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Gypsum wood fiber structural insulated panel arrangement

a technology of structural insulation and gypsum wood fiber, which is applied in the direction of building components, buildings, constructions, etc., can solve the problems of reducing the use value of the panel, increasing the cost of the panel, and preventing the use of the panel in many types of common structures, etc., and achieves the effect of low cos

Inactive Publication Date: 2008-10-09
UNITED STATES GYPSUM CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0012]The present invention represents an improvement over the prior art by providing a low cost structural insulated panel having a plastic foam inner core and opposed outer facings comprised of gypsum wood fiberboard without the need for OSB or plywood or other structural wood sheathing which has previously been used on the exterior surface of panels for structural strength when gypsum or cementitious panels were used on the interior facing.
[0014]The present invention increase the tensile strength of a gypsum or cementitious sheet in a multi-layered structural insulated panel arrangement that renders the panel resistant to moisture and which overcomes the warping of multilayer panels that use gypsum or cement panels on one surface and OSB panels on the other surface.
[0015]Another aspect of the present invention is to provide a high strength structural panel system for building construction which is fire and moisture resistant and is thus capable of serving as a vapor barrier. In addition, the gypsum wood fiber panels provide a ready to finish surface.

Problems solved by technology

But panels strengthened in this manner are subject to moisture degradation and insect infestation when used on the outside of a structure.
Another approach employs a metal facing on one or both surfaces of the structural insulated panel to increase panel strength and environmentally isolate one side of the panel from the other, but this substantially increases the cost of the panel and precludes use of the panel in many types of common structures.
This earlier developed panel assembly was not a structural insulation panel system and required the use of framing e.g. wood framing, and the assembly did not recognize the benefit of using a reinforced gypsum cellulose fiber board on both the interior face of the panel and the outer sheathing panel to meet the needs of the building industry for an acceptable structural insulation panel without use of exterior OSB or cementitious composite board sheathing.
SIP panels manufactured using OSB and Foam do not meet this requirement and require an additional interior layer of gypsum board since the OSB layer is not suitable for interior decoration.
SIP panels manufactured using gypsum boards do not have the structural capacity to be used for load-bearing walls.

Method used

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  • Gypsum wood fiber structural insulated panel arrangement
  • Gypsum wood fiber structural insulated panel arrangement
  • Gypsum wood fiber structural insulated panel arrangement

Examples

Experimental program
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Effect test

example 1

[0053]SIP panels are manufactured by Stress Panel Manufacturing using 1.27 cm. (½ in.) FIBEROCK® brand sheathing panels adhesively attached on both sides of either 8.89 or 16.51 cm. (3.5 or 6.5 in.) thick polystyrene foam. The panels were created using 31.78 kg / m3 (2 lb / ft3) expanded polyethylene foam (EPS foam). A total of six 1.22×2.44 m. (4×8 ft) panels were tested to determine the load capacity of the system. Tests were conducted according to ASTM E-72-05 and ASTM E-330. The axial load tests were conducted on the panels without splines.

[0054]A 11.43 cm. (4½ in.) thick panel was cut vertically into a 61 cm. (24 in.) strip and the 2.44 m. (8 ft) tall section axially loaded to failure. Loading was conducted by placing flat steel plates at the top and bottom of the specimen and placing the loading ram ⅙ of the panel thickness away from the center of the panel, as described in ASTM E-72-05. The load at failure was approximately 8636.4 kg. (19,000 lb), which is equivalent to an ultima...

example 2

[0061]Tests were conducted according to ASTM C514-04 to determine the amount of force required to remove various fasteners from 1.27 cm. (½ in.) FIBEROCK® brand gypsum wood fiber panels available commercially from United States Gypsum Company, Chicago, Ill., USA. Results were also obtained for 1.48 cm. ( 7 / 16 in.) panels of oriented strand board (OSB) and plywood, meeting ASTM commercially available from a number of suppliers such as Louisiana Pacific and Weyerhaeuser. Results are shown in TABLE 1, below.

[0062]From the table it was found that the 1.27 cm. (0.50 in.) FIBEROCK® brand gypsum wood fiber sheathing would not hold nails and thus for any particular application where bonding strength was required, screws would need to be used.

TABLE 1Nail-holding Strength in Kg (lbs.)1.27 cm.0.4860.486 cm.FIBEROCK ® BrandFastener Descriptioncm. OSBPlywoodSheathing1½ in. roofing nails23.221.43.646 d nails33.226.44.551½ in. G screws132.7155.539.541¼ in. drywall101.8131.838.2screws1⅝ in. drywall...

example 3

[0064]Tests were conducted to determine the shear strength of various fasteners in FIBEROCK® brand sheathing. This data may be used to determine the number of fasteners required to attach SIPS panels to footers and headers.

[0065]Tests were conducted by attaching 5.08×15.24×1.91 cm. (2×6×¾ in.) plywood to 15.24 cm.×15.24 cm.×1.27 cm. (6 in.×6 in.×0.5 in.) FIBEROCK® brand sheathing and to 15.24 cm.×15.24 cm.×1.525 cm. (6 in.×6 in.×⅝ in.) FIBEROCK® brand sheathing using single fasteners. These fasteners are either USG Exterior Sheathing Screws, standard drywall nails or 3.81 cm. (1½ in.) long staples with 0.635 cm. (¼ in.) crowns. In each case, the fastener was 1.91 cm. (¾ in.) from the edge of the panel.

[0066]Shear strength to failure values for various fasteners used for joining FIBEROCK® brand gypsum wood fiber board sheathing to plywood obtained from the testing are shown in the bar graph in FIG. 10. For each configuration, five samples were evaluated. For screws in 1.27 cm. and 1....

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Abstract

A generally planar, structural insulated panel for building construction includes a pair of outer facings disposed on opposed surfaces of a plastic foam core. Both of the outer facings are gypsum cellulose fiber board such as gypsum wood fiber board. Disposed on the exterior surface of the gypsum wood fiber board on the exterior surface and between another expanded polystyrene insulation panel is a weather resistant barrier that is fastened to the gypsum wood fiber board. The exterior surface of the second insulation panel is fastened to the gypsum wood fiber board by mechanical fasteners. The insulation panels are then coated with a basecoat which has an embedded mesh reinforcement and then a finishing coat is applied to the base coating. Vinyl or aluminum metal siding can be fastened to the structural assembly by G screw fasteners or other mechanical fasteners.

Description

FIELD OF THE INVENTION[0001]This invention relates generally to structural insulated panel arrangements used in a building construction system and is particularly directed to a structural insulated panel having a plastic foam core and a pair of opposed outer facings made from gypsum wood fiber board, and a panel system for providing protection of the exterior gypsum wood fiber facing from moisture damage.BACKGROUND OF THE INVENTION[0002]Structural Insulated Panels (SIPs) are gaining increasing acceptance in the building construction industry as an alternative to the stick built approach. SIP construction employs two rigid faces on either side of a light insulating foam core. High strength bonding of the outer facings to the inner core forms a structural I-beam in the form of flat panels which are typically joined together by lumber and nails. The outer, opposed panel faces are typically formed from conventional building materials such as gypsum or cementitious composites, plywood, o...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): E04C2/284
CPCE04C2/246E04C2/284
Inventor MCDONALD, DAVID B.
Owner UNITED STATES GYPSUM CO
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