# US 2025/0154764 A1 · Insulation and Weather Resistant Barrier Systems

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 2025/0154764 A1
- Document ID: US20250154764A1
- Status: Published application
- Kind: A1
- Application number: 18/775,125
- Filed: 2024-07-17
- Published: 2025-05-15
- Earliest claimed: 2023-07-17
- Applicants: Henry Company, LLC
- Inventors: Divya Chopra; Thomas Savoy
- Web page: https://patentgrep.com/patent/US20250154764A1

## CPC

- B32B 3/06: for securing layers together; for attaching the product to another member, e.g. to a support {, or to another product, e.g. groove/tongue, interlocking}
- E04C 2/296: composed of insulating material and non-metallic or unspecified sheet-material (E04C2/288 takes precedence)
- B27N 3/007: {and at least partly composed of recycled material}
- B27N 3/04: from fibres
- B27N 7/005: {Coating boards, e.g. with a finishing or decorating layer}
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)}
- B32B 5/12: characterised by the relative arrangement of fibres or filaments of {different layers, e.g. the fibres or filaments being parallel or perpendicular to each other}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 5/245: {another layer next to it being a foam layer}
- B32B 7/02: Physical, chemical or physicochemical properties
- B32B 7/022: Mechanical properties
- B32B 7/03: with respect to the orientation of features (direction of fibres or filaments B32B5/12)
- B32B 7/14: applied in spaced arrangements, e.g. in stripes
- B32B 21/02: {the layer being formed} of fibres, chips, or particles {, e.g. MDF, HDF, OSB, chipboard, particle board, hardboard}
- B32B 21/042: {of wood (B32B21/13 takes precedence)}
- B32B 21/047: {of foam}
- B32B 21/06: of paper or cardboard
- B32B 21/14: comprising wood board or veneer
- B32B 29/002: {as the main or only constituent of a layer, which is next to another layer of the same or of a different material (next to a layer of a particular substance B32B9/06; next to a bituminous or tarry layer B32B11/06; next to a water-setting substance layer B32B13/08; next to a metal layer B32B15/12; next to a glass layer B32B17/065; next to a layer formed of natural mineral fibres or particles B32B19/046; next to a wood layer B32B21/06; next to a cellulosic plastic layer B32B23/06; next to a natural or synthetic rubber layer B32B25/06; next to a synthetic resin layer B32B27/10)}
- B32B 29/02: next to a fibrous or filamentary layer
- B32B 29/06: specially treated, e.g. surfaced, parchmentised
- E04C 2/24: laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
- E04C 2/243: {one at least of the material being insulating}
- E04C 2/246: {combinations of materials fully covered by E04C2/16 and E04C2/20}
- A01D 43/10: with means for crushing or bruising the mown crop
- B27N 3/02: from particles
- B32B 2250/03: 3 layers
- B32B 2250/04: 4 layers
- B32B 2250/44: Number of layers variable across the laminate
- B32B 2255/08: on wood layer
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/028: Paper layer
- B32B 2260/046: Synthetic resin
- B32B 2262/065: Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
- B32B 2266/0214: Materials belonging to B32B27/00
- B32B 2266/0228: Aromatic vinyl resin, e.g. styrenic (co)polymers
- B32B 2266/025: Polyolefin
- B32B 2266/0278: Polyurethane
- B32B 2272/00: Resin or rubber layer comprising scrap, waste or recycling material
- B32B 2307/304: Insulating
- B32B 2307/306: Resistant to heat
- B32B 2307/712: Weather resistant
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/72: Density
- B32B 2307/724: Permeability to gases, adsorption
- B32B 2307/7265: Non-permeable
- B32B 2307/7376: Thickness
- B32B 2307/744: Non-slip, anti-slip
- B32B 2607/00: Walls, panels
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S)
- B27N: MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL (containing cementitious material B28B; shaping of substances in a plastic state B29C; fibreboards made from fibrous suspensions D21J; drying F26B17/00)
- A01D: HARVESTING; MOWING

## Abstract

This invention relates to insulated wall-sheathing (IWS) panels, a panel assembly comprising such panels, and systems for use in building construction designed to provide moisture permeable panels that protect from bulk water, excess air, and thermal transfer. More specifically, this invention relates such panel used for construction purposes, comprising an insulation layer; a wood-composite panel; a nail-gasketing adhesive layer; and a weather-resistive barrier layer; wherein the weather-resistive barrier (WRB) layer exceeds the dimension of the wood-composite panel from at least one of its edges to create an extension flap; and wherein the extension flap of the WRB layer further comprises a removably attached release-liner on its back.

## Claims

### Claim 1

A first IWS panel used for construction purposes, comprising the following layers:
an optional insulation facer layer having an outer surface and an inner surface;
a first insulation layer having an outer surface and an inner surface; wherein, when the insulation facer layer is present, the inner surface of the insulation facer is planarly and contactably attached to the outer surface of the insulation layer;
a first structurally stable panel having an outer surface and an inner surface, and at least one edge extending between its outer surface and the inner surface; wherein the inner surface of the first insulation layer is planarly and contactably attached to the outer surface of the first structurally stable panel; and
a first WRB layer having an outer surface and an inner surface, wherein the inner surface of the WRB layer is secured to the outer surface of the first structurally stable panel through an adhesive layer, or through a fastener-gasketing layer, or through an adhesive layer and a fastener-gasketing layer;
wherein the WRB layer exceeds the dimension of the first structurally stable panel from at least one of its edges to create an extension flap; and
wherein the extension flap of the WRB layer further comprises a removably attached release-liner attached to the WRB layer's inner surface.

### Claim 2 (depends on 1)

The IWS panel as recited in claim 1, wherein the structurally stable panel is a wood-composite panel.

### Claim 3 (depends on 2)

The IWS panel as recited in claim 2, wherein the wood-composite panel is a lignocellulosic panel.

### Claim 4 (depends on 3)

The IWS panel as recited in claim 3, wherein the lignocellulosic panel is an OSB panel.

### Claim 5 (depends on 1)

The IWS panel as recited in claim 1, wherein the WRB layer is substantially bulk water resistant and substantially water vapor permeable.

### Claim 6 (depends on 1)

The IWS panel as recited in claim 1, wherein the extension flap is continuous or discontinuous along the length of the edge from which it exceeds beyond the panel.

### Claim 7 (depends on 1)

The IWS panel as recited in claim 1, wherein the extension flap, in the direction perpendicular to the edge of the lignocellulosic panel, is 0.1% to 50% of the shortest and the longest dimension of the lignocellulosic panel, respectively.

### Claim 8 (depends on 7)

The panel assembly as recited in claim 7, wherein the extension flap in its direction parallel to the edge of the lignocellulosic panel, is from 0% to 20% the length of the edge of the panel.

### Claim 9 (depends on 8)

The IWS panel as recited in claim 8, wherein, the release liner covers the surface area of the extension flap of the barrier layer from about 10% to 100%.

### Claim 10 (depends on 1)

The IWS panel as recited in claim 1, wherein the insulation layer is foam insulation comprising polyisocyanurate foam, polystyrene foam, polyurethane foam, EPS, GPS, XPS, or a combination thereof.

### Claim 11 (depends on 1)

The IWS panel as recited in claim 1, wherein the insulation layer has a density in the range of about 1 to about 20 pounds per cubic feet (pcf) according to ASTM D1622.

### Claim 12 (depends on 1)

The IWS panel as recited in claim 1, wherein the insulation layer has a water absorption of less than about 10% according to ASTM C209 or ASTM C2842.

### Claim 13 (depends on 1)

The IWS panel as recited in claim 1, wherein the insulation layer has a water vapor permeance from about 0.1 to about 20 perms as determined according to ASTM E96.

### Claim 14 (depends on 1)

The IWS panel as recited in claim 1, wherein the system exhibits a thermal resistance value (R-value) from about 1 to about 15 according to ASTM C1289-02.

### Claim 15 (depends on 1)

The IWS panel as recited in claim 1, wherein the insulation layer further comprises a membrane layer.

### Claim 16 (depends on 15)

The IWS panel as recited in claim 15, wherein the insulation membrane layer comprises radiant barrier material, polymeric film, polymeric fabric, paper, cellulosic material, reinforcing scrim, or a combination thereof.

### Claim 17 (depends on 1)

The IWS panel as recited in claim 1, wherein the insulation layer is secured to the panel using an adhesive selected from a phenol-formaldehyde resin, hot-melt adhesive, polyvinyl acetate (PVA) resin, or a combination thereof.

### Claim 18 (depends on 1)

The IWS panel as recited in claim 1, wherein the WRB barrier layer comprises a resin-impregnated paper substantially covering the outward facing surface of the panel, the resin-impregnated paper having a paper basis weight of 21.772 kg (48 lbs.) to about 102.058 kg (225 lbs.) per ream and a resin content of less than 80% by dry weight.

### Claim 19 (depends on 18)

The IWS panel as recited in claim 18, wherein each panel and barrier layer has a water vapor transmission rate from about 0.7 to about 7 grams/m2/24 hrs as determined according to ASTM E96 procedure A (at 73° F.-50% RH) and a liquid water transmission rate from about 1 to about 28 grams/100 in2/24 hrs via Cobb ring according to ASTM D5795.

### Claim 20 (depends on 19)

The IWS panel as recited in claim 19, wherein an outer surface of the barrier layer is textured.

### Claim 21 (depends on 20)

The IWS panel as recited in claim 20, wherein the textured outer surface provides a wet coefficient of friction in a range of about 0.8 to about 1.1 (English XL Tribometer) and a dry coefficient of friction of at least about 0.8 (English XL Tribometer).

### Claim 22 (depends on 1)

The IWS panel as recited in claim 1, wherein said panel comprises an oriented strand board, a plywood, a particleboard, a chipboard, a medium-density fiberboard, or a waferboard.

### Claim 23 (depends on 1)

The IWS panel as recited in claim 1, wherein the structurally stable panel comprises other plant-based materials, said other plant-based materials are described as below:
grass, including perennial grass, switchgrass such as Panicum virgatum L, Miscanthus, Sorghum, sugarcane, millets, Napier grass, giant reed, and other forage and turf grasses, subalpine grasses, native grass, sedge, rush include Agrostis exarata (Spike Bentgrass), Ammophila arenaria (European sand dune or beach grass), Ammophila breviligulata (American beach grass), Ammophila champlainensis Seymour, Ammophila maritima, Beckmannia zyzigachne (American Sloughgrass), Bromus carinatus (California Brome), Bromus vulgaris (Columbia Brome), Carex densa (Dense-Headed Sedge), Carex feta (Green-Sheathed Sedge), Carex leporina (Harefoot Sedge), Carex lenticularis (=C. kelloggii) (Shore Sedge), Carex lyngbyel (Lyngby Sedge), Carex macrocephala (Big Headed Sedge), Carex obnupta (Slough Sedge), Carex pansa (Foredune Sedge), Carex unilateralis (One-Sided Sedge), Deschampsia caespitosa (Tufted Hair Grass), Eleocharis palustis (Creeping Spike rush), Elymus glaucus (Blue Wild Rye), Festuca idahoensis var. roemeri (Roemer's Fescue), Festuca rubra var. littoralis (Shore Fescue), Festuca subulata (Bearded Fescue), Glyceria elata (Tall Mannagrass), Glyceria occidentalis (Western Mannagrass), Hordeum brachyantherum (Meadow Barley), Juncus effusus (Soft Rush), Juncus patens (Spreading Rush), Juncus tenuis (Slender Rush), Lozula campestris (Woodrush), Phalaris arundinacea (Reed Canary Grass), Phalaris aquatica, Phalaris tuberosa (Staggers Grass), Phalaris canariensis, Poa Macrantha (Dune Bluegrass), ReGreen (Sterile Hybrid Wheat), Scirpus acutus (Hardstem Bullrush), Scirpus americanus, Scirpus cyperimus, Bullrush), Scirpus microcarpus, Scirpus validus, Sparaganium eurycarpum (Giant Burreed), Triglochin maritinum (Seaside Arrowgrass), Typha latifolia (Cattail), Alopecuris geniculatus, Carex pachystachya, Carex stipata (grass like), Danthonia californica, Eleocharis ovata (grass like), Glycaria grandis, Juncus acuminatus, Juncus bolanderi and Juncus ensifolius (Daggar leaf rush). By way of example, other grasses include the Lily of the Nile (Agapanthus africanus), white fountain grass (Pennisetum ruppellii), muhly grass (Muhlenbergia capillaris), African iris (Dietes vegeta), podocarpus (Podocarpus macrophyllus), wax myrtle (Myrica cerifera), Aztec grass (Ophiopogon intermedius argenteomarginatus), mondo grass (Ophiopogon japonicus), evergreen giant (Liriope muscan), evergreen Paspalum (Paspalum quadrifarium) and sand cord grass (Spartina bakerii).

### Claim 24 (depends on 1)

The panel as recited in claim 1, wherein the structurally stable panel comprises other plant-based materials, said other plant-based materials comprising flax fibers and flax shives produced from processing waste flax straw.

### Claim 25 (depends on 24)

The panel as recited in claim 24, wherein the lignocellulosic component in the wood-composite panel includes more than one of the plant-based materials.

### Claim 26 (depends on 25)

The panel as recited in claim 25, wherein the wood composite panel comprises a binder material and other plant-based material, wherein said panel includes at least 70 percent other plant-based material by weight and at least 2.5 percent thermoplastic binder by weight.

### Claim 27 (depends on 26)

The panel as recited in claim 26, wherein said thermoplastic binder material comprises high density polyethylene.

### Claim 28 (depends on 26)

The panel as recited in claim 26, wherein said thermoplastic binder material comprises recycled high-density polyethylene.

### Claim 29 (depends on 26)

The panel as recited in claim 26, wherein said binder material is a formaldehyde-free binder.

### Claim 30 (depends on 29)

The panel as recited in claim 29, wherein said binder material contains zero volatile organic compounds (VOC).

### Claim 31 (depends on 30)

The panel as recited in claim 30, wherein said binder material comprises polymeric methylene diphenyl diisocyanate (PMDI).

### Claim 32 (depends on 31)

The panel as recited in claim 31, wherein said binder material comprises a protein-based resin.

### Claim 33 (depends on 32)

The panel as recited in claim 32, wherein said protein-based resin is selected from the group of protein-based resins consisting of a soy protein-based resin, a canola protein-based resin, a castor protein-based resin, jatropha protein-based resin and combinations thereof.

### Claim 34 (depends on 26)

The panel as recited in claim 26, wherein said panel includes 80 to 90 percent other plant-based material portions by weight, 8 to 12 percent recycled high density polyethylene and 3 to 5 percent polymeric methylene diphenyl diisocyanate (PMDI) by weight.

### Claim 35 (depends on 1)

The panel as recited in claim 1, wherein said panel comprises at least two oriented strand layers, each oriented strand layer containing a binder material and other plant-based material portions, each oriented strand layer having a layer axis with greater than 90% of said other plant-based material portions aligned within +/−45 degrees of said layer axis, and wherein at least one oriented strand layer has a layer axis oriented at a non-zero angle relative to a layer axis of another oriented strand layer.

### Claim 36 (depends on 1)

The panel as recited in claim 1, wherein said structurally stable panel is selected from the group of wood composite panel types consisting of oriented strand wood composite panel, fiber wood composite panel, particle wood composite panel and layer comprising other plant-based material.

### Claim 37 (depends on 1)

The panel as recited in claim 1, wherein said panel has a density in the range of 42 to 54 lbs/ft3.

### Claim 38 (depends on 1)

A panel assembly comprising at least two panels juxtaposed and/or adhered to each other, wherein at least one panel is according to the IWS panel, as recited in claim 1.

### Claim 39

A method of manufacturing an IWS panel or an IWS panel system, wherein the wood composite panel is made by a method comprising the steps of:
combining a binder material and other plant-based material portions to produce a combined material, wherein said combined material includes at least 70 percent other plant-based material portions by weight and at least 2.5 percent thermoplastic binder by weight; and
heating and pressing said combined material.

### Claim 40 (depends on 39)

The method as recited in claim 39, wherein the heating and pressing step is accomplished in a press at a temperature in the range of 125 to 400 degrees Fahrenheit.

### Claim 41 (depends on 40)

The method as recited in claim 40, wherein the heating and pressing step is accomplished in a press at a pressure in the range of 100 to 300 psi.

### Claim 42 (depends on 39)

The method as recited in claim 39, wherein said other plant-based material portions have a moisture content in the range of about 1.0 to 5.0 percent when combined with the binder.

### Claim 43 (depends on 42)

The method as recited in claim 42, further comprising the steps of:
harvesting other plant materials by mowing other plant-based materials:
conditioning each mowed stalk at the harvest site by crimping the mowed stalk at a plurality of locations to increase other plant-based material drying;
refining other plant-based material into fibers using a mill; and
screening the fibers to remove other plant-based material fines.

### Claim 44

A wood composite panel made by a process comprising the steps of:
combining a binder material and other plant-based material portions to produce a combined material, wherein said combined material includes at least 70 percent other plant-based material portions by weight and at least 2.5 percent thermoplastic binder by weight; and
heating and pressing said combined material.