Multi-material sheet system

Abstract

A deck system that encloses a building structure is provided that combines a lightweight structural layer and a high R value thermal insulation layer to provide a unique solution. The aggregate layer of the cladding system provides the following beneficial effects: reduced thickness, reduced weight, improved thermal insulation, improved structural strength, improved tackiness, improved fire and smog performance, and enhanced energy efficiency. All aspects of the disclosed panel system may contribute to overall improved performance and sustainability of building structures.

Description

Background Art

[0001] In contemporary building construction, wall sheathing systems are employed to provide structural support, insulation, and protection from external environmental elements. Conventional wall sheathing materials, such as plywood and oriented strand board (OSB), have been widely used and are generally viewed as being able to provide structural support or rigidity to a structure; however, these materials generally lack adequate thermal insulation properties. Among other drawbacks, the thermal insulation properties of conventional sheathing are insufficient to translate into greater energy consumption for maintaining temperature and humidity levels in air-conditioned spaces.

[0002] To address insulation challenges, conventional practice involves the application of a separate layer of insulation in combination with conventional wall sheathing materials. While this approach can improve energy efficiency, it increases the complexity of the construction process and increases material and labor costs. In addition to their limited insulating capabilities, conventional wall sheathing materials are susceptible to moisture penetration and degradation over time, which can compromise the structural integrity and thermal performance of the building envelope. To address moisture issues, conventional building practices require wrapping the sheathing with a waterproof wrap. Applying the wrap is a labor-intensive task, which can increase labor and material costs. In addition, the wrap is often susceptible to shifting during construction and can trap moisture between the wrap and the sheathing. Summary of the invention

[0003] The present disclosure relates to a high strength yet lightweight multi-material sheathing system that provides enhanced thermal insulation and weatherability properties when used to enclose at least a portion of a building structure. The disclosed wall sheathing system combines a lightweight structural layer and a high R-value insulation layer to provide a unique solution. Embodiments of the present disclosure relate to a sheathing system that utilizes one or more thin layers of strong yet lightweight materials combined with a high R-value insulation layer. The collective layers of the sheathing system provide the following benefits: reduced thickness, reduced weight, improved thermal insulation, improved structural strength, improved nailability, improved fire and smoke resistance, and enhanced energy efficiency. All aspects of the disclosed sheathing system can contribute to the overall improved performance and sustainability of a building structure.

[0004] According to aspects disclosed herein, a cladding system is provided, comprising one or more structural layers and an insulating layer. The structural layer comprises a polycarbonate material and has a first surface and an opposing second surface. In an exemplary aspect, the structural layer is substantially waterproof as a whole and substantially water vapor permeable. The insulating layer comprises extruded polystyrene and has a third surface and an opposing fourth surface. The third surface of the insulating layer is secured to the second surface of the structural layer. In some additional aspects, the cladding system further comprises an additional structural layer comprising a polycarbonate material and having a fifth surface and an opposing sixth surface. The fifth surface of the additional structural layer may be at least partially secured to the fourth surface of the insulating layer.

[0005] According to the disclosed aspects, the sheathing system weighs less than conventional systems that weigh between 10 pounds and 45 pounds, has a thickness of no greater than 1.5 inches, preferably no greater than one inch, and has an R-value of at least 3.5, preferably at least 4.5. Thus, the disclosed sheathing system is superior to conventional systems that are typically heavier, thicker, and have lower R-values.

[0006] This summary is provided to introduce but not to limit the scope of the methods and systems that are provided in full detail below. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The present invention is described in detail herein with reference to the accompanying drawings, in which:

[0008] Figure 1A depicts a perspective view of a three-dimensional cladding system according to aspects of the present invention;

[0009] Figure 1B depicts an exploded view of a three-dimensional cladding system according to aspects of the present invention;

[0010] Figure 2A depicts a cross-sectional view of a three-dimensional cladding system according to aspects of the present invention;

[0011] Figure 2B depicts a cross-sectional view of a three-dimensional cladding system according to aspects of the present invention;

[0012] Figure 3A depicts a perspective view of a three-dimensional cladding system according to aspects of the present invention;

[0013] Figure 3B depicts an exploded view of a three-dimensional cladding system according to aspects of the present invention;

[0014] Figure 4 depicts a cross-sectional view of a three-dimensional cladding system according to aspects of the present invention;

[0015] Figure 5 depicts a cross-sectional view of a three-dimensional cladding system according to aspects of the present invention;

[0016] Figure 6 depicts a cross-sectional view of a three-dimensional cladding system according to aspects of the present invention;

[0017] Figure 7 depicts a cross-sectional view of a three-dimensional cladding system according to aspects of the present invention;

[0018] Figure 8 depicts a cross-sectional view of a three-dimensional cladding system according to aspects of the present invention;

[0019] Fig.9Adepicts a perspective view of a three-dimensional cladding system according to aspects of the present invention;

[0020] Fig. 9B depicts a cross-sectional view of a three-dimensional cladding system according to aspects of the present invention;

[0021] Fig. 10A depicts a cross-sectional view of a three-dimensional cladding system according to aspects of the present invention;

[0022] Fig. 10B depicts a cross-sectional view of a three-dimensional cladding system according to aspects of the present invention;

[0023] FIG. 11A to FIG. 11G depicts exemplary physical data according to aspects of the present invention;

[0024] FIG. 12A to FIG. 12D depicts exemplary physical data according to aspects of the present invention; and

[0025] FIG. 13A to FIG. 13D Exemplary physical data according to aspects of the present invention are depicted. DETAILED DESCRIPTION

[0026] Unless otherwise defined, all technical and scientific terms used herein have the same meanings as those generally understood by those of ordinary skill in the art to which the embodiments belong. Although any methods and materials similar or equivalent to those described herein may be used in the implementation or testing of various embodiments, preferred methods and materials are described herein. In the accompanying drawings, the thickness of lines, layers, and regions may be magnified for clarity. It should be noted that the same numbers represent the same elements in all drawings.

[0027] As used in the specification and the appended claims, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0028] Unless otherwise indicated, all numbers used in the specification and claims expressing amounts of ingredients, chemical and molecular properties, reaction conditions, and the like should be understood as being modified in all instances by the term "about". Therefore, unless indicated to the contrary, the numerical parameters set forth in the specification and the appended claims are approximate values ​​that may vary depending upon the desired properties sought to be obtained by the exemplary embodiments herein. At the very least, each numerical parameter should be interpreted in light of the number of significant digits and ordinary rounding techniques.

[0029] Unless otherwise indicated, any element, property, feature, or combination of elements, properties, and features may be used in any embodiment disclosed herein, whether or not the element, property, feature, or combination of elements, properties, and features is explicitly disclosed in the embodiment. It should be readily understood that features described with respect to any particular aspect described herein may be applicable to other aspects described herein, as long as the feature is compatible with that aspect.

[0030] Every numerical range given throughout the specification and claims will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.

[0031] The term "R-value" is a unit used to measure the effectiveness of insulation and is the reciprocal of thermal conductivity. For foam boards with substantially parallel faces, it is defined as the value of thermal conductivity per unit area (square feet, ft) throughout the thickness (inches or meters) of the board material. 2 Or square meters, m 2 ) is the rate of heat energy flow (BTU / hr or Watts) per degree of temperature difference (Fahrenheit or Kelvin). The thermal performance of polymer insulation products is based on the insulation product's R-value, which is a measure of the product's resistance to heat flow. The R-value is defined by formula (1):

[0032] R=T / k

[0033] Where "T" is the thickness of the insulation product in inches and "k" is the insulation temperature in BTU·in / hr·ft 2 ·℉, and "R" is the thermal conductivity of the insulation product in hr·ft 2 The R-value of the insulation material expressed in °F / BTU.

[0034] As used herein, the thickness (T) of an insulation product may be determined in accordance with ASTM C167-18, and the k value and area weight (in lb / ft 2 Both can be measured according to ASTM C518-21 or ASTM C177-19.

[0035] Aspects related to a sheathing system for constructing a building structure (e.g., a residence, a commercial building, an industrial building) are described below. The disclosed sheathing system may include panels that can be attached to a frame of a building structure to form a sheathing that encloses at least a portion of the building structure. By way of example, a sheathing formed by the disclosed sheathing system may correspond to a wall portion (e.g., a vertical surface) or a roof portion of a building structure.

[0036] The multi-material sheathing system disclosed herein provides various improvements over conventional sheathing systems. The unique collection of individual layers (also referred to herein as "components") used in the production of the disclosed sheathing system provides a stronger, thinner, and lighter sheathing with a higher R-value per inch of overall thickness, which provides several advantages over conventional sheathing systems.

[0037] The materials used in the novel cladding system of this article provide a thinner structural layer that maintains or exceeds the structural performance of conventional systems. As can be understood by those of ordinary skill in the art, thinner materials generally take up less space within the building envelope, thereby allowing more efficient use of the interior space. This may be particularly critical in applications where it is necessary to maximize the available area (such as in residential or commercial buildings). Thinner materials are also generally lighter in weight, which can simplify handling, transportation and installation. In addition, as will be described, the use of alternative materials for cladding systems greatly reduces weight. The reduced weight can also have a positive impact on the structural loads on the foundation and frame of the building. Thin materials provide architects and builders with greater flexibility in designing and realizing various architectural elements (such as curves, angles and complex details). Due to easier handling and installation, this can also achieve faster construction time. Thin materials can then achieve reduced labor costs and faster project completion.

[0038] The material used and described herein provides an insulated sheathing system with a high R value. The higher the R value, the more effective the thermal insulation properties of the sheathing system. More specifically, a sheathing system with a high R value generally indicates that the sheathing system is effective in reducing heat flow through walls, roofs and floors. This means lower energy consumption, lower utility bills and smaller carbon footprints for heating and cooling. High R value sheathing systems also help maintain more consistent indoor temperatures by reducing ventilation, cold spots and heat losses, further providing occupants with a comfortable living or working environment throughout the year. As is generally known in the construction industry, the minimum insulation R value on the exterior sheathing of a building structure may be required by regulations. In this regard, in order to obtain enough R values, after the sheathing is attached to the building structure, conventional sheathing systems may require builders to increase insulation, which further complicates the construction process and causes additional resource expenditures.

[0039] Go to Figure 1A and Figure 1B , an example of a cladding system for externally enclosing at least a portion of a building structure is illustrated according to an exemplary aspect of the present invention. Figure 1A Depicted is a sheathing system 100 coupled to a building frame structure 102. The sheathing system 100 includes a structural layer 104 and an insulating layer 106 (ie, a "2-layer system"). Figure 1BAs shown, the structural layer 104 includes a first surface 114 and a second surface 115 opposite to the first surface 114. The structural layer 104 may have a thickness measured from the first surface 114 to the second surface 115 opposite to the first surface 114. The thermal insulation layer 106 includes a third surface 116 and a fourth surface 117 opposite to the third surface 116. The thickness of the thermal insulation layer 106 may be measured from the third surface 116 to the fourth surface 117.

[0040] The sheathing system 100 is formed by coupling the second surface 115 of the structural layer 104 to the third surface 116 of the insulating layer 106, wherein the sheathing system 100 has an overall thickness measured from the first surface 114 to the fourth surface 117. More specifically, the structural layer 104 can be coupled to the insulating layer 106 by bonding, adhering, applying, or mechanically fastening one layer to the other. By way of example, the sheathing system 100 can be formed by applying a glue layer to the second surface 115 of the structural layer 104 or the third surface 116 of the insulating layer 106 and adhering one surface to the other. In some embodiments, the glue layer can have a thickness of about 4.885 gm / cm 2 (1lbs. / MSF) to about 244.5gm / cm 2 By way of non-limiting example, the glue layer may include any type of adhesive, such as a resin (eg, phenolic resin, polyvinyl acetate), a hot melt adhesive, an isocyanate-based adhesive, tar, or other adhesive.

[0041] continue FIG. 2A to FIG. 2B , illustrating different arrangements for coupling the sheathing system 100 to the building frame structure 102. Figure 2A , along the cutting line ( Figure 1A 2A) depicts Figure 1A FIG. 1 is a cross-sectional view of a cladding system 100 . Figure 2A The illustrated configuration contemplates the sheathing system 100 having an insulation layer 106 adjacent to the building frame structure 102 . Figure 2B The illustrated configuration contemplates the sheathing system 100 having a structural layer 104 adjacent to a building frame structure 102. The sheathing system 100 may be fastened to the building frame structure 102 by using fasteners 210. The fasteners 210 may include any type of fastener, such as nails, screws, bolts, adhesives, anchors, rail moldings, cleats, magnets, nail plates, attractors, hooks and loops, or any other suitable fasteners generally known in the art.

[0042] Fasteners 210 may be used to secure the sheathing system 100 to the building frame structure 102. Preferably, the sheathing system 100 provides resistance to pullout of the fasteners 210 from the sheathing system 100. The sheathing system 100 comprises a unique layered panel system having specific materials selected for each layer. The materials selected for each layer allow the sheathing system 100 to meet or exceed current industry standard sheathing systems in terms of nail pull forces. For example, in one exemplary embodiment, the sheathing system 100 may be comprised of panels having a 1 / 8 inch thick structural layer 104 comprised of a polycarbonate material. The use of polycarbonate as the structural layer 104 imparts to the sheathing system 100 better resistance to nail pullout than industry standard sheathing systems. BRIEF REFERENCE Fig.11A , the embodiments described herein meet or exceed industry standard products. Fig.11A The 2-layer system shown has a thickness of 7 / 8 inch and a nail pull force of greater than 160 lbs / inch or 180 lbs / inch as measured according to ASTM D1037 standard. The 2-layer system is composed of a polycarbonate structural layer 104 and an insulation layer 106 comprising extruded polystyrene (XPS). In comparison, industry standard wall sheathing composed of oriented strand board (OSB) with a thickness of 7 / 16 inch has a nail pull force of 60 lbs / inch or 137 lbs / inch.

[0043] continue Figure 2A and Figure 2B , describes different thicknesses of the sheathing system 100, and may vary based on its intended use. In specific implementations where it is desired to have better insulation properties, the overall thickness of the sheathing system 100 may be larger. For example, when the overall thickness of the sheathing system 100 is two inches, the sheathing system 100 may have an R-value of 10. In specific implementations where lower insulation properties are acceptable, the sheathing system 100 may have an overall thickness of one inch or less while still maintaining an R-value of at least 3.5. Those skilled in the art will appreciate that many other thicknesses may be used (e.g., when the overall thickness is 1.5 inches, the sheathing system 100 may have an R-value of 7), but the overall thickness of the sheathing system 100 is preferably in the range of 0.5 inches to 2 inches. It is contemplated that values ​​outside the overall thickness range may be used, depending on the needs of the project partners. As with conventional sheathing solutions, the R-value of the sheathing system 100 increases with its overall thickness. Therefore, the sheathing system 100 may have an R-value of at least in the range of 3.5 to 10. In various embodiments, the overall R-value of the sheathing system may vary depending on the ratio of the insulation layer 106 to the structural layer 104 .

[0044] As described above, the ratio of the thickness of the structural layer 104 to the thickness of the insulation layer 106 can vary based on the specific needs of the project. For example, when greater structural strength is desired in an area prone to high winds or seismic forces, it may be desirable to increase the relative structural thickness. In another example, when higher insulation is desired and strength can be sacrificed, such as in a lower temperature climate, it may be desirable to increase the relative thickness of the insulation layer. In a preferred arrangement, the ratio of the thickness of the insulation layer 106 to the thickness of the structural layer 104 is about 3:1. For example, a sheathing system with a 3:1 ratio and an overall thickness of 1 inch will have a 1 / 4 inch structural layer 104 and a 3 / 4 inch insulation layer 106. In other exemplary embodiments, by way of non-limiting example, the ratio of the thickness of the insulation layer 106 to the thickness of the structural layer 104 can be 6:1, 5:1, 4:1, 2:1, 1.5:1, or 1:1. Additional ratios not disclosed herein are considered to be within the scope of the present disclosure.

[0045] Based on the structural needs of the building, the structural layer 104 can have a variety of thicknesses. By way of example, the structural layer 104 can have a thickness of 1 / 8 inch. In addition, the structural layer can have a thickness in the range of 1 / 64 inch and 1 inch. In order to accommodate the above-mentioned different insulation needs, the insulation layer 106 can have a thickness in the range of 1 / 4 inch and 11 / 2 inches. Therefore, the combined thickness of the structural layer 104 and the insulation layer 106 can be in the range of 1 / 2 inch to 2 inches. In an exemplary construction, the thickness of the structural layer 104 and the insulation layer 106 is equal to or less than 1 inch, with an R-value of 3.5 or greater. In another exemplary construction, the thickness of the structural layer 104 and the insulation layer 106 is equal to or less than 1 inch, with an R-value of 5 or greater. In addition, an alternative embodiment has an R-value to thickness ratio of at least 5, thereby achieving a 2-inch system with an R-value of 10.

[0046] As described herein, the purpose of the insulation layer 106 is to provide enhanced thermal resistance. The insulation layer 106 of the sheathing system 100 may include a material selected to have a high R-value. In an exemplary embodiment, the insulation layer includes extruded polystyrene (XPS). It is expected that the insulation layer 106 may include any insulation material, including but not limited to fiberglass, wood, foam, polymer, wood composite, expanded polystyrene (EPS), foamed polyurethane, polyisocyanurate board, fiber reinforced polymer, thermoplastic, polymer-based material, mineral wool, closed-cell thermoplastic, thermoplastic polystyrene, polyethylene terephthalate, polyester resin, phenolic foam, aerogel blanket, aerogel board, cellulose insulation material, rock wool insulation material or any combination thereof. Polymer-based insulation materials that may also or optionally be used for the insulation layer 106 may include polyurethane, phenolic foam, TPO, thermoplastic polyolefin (TPO) and ethylene propylene diene monomer (EPDM) and the like.

[0047] On the other hand, the structural layer 104 provides rigidity and structural support for the building structure's envelope. Thus, the structural layer 104 may be composed of any one or more materials that resist dynamic forces, such as polycarbonate or a composite material. Additional materials that may provide the rigidity and structural support required for the structural layer 104 may be one or more of the following materials: such as polypropylene, high-density polyethylene (HDPE), or wood composites. The structural layer 104 may include polymers, polycarbonate, stainless steel, glass, polyester, polypropylene, polyethylene, acrylic acid, acrylonitrile styrene acrylate, cyclic olefin copolymers, polycyclohexylene terephthalate, polyetherketone, polyaryletherketone, polyetherimide, polyethersulfone, polymethylmethacrylate, polyvinyl chloride, polyphthalamide, polyphenylene oxide, polyphenylene sulfide, recycled HDPE, any recycled plastic or polymer, polysulfone, or syndiotactic polystyrene. The polymer may include one or more of: polyethylene styrene, plexiglass, high density polypropylene (HDPP), hard plastic, soft plastic, polyethylene terephthalate, acrylonitrile butadiene styrene, thermoplastics, thermosets, elastomers, hemp, shellac, amber, wool, silk, natural rubber, cellulose, silicone, polybutylene terephthalate, styrene butadiene rubber, or other polymers or copolymers. In another example, recycled materials (including recycled polycarbonate) may be used for the structural layer 104. In addition, other recycled materials may also be considered for the structural layer 104, such as recycled plastics or composite materials made from recycled wood fibers and plastics.

[0048] In other aspects, the structural layer 104 can include a polymer composite formed from a polymer and at least one filler material. Adding the filler material can add desired physical properties, such as texture, color, strength, reduced weight, or other physical properties to the structural layer 104. The polymer composite can include the filler material added to the polymer at a weight ratio of filler material to polymer between 1 wt % and 90 wt %. In other aspects, the filler material may include any amount of powder, talc, calcium carbonate, calcium carbonate pellets, cellulose, sand, silica, magnesium oxide, aluminum oxide, clay, inorganic powder, colorant, ground tire rubber, rubber, calcium sulfate, calcium silicate, barium sulfate, mica, kaolin, silica, diatomaceous earth, minerals, glass fiber, carbon fiber, glass, polymer beads, magnesium hydroxide, fly ash, polymer foam beads, masonry filler, wollastonite, short glass fibers, long glass fibers, glass beads, coal, dolomite, carbon black, silica, magnetite, hematite, halloysite, zinc oxide, titanium dioxide, Al(OH)3, Mg(OH)2, concrete filler, gravel, stone, sand, steel, aluminum, or any other material that may be added to the polymer of structural layer 104. In alternative embodiments, organic fillers, rice husks, nut flour, wood flour, plant fibers, cotton fibers, starch, synthetic organic fillers, rubber particles, chalk, quartz powder, granite, aluminosilicates, vermiculite, nepheline syenite, barium ferrite, barium titanate, molybdenum disulfide, potassium titanate, metal oxides, metal hydrates, metal powders, zinc, beryllium oxide, foaming agents, PBT, ceramics, or other materials that can be added to polymers can be used as filler materials. In another embodiment, glass fibers, carbon fibers, mineral fillers (e.g., calcium carbonate, talc or mica), aramid fibers, glass beads, nanoclays, metal particles, natural fibers (e.g., hemp, jute or flax), graphene, rubber particles, ceramic fillers (e.g., alumina or silica), recycled materials (e.g., plastic or rubber materials), wood fibers / flour, conductive fillers (e.g., carbon black or metal powders), flame retardant fillers (e.g., phosphorus-based compounds or halogenated additives) can be considered as filler materials.

[0049] In some embodiments, the filling material can have a size of up to 1mm. In a non-limiting example, the polymer composite material can have a filling material composed of materials of various sizes from 1 micron to 1000 microns, from 1 micron to 1 centimeter or from 10 meshes to 100 meshes. In one embodiment, the filling material can be added to the polymer in a ratio of up to 90 weight % with 1 weight % of the polymer. In another embodiment, the ratio between 30 weight % and 60 weight % of the polymer can be used for the filling material.

[0050] The sheathing system 100 can be milled or formed into any desired shape or size. Made in one or more standard sizes (e.g., 1.319m×2.438m (4ft.×8-ft.), 1.319m×3.048m (4ft.×10ft.), or 1.319m×3.658m (4ft.×12ft.) as a flat sheet (i.e., panel), the sheathing system 100 can be formed or cut according to specific size and / or design requirements (e.g., different geometries). Using cutting or forming tools available on the job site (e.g., circular saws) or precision tools (e.g., computer numerical control (CNC) machines), each layer of the sheathing system 100 can be cut or milled accordingly.

[0051] In additional embodiments, the structural layer 104 can resist peel forces and exceed the ASTM E72 industry standard for structural wall sheathing systems. The ASTM E72 standard determines the ability of the sheathing system 100 to deflect a static load (i.e., resist peeling). The peel resistance of a specific embodiment is relative to Fig. 11B For example, in one embodiment, the sheathing system 100 can have a peel strength maximum force greater than 640 pounds per linear foot (plf) according to ASTM E72 testing, which is greater than or equal to standard systems in the industry.

[0052] The structural layer 104 can be resistant to large amounts of water but can be permeable to water vapor. The structural layer 104 can be characterized by a water vapor permeability in the range of about 0.1 USperm to about 1.0 USperm and having a water vapor permeability of about 0.07 g / m 2 / 24hr to about 7g / m 2 / 24hr water vapor transmission rate. (at 73°F-50% RH via ASTM E96 Procedure A). According to ASTM D5795, additional embodiments of the structural layer 104 have a water vapor transmission rate of about 0.1 USperm to about 12 U.S.perm (at 73°F-50% RH via ASTM E96 Procedure B), and a liquid water transmission rate (g / 100 in) of about 1 to about 28. 2 / 24hr, via Cobb ring).

[0053] Now go to Figure 3A and Figure 3B , illustrates a cladding system 300 having at least three layers. At a high level, the cladding system 300 includes Figures 1A to 2B306; i.e., the cladding system 300 includes the first structural layer 304, the insulation layer 306, and the second structural layer 308 (i.e., a "3-layer cladding system"). Thus, the cladding system 300 and each of the first structural layer 304 and the insulation layer 306 may have any one or more characteristics of the cladding system 100, the structural layer 104, and the insulation layer 106, respectively, such as with respect to Figures 1A to 2B In addition, the second structural layer 308 may have any one or more characteristics of the structural layer 104, such as Figures 1A to 2B described.

[0054] Including both the first structural layer 304 and the second structural layer 308 may be advantageous because it provides weather resistance to both sides of the thermal insulation layer 306. Fig. 11C , the first structural layer 304 and the second structural layer 308 may provide improved peel resistance over a single structural layer. Other design and structural requirements for a particular intended use may make it advantageous to have a second structural layer rather than a single structural layer.

[0055] Watch now Figure 3A and Figure 3B , an example of a cladding system 300 is illustrated according to an exemplary aspect of the present invention. Figure 3B As shown, the cladding system 300 includes a fourth surface 317 of the insulation layer 306 and a third surface 316 of the insulation layer 306 opposite to the fourth surface 317. The thickness of the insulation layer 306 can be measured from the third surface 316 to the fourth surface 317. In addition, the first structural layer 304 includes a second surface 315 and a first surface 314 opposite to the second surface 315. The thickness of the first structural layer 304 can be measured from the first surface 314 to the second surface 115. In addition, the second structural layer 308 includes a sixth surface 319 and a fifth surface 318 opposite to the sixth surface 319. The thickness of the second structural layer 308 can be measured from the fifth surface 318 to the sixth surface 319.

[0056] The sheathing system 300 is formed by coupling the second surface 315 of the first structural layer 304 to the third surface 316 of the insulation layer 306. Additionally, the fourth surface 117 of the insulation layer 306 is coupled to the fifth surface 318 of the second structural layer 308. More specifically, the first structural layer 304 may be coupled to the insulation layer 306 by bonding, adhering, applying, or mechanically fastening one layer to the other. Additionally, the second structural layer 308 may be coupled to the insulation layer 306 by bonding, adhering, applying, or mechanically fastening one of the layers to the other. By way of example, the sheathing system 300 may be formed by applying a glue layer or adhesive to the second surface 315 of the first structural layer 304 or the third surface 316 of the insulation layer 306 and adhering one surface to the other. By way of another example, the sheathing system 300 may be formed by applying a glue layer or adhesive to the fourth surface 317 of the insulation layer 306 or the fifth surface 318 of the second structural layer 308 and adhering one surface to the other.

[0057] As discussed with respect to other aspects described herein, the ratio of the thickness of the first structural layer 304 and the second structural layer 308 relative to the thickness of the insulation layer 306 may vary based on the intended use of the disclosed sheathing system. For example, when greater structural strength is required, such as in areas prone to high winds or seismic forces, the combined thickness of the first structural layer 304 and the second structural layer 308 may increase as a proportion of the overall thickness of the sheathing system or the thickness measured from the first surface 314 to the sixth surface 319. In another example, when greater insulation is desired and strength may be sacrificed, such as in lower temperature climates, the insulation layer may account for a greater proportion of the overall thickness. In a preferred arrangement, the ratio of the thickness of the insulation layer 306 relative to the combined thickness of the first structural layer 304 and the second structural layer 308 may be about 3:1. In one embodiment, the sheathing system 300 may have a ratio of the thickness of the insulation layer 306 relative to the combined thickness of the first structural layer 304 and the second structural layer 308 of about 3:1 and an overall thickness of 1 inch. This embodiment may have a combined thickness of first structural layer 304 and second structural layer 308 of 14 inches and a thickness of thermal insulation layer 306 of 3 / 4 inches. In some other embodiments, by way of non-limiting example, the ratio of thermal insulation layer 306 thickness to the combined thickness of first structural layer 304 and second structural layer 308 may be 6:1, 5:1, 4:1, 2:1, 1.5:1, or 1:1. Additional ratios are contemplated.

[0058] The purpose of the first structural layer 304 and the second structural layer 308 is to provide rigidity and structural support for the building structure's envelope. In addition, the materials used for the first structural layer 304 and the second structural layer 308 can provide other physical properties based on the intended use. For example, according to one or more design constraints, the sheathing system 300 can be spaced apart to have a specific external texture, weight or other physical properties. For example, in one embodiment, due to high seismic activity, the sheathing system 300 may require excellent peeling resistance. In addition, the sheathing system 300 may require a specific texture, nail pulling force or other physical properties to help the building envelope. Therefore, the first structural layer 304 and the second structural layer 308 can be composed of any one or more materials that are peeling resistant, light weight, have one or more textures, resist nail pulling or provide other desired physical properties. In one embodiment, both the first structural layer 304 and the second structural layer 308 can contain the same material. In an alternative embodiment, if the first structural layer 304 and the second structural layer 308 require different physical properties, they can each be formed by different materials.

[0059] As described above, the first structural layer 304 and the second structural layer 308 may have different physical requirements and, therefore, may have different thicknesses. In one example, the first structural layer 304 may be exposed to external impact forces and may require a thicker material to resist such impacts. Alternatively, the second structural layer 308 may not require such impact resistance and, therefore, may be thinner than the first structural layer 304. Thus, the first structural layer 304 may have a thickness in the range of 1 / 64 inch and 1 inch. The second structural layer 308 may have a thickness in the range of 1 / 64 inch and 1 inch. The thermal insulation layer 306 may have a thickness in the range of 1 / 4 inch and 1 1 The combined thickness of the first structural layer 304, the insulation layer 306, and the second structural layer 308 can be in the range of 1 / 2 inch and 2 inches. In an exemplary configuration, the first structural layer 304, the insulation layer 306, and the second structural layer 308 have a thickness equal to or less than 1 inch, with an R-value of 5 or greater. Additionally, alternative embodiments have an R-value to thickness ratio of at least 5, thereby achieving a 2-inch system with an R-value of 10.

[0060] Watch now Figure 4 , according to aspects of the present invention, depicts Figure 3A The cladding system 300 is arranged along the cutting line ( Figure 3A4.) is a cross-sectional view. The sheathing system 300 includes at least an insulating layer 306 adhered to a first structural layer 304 and a second structural layer 308. The sheathing system 300 can be fastened to the frame structure 302 by using fasteners 410. The fasteners 410 may include fasteners such as nails, screws, or any other suitable fasteners known in the art. In one embodiment, the distance from the outward-facing or outer surface of the first structural layer 304 to the inward-facing or inner surface of the second structural layer 308 adjacent to the frame structure 302 (i.e., the thickness of the sheathing system 300) is one inch or less and has an R-value of 5 or greater. In another embodiment, the distance from the outer surface of the first structural layer 304 to the inner surface adjacent to the frame structure 302 is 1.5 inches or less, and the R-value is 7.5 or greater. In yet another embodiment, the distance from the outer surface of the first structural layer 304 to the inner surface adjacent to the frame structure 302 is no greater than two inches.

[0061] Now go to Figure 5 , Figure 5 A cross-section of a top view of one embodiment of a cladding system 500 prior to installation is depicted. The cladding system 500 is illustrated as having drainage channels or grooves to prevent moisture accumulation. At a high level, the cladding system 500 includes Figures 1A to 2B The sheathing system 100 is a composite sheathing system 100 with a plurality of drainage grooves 506 added thereto; that is, the sheathing system 500 includes a structural layer 502, an insulating layer 504, and a plurality of drainage grooves 506. Therefore, the sheathing system 500 and each of the structural layer 502 and the insulating layer 504 may have any one or more characteristics of the sheathing system 100, the structural layer 104, and the insulating layer 106, respectively, such as Figures 1A to 2B A plurality of drain grooves 506 may be recessed within (or extend from) the insulation layer 504. The offset or recessed distance formed by the drain grooves 506 is depicted by a distance 510 extending from the recessed surface 516 to the outer surface 514 of the insulation layer 504. The distance 510 is in the range of 0.01 inches to 0.1 inches. In one embodiment, the distance 508 from the outer structural surface 512 to the outer insulation surface 514 is in the range of from about one inch to about two inches.

[0062] Figure 6 Similarly depicted is a cross-section of a top view of a cladding system 600, which includes a first structural layer 602, an insulating layer 604, and a second structural layer 606. In addition, the second structural layer 606 may include a drainage channel 618. The insulating layer 604, the first structural layer 602, and the second structural layer 606 may include the previously described structures, such as Figure 3A , Figure 3B and Figure 4 Therefore, for the sake of brevity, the detailed description of the thermal insulation layer 604, the first structural layer 602 and the second structural layer 606 will not be discussed in detail. Figure 6 The cladding system 600 illustrated in FIG.

[0063] The drain grooves 618 may be recessed within (or extend from) the second structural layer 606. The offset or recessed distance formed by the drain grooves 618 is depicted by a distance 614 extending from the recessed surface 616 of the second structural layer 606 to the extended surface 612. The distance 614 from the recessed surface 616 to the extended surface 612 is in the range of 0.01 inches to 0.1 inches. In one embodiment, the distance 608 from the exterior first structural layer surface 610 to the extended surface 612 is one inch or less. In additional embodiments, the number of drain grooves 618 per foot of the sheathing system 600 may be in the range of 1 drain groove per foot to 12 drain grooves per foot.

[0064] Similar to Figure 5 In contrast to the gutter 508 described in the previous embodiment, gutter 618 is designed on the surface of the sheathing system 600 so that gravity allows water to drain from the sheathing system 600. The gutter 618 creates a path for directing water away from the sheathing system 600 and away from the building envelope. The sheathing system 600 may include a series of vertically arranged gutter 618 so that when water or moisture encounters the gutter 618, gravity pulls the water downward and away from the building envelope. In one embodiment, the gutter 618 may be configured as follows: Figure 6 In an additional embodiment, the drain groove 618 is a V-shaped groove, a rectangular groove, or a curved groove. Additional shapes can be considered for use as the drain groove 618.

[0065] The arrangement of the drain grooves 618 can be oriented vertically so that water flows directly downward. In addition, when the sheathing system 600 is installed, the drain grooves 618 can be oriented in a horizontal arrangement or parallel to the ground. In another embodiment, the drain grooves 618 can be oriented in a diagonal arrangement, a radial arrangement, or a serpentine arrangement.

[0066] Watch now Figure 7 , Figure 7 A cross-section of a top view of a sheathing system 700 is depicted that includes a first structural layer 702, an insulating layer 704, and a second structural layer 706. In the illustrated embodiment, the insulating layer 704 includes drainage grooves 708 that allow moisture to flow between the second structural layer 706 and the insulating layer 704. The insulating layer 704, the second structural layer 706, and the first structural layer 702 may include the aforementioned Figure 3A , Figure 3B and Figure 4 Therefore, for the sake of brevity, the detailed description of the thermal insulation layer 704, the second structural layer 706 and the first structural layer 702 will not be discussed in detail. Figure 7 The cladding system 700 illustrated in FIG. 7 is repeated.

[0067] Similar to About Figure 6 As described above, drains 618, 708 are designed as part of the cladding system 700 so that gravity allows water to drain from the cladding system 700. Figure 7 As shown, the gutter 708 is part of the insulation layer 704 as a space between the insulation layer 704 and the second structural layer 706. The placement of the gutter 708 allows for the extraction of any moisture between the insulation layer 704 and the second structural layer 706. The gutter 708 creates a path for directing water away from the sheathing system 700, away from the insulation layer 704, and away from the building envelope. The sheathing system 700 may include a series of vertically arranged gutter 708 so that when water or moisture encounters the gutter 708, gravity pulls the water downward and away from the insulation layer 704. In one embodiment, the gutter 708 may take the form of Figure 7 In an additional embodiment, the drainage groove 708 is a V-shaped groove, a rectangular groove or a curved groove.

[0068] Now continue to see Figure 8 , a cross-section of a top view of one embodiment of a sheathing system 800 is shown. The sheathing system 800 includes a first structural layer 802, an insulating layer 804, a second structural layer 806, and drain grooves 808. The drain grooves 808 provide a varying cross-section with a non-vertical surface. The pattern of the drain grooves 808 is designed to improve the flow of moisture about the sheathing system 800 for eventual complete drainage from the sheathing system. The insulating layer 804, the second structural layer 806, and the first structural layer 802 may include the previously described, e.g. Figure 3A , Figure 3B and Figure 4 Therefore, for the sake of brevity, the detailed description of the thermal insulation layer 804, the second structural layer 806 and the first structural layer 802 will not be discussed in detail. Figure 8 The cladding system 800 illustrated in FIG.

[0069] The drain 808 is designed similar to Figure 6 As part of the cladding system 800, the gutter 808 allows gravity to drain water from the cladding system 800. The gutter 808 creates a path for directing water away from the cladding system 800 and away from the building envelope. Figure 8 As shown, the drain groove 808 may have a surface that deviates from the vertical direction.

[0070] An alternative embodiment for coupling the first structural layer 902, the thermal insulation layer 906, and the second structural layer 904 is Fig.9A and Fig. 9B For details, see Fig.9A, shows a perspective view of a cladding system 900, which includes a first structural layer 902, a second structural layer 904, an insulation layer 906, and one or more rods 908. For illustration purposes only, Fig.9A 904. The illustration has a cutaway portion showing the first structural layer 902 exposing the rod 908. In one embodiment, the rod 908 extends from the first structural layer 902 through the insulation layer 906 to the second structural layer 904. In some aspects, the rod 908 can take the form of a cylinder, a plane, a prism, a rod, or other shape that can connect the first structural layer 902 and the second structural layer 904 together.

[0071] Now go to Fig. 9B , Fig. 9B A cross section of a cladding system 900 is depicted incorporating a rod 908, a first structural layer 902, and a second structural layer 904. The rod 908 in the cladding system 900 can be made of a high strength and heat resistant polymer. Depending on the specific requirements of the cladding system 900, a variety of polymer materials can be used for the rod. For example, engineered thermoplastics such as nylon (e.g., nylon 6 or nylon 6 / 6), polypropylene, polycarbonate, or polyethylene terephthalate (PET) can all be suitable options for the rod 908.

[0072] In additional embodiments, in order to fuse the cladding system 900 together, a melting process can be used to fix the rods 908 to the first structural layer 902 and the second structural layer 904. In addition, the rods 908 can include a thermoplastic material, wherein the rods 908 can soften and fuse during the assembly process. The melting process or fusing process can involve applying heat to the rods 908, thereby causing them to soften and melt slightly. The rods 908 can penetrate the first structural layer 902, the second structural layer 904, and the insulation layer 906, filling any gaps or voids therebetween. When the molten rods 908 cool and solidify, they create a strong bond and form a fused connection, thereby permanently fixing the first structural layer 902 and the second structural layer 904 together at the ends 912 and 914.

[0073] In some embodiments, the melting process can be achieved by various methods. One method is to use a heated metal plate or a heated mold pressed against the first structural layer 902 and the second structural layer 904. The heat from the plate or the mold is transferred to the rods 908 at the ends 912 and 914, causing them to melt and fuse with the first structural layer 902 and the second structural layer 904. Alternatively, a local heat source (such as hot air or infrared heating) can be directed to a specific area where the rods 908 are inserted, thereby achieving selective melting and fusion.

[0074] In other embodiments, the sheathing system 900 may include rods 908 made of metal, which provide a robust and durable solution for connecting the first structural layer 902, the second structural layer 904, and the insulation layer 906. The metal rods provide high strength, rigidity, and resistance to various environmental conditions. Metals used for this purpose include stainless steel, aluminum, or steel alloys.

[0075] In some other embodiments, the rod 908 may have various diameters and lengths to accommodate different panel sizes and design requirements. The ends 914 and 912 of the rod may be threaded, allowing them to be easily inserted and securely fastened to the structural layer. Alternatively, the rod 908 may be designed with an enlarged head or flange that mechanically locks into the outer surface of the layer, providing a secure connection without the need for additional fasteners.

[0076] In additional embodiments, rod 908 may have a flange portion or enlarged portion on end 914 so that rod 908 holds insulation layer 906 to second structural layer 904. Rod 908 may then be connected to first structural layer 902 and second structural layer 904 using melting, fusing or other means.

[0077] Now turn to Fig. 10A and Fig. 10B , which depicts a cross-sectional view of the cladding system 1000 . Fig. 10A and Fig. 10B The panel system 1000 in the embodiment includes a first structural layer 1002, a second structural layer 1004, and a support layer 1006. The first structural layer 1002 and the second structural layer 1004 may have any of the properties of the first structural layer 304 and the second structural layer 308, respectively, as previously described with respect to Figure 3A , Figure 3B and Figure 4 Therefore, for the sake of brevity, the detailed description of the first structural layer 1002 and the second structural layer 1004 will not be described in detail. Fig. 10A and Fig. 10B The cladding system 1000 illustrated in FIG.

[0078] Between the first structural layer 1002 and the second structural layer 1004 is a support layer 1006. The support layer 1006 includes a series of walls or structures that separate the first structural layer 1002 and the second structural layer 1004. Fig. 10AAs shown, the support layer 1006 may have a series of walls extending vertically from the first structural layer 1002 to the second structural layer 1004. The support layer 1006 creates an elongated hexagonal space or void portion extending from the first structural layer 1002 to the second structural layer 1004, such as the insulating void portion 1008. For example, the support layer 1006 includes walls extending from the first structural layer 1002 to the second structural layer 1004, thereby creating the insulating void portion 1008. Fig. 10A As shown, the insulating void portion 1008 can be oriented to extend from the first structural layer 1002 and the second structural layer 1004. In another embodiment, as shown in FIG. Fig. 10B As shown, the support layer 1006 may have a series of structures extending from the first structural layer 1002 to the second structural layer 1004. The support layer 1006 creates an elongated hexagonal space or void portion parallel to the first structural layer 1002 and the second structural layer 1004, such as the insulating void portion 1008. Fig. 10B As shown, the insulating void portion 1008 may be oriented parallel to the first structural layer 1002 and the second structural layer 1004 .

[0079] The support layer 1006 can be made of any material that can be used or formed into a wall or support structure. For example, the support layer 1006 can be made of polycarbonate, polyurethane, metal, wood or any other structural support material, as required by the intended use of the support layer 1006.

[0080] The insulating void portion 1008 refers to the space or cavity created by the supporting layer 1006 of the sheathing system 1000. The insulating void portion 1008 may be filled with insulating material to ensure that the insulating material is properly contained within the panel. In some embodiments, the insulating material may include various insulating substances such as foam, fiberglass, or polymer-based insulation. The insulating void portion 1008 may be filled with spray foam, polyisocyanurate, EPS, recycled XPS, XPS, or other insulating materials. These materials may be sprayed, poured, or filled into the insulating void portion 1008. Fig. 10A As shown, where the insulation gap portion 1008 is perpendicular to the first structural layer 1002 and the second structural layer 1004, the insulation gap portion 1008 can be filled when one or more of the structural layers are not secured to the sheathing system 1000. Fig. 10B As shown, there is an insulation gap portion 1008 parallel to the first structural layer 1002 and the second structural layer 1004, and the insulation gap portion 1008 can be filled when the panel system 1000 is fully assembled.

[0081] In some embodiments, the support layer 1006 in the sheathing system 1000 can be designed with a honeycomb pattern, thereby creating a series of interconnected hexagonal cells or cells that form a regular and uniform structure throughout the support layer. The multiple hexagonal cells or cells created by the support layer 1006 create a network of interconnected walls that evenly distributes applied loads and stresses on the sheathing system 1000, thereby improving its structural integrity. Fig. 10A As shown, the hexagonal cells or insulating interstitial portions 1008 can be oriented such that the openings of the insulating interstitial portions 1008 are adjacent to or facing the first structural layer 1002 and the second structural layer. Fig. 10B As shown, the hexagonal cells or insulating interstitial portions 1008 may be oriented such that the openings of the insulating interstitial portions 1008 are perpendicular to the first structural layer 1002 and the second structural layer.

[0082] In addition to the honeycomb pattern, it is also contemplated that various other patterns may be employed in the support layer 1006 of the cladding system 1000. These patterns provide different structural characteristics and may be selected based on specific design requirements and desired performance attributes. Other patterns may include, for example: a square grid pattern having a series of interconnected square cells that form a grid-like structure; a triangular truss pattern consisting of interconnected triangular cells that produce a truss-like frame; a diamond pattern characterized by interconnected diamond cells that form a repeating pattern; or a hexagonal grid pattern, which is similar to a honeycomb pattern and consists of interconnected hexagonal cells. However, unlike the honeycomb pattern, the hexagonal grid does not form a continuous network of cells, but rather a grid-like arrangement. In another embodiment, the support layer 1006 may include a random pattern, which is a non-repeating arrangement of cells or voids. The support layer may be designed to have voids of different sizes and shapes, thereby providing flexibility in material distribution and load-bearing capacity.

[0083] The inventive concept has been described above generally and with reference to various exemplary embodiments. Although the general inventive concept has been set forth in what are believed to be exemplary illustrative embodiments, a number of alternatives known to those skilled in the art may be selected in the disclosure. In addition, the following data relating to the embodiments described herein are intended to better illustrate the present invention, but in no way limit the general inventive concept of the present invention.

[0084] FIG. 11A to FIG. 13D Depicted are data related to embodiments of a 2-layer sheathing system (i.e., a structural layer and an insulating layer) and / or a 3-layer sheathing system (i.e., a first structural layer, an insulating layer, and a second structural layer), as previously described with respect to, e.g. Figures 1A to 2B and FIG. 3A to FIG. 4 Specifically, FIG. 11A to FIG. 11GData related to a 2-layer sheathing system and / or a 3-layer sheathing system is illustrated, wherein one or more structural layers comprise polycarbonate (PC) and the insulation layer comprises extruded polystyrene (XPS) (eg, "1 / 16 inch PC / XPS 3-layer R5"). FIG. 12A to FIG. 12D Data related to a 2-layer superstrate system and / or a 3-layer superstrate system is illustrated, wherein one or more structural layers comprise polycarbonate (PC) and the insulation layer comprises polyethylene terephthalate (PET) (eg, "1 / 16 inch PC / PET 3-layer R5"). FIG. 13A to FIG. 13D Data relating to a 3-layer panel system is illustrated, wherein the structural layer comprises polycarbonate (PC) and the insulating layer comprises polyurethane (PU) (eg, "1 / 32 inch PC / PU 3-layer R5").

[0085] also, FIG. 11A to FIG. 13D Embodiments of 2-layer sheathing systems and / or 3-layer sheathing systems are illustrated wherein the thickness or width of each structural layer may vary between 1 / 16 inch, 1 / 32 inch, or 1 / 8 inch for an overall sheathing system thickness or width of one (1) inch or less. For example, an embodiment identified as "1 / 16" PC / XPS 3-layer R5" refers to a 3-layer sheathing system having a first structural layer and a second structural layer, each structural layer comprising polycarbonate and each having a thickness of 1 / 16 inch, and an XPS insulation layer having a thickness of 3 / 4 inch.

[0086] in addition, FIG. 11A to FIG. 13D Comparative data is included in the case of industry standard sheathing systems identified as "OSB," "Product 1," "Product 2," and "Product 3." "OSB" refers to an industry standard wall sheathing composed of oriented strand board having a thickness of 7 / 16 inch. "Product 1" refers to an existing wall sheathing system including a thermoplastic structural layer, a polyisocyanurate layer, a facing layer, and having a thickness of 1 inch and 1 / 8 inch. "Product 2" and "Product 3" refer to existing wall sheathing systems including OSB layers and polyisocyanurate insulation layers of varying thicknesses to achieve varying levels of insulation.

[0087] FIG. 11A to FIG. 13D The representative data shown demonstrates the superior capabilities of the cladding system embodiments described herein. Clearly, the presently disclosed cladding system outperforms current industry standard products in most categories and outperforms industry standard products overall.

[0088] FIG. 11A to FIG. 11G Depicted are data associated with a 2-layer sheathing system and / or a 3-layer sheathing system wherein the insulation layer comprises extruded polystyrene (XPS) and one or more structural layers comprises polycarbonate (PC). Fig.11AData related to a nail pull test performed according to ASTM DI 037 standard are shown. The nail pull test is used to evaluate the resistance of a fastener in a material. During the test, a nail is driven into the material under investigation and the force required to pull the nail out of the material is measured. Fig.11A The data depicted in show the performance of several embodiments described herein that are superior to current industry standard products. The currently disclosed sheathing system has a nail pulling force between 20lbs and 200lbs. In addition, the currently disclosed sheathing system has a preferred nail pulling force between 50lbs and 200lbs. In another preferred embodiment, the currently disclosed sheathing system has a nail pulling force between 120lbs and 200lbs. In contrast, the industrial standard sheathing system shows a nail pulling force less than 60lbs. For example, as shown in the figure, 1 / 16 inch PC / XPS 3-layer R5 sheathing system and 1 / 8 inch PC / XPS2-layer R5 sheathing system provide an average nail pulling force of 140lbs and 165lbs respectively. In contrast, OSB sheathing, product 2 and product 3 each provide an average nail pulling force of about 60lbs. Product 1, which is a wall sheathing system including a thermoplastic structural layer, a polyisocyanurate layer, a facing layer, and having a thickness of 1 inch and 1 / 8 inch, exhibited an average nail pull force of less than 15 lbs.

[0089] Fig. 11B and Fig. 11C Data related to a series of tests performed to measure structural performance and evaluate the resistance of implemented sheathing systems to lateral forces, such as those experienced during seismic events or high wind conditions, are described. Fig. 11B Using ASTM E72 standard and Fig. 11CASTM E564 standard is used to measure the peeling performance of each panel. The data shows the excellent performance of the implemented panel compared with the current cover plate system. The current disclosed cover plate system provides a peel strength greater than 440plf. In a preferred embodiment, the disclosed cover plate system provides a peel strength greater than 475plf. In an additional preferred embodiment, the disclosed cover plate system has a peel strength greater than 700plf. 1 / 16 inch PC / XPS 3-layer panel has an average peel strength maximum force of 760plf using ASTM E72 method and 805plf using ASTM E564 method. 1 / 32 inch PC / XPS 3-layer panel has an average peel strength maximum force of 780plf using ASTM E72. 1 / 8 inch PC / XPS2-layer panel has an average peel strength maximum force of 795plf using ASTM E72 method and 790plf using ASTM E564 method. In contrast, each of the industrial standard products shows a significantly lower peel strength maximum force, thereby indicating the excellent peeling performance of the current embodiment. OSB has an average peel strength maximum force of 680 plf using ASTM E72 method and 645 plf using ASTM E564 method. Product 1 has an average peel strength maximum force of 490 plf using ASTM E72 method and 600 plf using ASTM E564 method. Using ASTM E72 method, Product 2 has an average peel strength maximum force of 610 plf and Product 3 has an average peel strength maximum force of 400 plf.

[0090] Fig.11D Data describing the weight of the 4 foot by 8 foot panels of each sheathing system tested is provided. Fig.11EDescribe the thickness and corresponding R-value of disclosed cladding system compared with industrial standard or existing cladding system.Current disclosed cladding system has the weight between 5lbs and 40lbs and the preferred weight between 10lbs and 30lbs.In addition, current disclosed cladding system has the thickness between 0.5 inch and 1.5 inch, wherein the preferred thickness is between 0.8 inch and 1.06 inch.In addition, current disclosed cladding system has the R-value between 2 and 9, wherein the preferred R-value is between 3.5 and 6.As shown in the figure, 1 / 16 inch PC / XPS 3 layers R5 panel has the weight of 30lbs and the thickness of 7 / 8 inch.In addition, 1 / 32 inch PC / XPS 3 layers R5 panel has the weight of 20lbs and the thickness of 13 / 16 inch.In addition, 1 / 8 inch PC / XPS2 layers R5 panel has the weight of 30lbs and the thickness of 7 / 8 inch. OSB has a weight of 52 lbs and a thickness of 7 / 16 inches, product 1 has a weight of 23 lbs and a thickness of 17 / 16 inches, product 2 has a weight of 60 lbs and a thickness of 1 inch, and product 3 has a weight of 62 lbs and a thickness of 1.5 inches. Fig.11D and Fig.11E As is apparent in the drawings, the presently disclosed embodiments are lighter per thickness than currently available standard products while still maintaining high peel performance (see, e.g., FIG. 11B to FIG. 11C ).

[0091] Fig.11E and Fig.11F Data related to the R-values ​​of the disclosed sheathing systems compared to industry standard or existing sheathing systems are provided. For each of the polycarbonate sheathing systems, the overall thickness is less than one inch and the R-value is 5 or greater. The 1 / 16 inch PC / XPS 3-layer R5 panel has an R-value of 5 and an R-value of 0.2 per pound per inch. The 1 / 32 inch PC / XPS 3-layer R5 panel has an R-value of 5 and an R-value of 0.32 per pound per inch. The 1 / 8 inch PC / XPS 2-layer R5 panel has an R-value of 5 and an R-value of 0.2 per pound per inch. In comparison, OSB has an R-value of 0 and an R-value of 0 per pound per inch; Product 1 has an R-value of 6 and an R-value of 0.24 per pound per inch; Product 2 has an R-value of 3 and an R-value of 0.05 per pound per inch; and Product 3 has an R-value of 6 and an R-value of 0.07 per pound per inch. As shown, the presently disclosed sheathing system has a higher R-value per pound per inch than the industry standard sheathing system, even while maintaining peel performance. Product 1 has a comparable R-value per pound per inch, but suffers significantly in peel performance. Thus, the present sheathing system embodiments outperform the current industry standard products.

[0092] like Fig.11G, the fire resistance performance of the disclosed sheathing system is shown compared to the industry standard or existing sheathing system. ASTM E84 is a test method for evaluating the fire and smoke performance of building materials, specifically for interior wall and ceiling finishes. The E84 test is also known as the "Standard Test Method for Surface Burning Characteristics of Building Materials," which is generally used to evaluate how materials behave when exposed to flames and how they contribute to the generation and spread of smoke. The currently disclosed sheathing system has a fire resistance between 0 and 150, with a preferred fire resistance of less than 20. For example, the flame E84 of a PC / XPS 3-layer panel is 0. The flame E84 of a 3-layer 1 / 8-inch panel is 10. In contrast, the flame E84 of OSB is 150. The flame E84 of product 1 is 75. The flame E84 exhibited by product 2 is 60, and the flame E84 exhibited by product 3 is 60. The flame performance of the embodiments described herein exceeds the flame performance of the industry standard products.

[0093] Go to FIG. 12A to FIG. 12D , the data depicted show a 3-layer panel system in which the insulation layer comprises polyethylene terephthalate (PET) and the first and second structural layers each comprise polycarbonate (PC). Fig. 12A Depicted are the results of nail pull tests according to ASTM D1037, as previously described. As shown, the currently disclosed sheathing system has a nail pull force between 20lbs and 200lbs. In addition, the currently disclosed sheathing system has a preferred nail pull force between 50lbs and 200lbs. In contrast, the industrial standard sheathing system exhibits a nail pull force of approximately 60lbs. Therefore, the currently disclosed sheathing system has superior nail pull properties than the industrial standard or existing sheathing system. For example, as shown, the 1 / 32 inch PC / PET 3-layer R4 sheathing system has an average nail pull force of 80lbs. However, OSB, Product 1, Product 2, and Product 3 all show a nail pull force of approximately 60lbs.

[0094] Fig. 12B The data shown corresponds to the weight of the 4 foot by 8 foot sheathing system tested. Fig. 12C Shown are the thicknesses and corresponding R-values ​​of a 3-layer sheathing system compared to industry standard or existing sheathing systems. Fig.12DThe R-value per inch of the disclosed 3-layer cladding system is shown compared to the industrial standard or existing cladding system. As shown, the currently disclosed cladding system can have a weight between 5lbs and 40lbs and a preferred weight between 10lbs and 30lbs. In addition, the currently disclosed cladding system provides a thickness between 0.5 inches and 1.5 inches, wherein the preferred thickness is between 0.8 inches and 1.06 inches. In addition, the currently disclosed cladding system provides an R-value between 2 and 9, wherein the preferred R-value is between 3.5 and 6. In contrast, the R-value provided by the existing product 2, which is significantly heavier (62lbs) with a thickness of one inch, is 3. Obviously, the current embodiment shown is lighter per thickness than the available industrial standard products, while providing a high R-value while maintaining peeling performance. Product 1 has a considerable R-value per pound per inch, but is significantly impaired in terms of peeling performance. Therefore, the current embodiment is still far superior to the industrial standard products.

[0095] Continue to FIG. 13A to FIG. 13D , the data depicted shows a 3-layer sheathing system where the insulation layer comprises polyurethane (PU) and the first structural layer and the second structural layer each comprise polycarbonate (PC). As shown, the current sheathing system has a nail pull force between 20 lbs and 200 lbs. In addition, the sheathing system has a preferred nail pull force between 50 lbs and 200 lbs. Fig.13A The results of the nail pull test according to ASTM D1037 as described above are depicted. The 1 / 32 inch PC / PU 3-layer R5 panel has an average nail pull force of 58 lbs. The 1 / 32 inch PC / PET 3-layer R5 has a thickness of 13 / 16 inch, so the system has a required average nail pull force of 71 lbs / inch. The OSB has an average nail pull force of 57 lbs / inch. Product 1 has a nail pull force of 9 lbs / inch. Product 2 has a nail pull force of 60 lbs / inch, and Product 3 has an average nail pull force of 60 lbs / inch.

[0096] Fig. 13B The results shown correspond to the weight of the 4 foot by 8 foot sheathing system tested. Fig. 13C Shown are the thicknesses and corresponding R-values ​​of a 3-layer sheathing system compared to industry standard or existing sheathing systems. Fig.13DThe R-values ​​per inch of the disclosed 3-ply sheathing system are shown compared to industry standard or existing sheathing systems. As shown, the 3-ply sheathing system has a weight of 20 lbs, a thickness of 13 / 16 inches, an R-value of 5, and an R-value of 0.32 per pound per inch. In comparison, OSB has a weight of 52 lbs, a thickness of 7 / 16 inches, an R-value of 0, and an R-value of 0 per pound per inch. Product 1 has a weight of 23 lbs, a thickness of 17 / 16 inches, an R-value of 6, and an R-value of 0.24 per pound per inch. Product 2 has a weight of 60 lbs, a thickness of 1 inch, an R-value of 3, and an R-value of 0.05 per pound per inch. Product 3 has a weight of 62 lbs, a thickness of 1.5 inches, an R-value of 6, and an R-value of 0.07 per pound per inch. The current embodiment shown has a higher R-value per pound per inch than other sheathing systems, even while maintaining peel performance. Product 1 has a comparable R-value per pound per inch, but suffers significantly in terms of release performance. Thus, the current embodiment is highly superior.

[0097] It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims.

[0098] Although specific elements and steps are discussed in conjunction with each other, it should be understood that any element and / or step provided herein is contemplated to be combined with any other element and / or step, regardless of whether it is explicitly provided, while still within the scope provided herein. Since many possible embodiments of the present invention can be made without departing from the scope of the present invention, it should be understood that all contents described herein or shown in the accompanying drawings should be interpreted as illustrative rather than restrictive.

Claims

1. A cladding system for externally enclosing at least a portion of a building structure, the cladding system comprising: a first structural layer having a first surface and a second surface opposite to the first surface; an insulation layer having a third surface and a fourth surface opposite the third surface, the third surface of the insulation layer being at least partially fixed to the second surface of the first structural layer; and a second structural layer, the second structural layer having a fifth surface and a sixth surface opposite the fifth surface, the fifth surface of the second structural layer being at least partially secured to the fourth surface of the insulating layer, wherein a distance from the first surface of the first structural layer to the sixth surface of the second structural layer is no greater than 1.5 inches, and the sheathing system has an R-value of at least 3.

5.

2. The panelling system of claim 1, wherein the first structural layer comprises a polymeric material comprising any one or more of: polycarbonate, polyester, polypropylene, polymethyl methacrylate, polyvinyl chloride, high density polyethylene, and copolymers thereof.

3. The paneling system of claim 1, wherein each of the second structural layers comprises a polymer material comprising any one or more of: polycarbonate, polyester, polypropylene, polymethyl methacrylate, polyvinyl chloride, high density polyethylene, and copolymers thereof.

4. The panelling system of claim 1, wherein the first structural layer comprises a polymer composite material having a polymer and one or more filler materials.

5. The panelling system of claim 1, wherein the second structural layer comprises a polymer composite material having a polymer and one or more filler materials.

6. The sheathing system of claim 1, wherein the insulation layer comprises any one or more of: extruded polystyrene, expanded polystyrene, foamed polyurethane, polyisocyanurate, mineral wool, polyethylene terephthalate, polyester, phenolic foam, aerogel felt, aerogel board, and polyurethane.

7. The paneling system of claim 1, wherein the paneling system has a nail pull force between 20 pounds and 200 pounds.

8. The cladding system of claim 1, wherein the cladding system has a peel performance greater than 440 plf.

9. The sheathing system of claim 1, wherein the distance from the first surface of the first structural layer to the sixth surface of the second structural layer is no greater than 1.5 inches and the sheathing system has an R-value of at least 4.

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10. The sheathing system of claim 1, wherein the distance from the first surface of the first structural layer to the sixth surface of the second structural layer is no greater than 1 inch and the sheathing system has an R-value of at least 3.

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11. The sheathing system of claim 1 , wherein the distance from the first surface of the first structural layer to the sixth surface of the second structural layer is no greater than 1 inch and the sheathing system has an R-value of at least 4.

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12. The cladding system of claim 1, wherein the cladding system has a weight between 10 pounds and 45 pounds.

13. The sheathing system of claim 12, wherein the distance from the first surface of the first structural layer to the sixth surface of the second structural layer is no greater than 1.5 inches and the sheathing system has an R-value of at least 4.

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14. A panel system for externally enclosing at least a portion of a building structure prior to being secured to the building structure, the panel system comprising: a structural layer having a first surface and a second surface opposite to the first surface; and an insulation layer having a third surface and an opposing fourth surface, the third surface of the insulation layer being at least partially secured to the second surface of the structural layer, wherein the sheathing system has a first distance from the first surface of the structural layer to the opposing fourth surface of the insulation layer of no greater than 1.5 inches, wherein the sheathing system has an R-value of at least 3.

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15. The sheathing system of claim 14, wherein the structural layer comprises any one or more of: polycarbonate, polyester, polypropylene, polymethyl methacrylate, polyvinyl chloride, high density polyethylene, and copolymers thereof.

16. The paneling system of claim 14, wherein the structural layer comprises a polymer composite material having a polymer and one or more filler materials.

17. The sheathing system of claim 14, wherein the insulation layer comprises any one or more of: extruded polystyrene, expanded polystyrene, foamed polyurethane, polyisocyanurate, mineral wool, polyethylene terephthalate, polyester, phenolic foam, aerogel felt, aerogel board, and polyurethane.

18. The cladding system of claim 14, wherein the cladding system has a peel performance greater than 440 plf.

19. The sheathing system of claim 1, wherein the distance from the first surface of the structural layer to the opposing fourth surface of the insulating layer is no greater than 1.5 inches and the sheathing system has an R-value of at least 4.

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20. The sheathing system of claim 1, wherein the distance from the first surface of the structural layer to the opposing fourth surface of the insulating layer is no greater than 1 inch and the sheathing system has an R-value of at least 3.

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21. The sheathing system of claim 1, wherein the distance from the first surface of the structural layer to the opposing fourth surface of the insulating layer is no greater than 1 inch and the sheathing system has an R-value of at least 4.

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22. The paneling system of claim 1, wherein the paneling system has a weight between 10 pounds and 45 pounds.

23. The sheathing system of claim 22, wherein the distance from the first surface of the structural layer to the opposing fourth surface of the insulating layer is no greater than 1.5 inches and the sheathing system has an R-value of at least 4.5.

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