the insulation core, wherein the second structural sheathing layer comprises a polymer;
- wherein the first and second structural sheathing layers each have a thickness of about 0.010 inches to about 0.250 inches.
A structural insulation panel, comprising:
- a single, continuous insulation core comprising extruded expanded polystyrene, the insulation core having an overall thickness in the range of about 0.5 inches to about 3.0 inches;
- a first polymer sheet disposed directly on and bonded to a first side of the single, continuous insulation core, the first polymer sheet functioning as a structural sheathing layer;
- and
- a second polymer sheet disposed directly on and bonded to a second, opposing side of the single, continuous insulation core, the second polymer sheet functioning as a structural sheathing layer;
- wherein the first polymer sheet and the second polymer sheet each have a nominal thickness of about 0.010 inches to about 0.250 inches.
A structural insulation panel comprising exactly three layers of material, wherein the three layers consist of a first polymer sheet, a single continuous layer of extruded expanded polystyrene disposed between and bonded to the first polymer sheet and a second polymer sheet, and the second polymer sheet, wherein the first polymer sheet and the second polymer sheet each have a thickness of about 0.010 inches to about 0.250 inches, and wherein the single continuous layer of extruded expanded polystyrene has a thickness in the range of about 0.5 inches to about 3.0 inches.
Dependencies are inferred from the claim text.