Multi-material coating system

Abstract

A coating system for enveloping building structures is provided that combines a lightweight structural layer with a high R-value insulating layer to provide a unique solution. The combined layers of the coating system provide the benefits of reduced thickness, reduced weight, improved insulation, improved structural strength, improved nailability, improved fire and smoke performance, and enhanced energy efficiency. All aspects of the disclosed coating system can contribute to the overall improved performance and sustainability of the building structure.

Description

[Technical Field]

[0001] In modern building construction, wall cladding systems are used to provide structural support, thermal insulation, and protection against external environmental factors. Traditional wall cladding materials, such as plywood and oriented strand board (OSB), are widely used and are typically considered to be able to provide structural support or rigidity to a structure; however, these materials generally lack sufficient thermal insulation properties. Among other drawbacks, the poor thermal insulation properties of traditional cladding materials lead to greater energy consumption to maintain temperature and humidity levels in conditioned spaces.

[0002] To address insulation challenges, traditional practices involve applying a separate insulation layer in conjunction with conventional wall cladding materials. While this approach can enhance energy efficiency, it adds complexity to the construction process and increases material and labor costs. In addition to their limited insulating capacity, conventional wall cladding materials are also susceptible to moisture penetration and deterioration over time, which can compromise both the structural integrity and thermal performance of the building envelope. To address moisture issues, traditional building practices require wrapping the cladding with a waterproof wrap. Applying the wrap is a labor-intensive task that can increase labor and material costs. Furthermore, the wrap is generally prone to displacement during construction, potentially trapping moisture between the wrap and the cladding. Summary of the Invention

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

[0004] According to embodiments disclosed herein, a covering system is provided that includes one or more structural layers and a thermal insulation layer. The structural layer comprises a polycarbonate material and has a first surface and an opposing second surface. In exemplary embodiments, the structural layer is substantially bulk water resistant and substantially water vapor permeable. The thermal insulation layer comprises extruded polystyrene and has a third surface and an opposing fourth surface. The third surface of the thermal insulation layer is secured to the second surface of the structural layer. In some further embodiments, the covering system also includes an additional structural layer that comprises a polycarbonate material and has a fifth surface and an opposing sixth surface. The fifth surface of the additional structural layer can be at least partially secured to the fourth surface of the thermal insulation layer.

[0005] According to the disclosed embodiments, the coating system is lighter than conventional systems that weigh between 10 and 45 pounds, has a thickness of 1.5 inches or less, preferably 1 inch or less, and has an R-value of at least 3.5, preferably at least 4.5. Thus, the disclosed coating system is superior to conventional systems that are generally heavier, thicker, and have lower R-values.

[0006] This summary is provided to introduce, but not limit, the scope of, the methods and systems that are provided in more detail below. [Brief explanation of the drawings]

[0007] The present invention is described in detail herein with reference to the accompanying drawings. [Figure 1A] 1 depicts a perspective view of a three-dimensional cladding system according to an embodiment of the present invention; [Figure 1B] 1 depicts an exploded view of a three-dimensional covering system according to an aspect of the present invention. [Figure 2A] 1 depicts a cross-sectional view of a three-dimensional cladding system according to an embodiment of the present invention. [Figure 2B] 1 depicts a cross-sectional view of a three-dimensional cladding system according to an embodiment of the present invention. [Figure 3A] 1 depicts a perspective view of a three-dimensional cladding system according to an embodiment of the present invention; [Figure 3B] 1 depicts an exploded view of a three-dimensional covering system according to an aspect of the present invention. [Figure 4] 1 depicts a cross-sectional view of a three-dimensional cladding system according to an embodiment of the present invention. [Figure 5] 1 depicts a cross-sectional view of a three-dimensional cladding system according to an embodiment of the present invention. [Figure 6] 1 depicts a cross-sectional view of a three-dimensional cladding system according to an embodiment of the present invention. [Figure 7] 1 depicts a cross-sectional view of a three-dimensional cladding system according to an embodiment of the present invention. [Figure 8] 1 depicts a cross-sectional view of a three-dimensional cladding system according to an embodiment of the present invention. [Figure 9A] 1 depicts a perspective view of a three-dimensional cladding system according to an embodiment of the present invention; [Figure 9B] 1 depicts a cross-sectional view of a three-dimensional cladding system according to an embodiment of the present invention. [Figure 10A] 1 depicts a cross-sectional view of a three-dimensional cladding system according to an embodiment of the present invention. [Figure 10B] 1 depicts a cross-sectional view of a three-dimensional cladding system according to an embodiment of the present invention. [Figure 11A] 1 depicts exemplary physical data according to an aspect of the present invention. [Figure 11B]1 depicts exemplary physical data according to an aspect of the present invention. [Figure 11C] 1 depicts exemplary physical data according to an aspect of the present invention. [Figure 11D] 1 depicts exemplary physical data according to an aspect of the present invention. [Figure 11E] 1 depicts exemplary physical data according to an aspect of the present invention. [Figure 11F] 1 depicts exemplary physical data according to an aspect of the present invention. [Figure 11G] 1 depicts exemplary physical data according to an aspect of the present invention. [Figure 12A] 1 depicts exemplary physical data according to an aspect of the present invention. [Figure 12B] 1 depicts exemplary physical data according to an aspect of the present invention. [Figure 12C] 1 depicts exemplary physical data according to an aspect of the present invention. [Figure 12D] 1 depicts exemplary physical data according to an aspect of the present invention. [Figure 13A] 1 depicts exemplary physical data according to an aspect of the present invention. [Figure 13B] 1 depicts exemplary physical data according to an aspect of the present invention. [Figure 13C] 1 depicts exemplary physical data according to an aspect of the present invention. [Figure 13D] 1 depicts exemplary physical data according to an aspect of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0008] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the embodiments belong. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of various embodiments, the preferred methods and materials are described herein. In the drawings, the thickness of lines, layers, and regions may be exaggerated for clarity. It should be noted that like numbers found throughout the drawings refer to like elements.

[0009] As used in this 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.

[0010] Unless otherwise indicated, all numbers expressing quantities of ingredients, chemical and molecular properties, reaction conditions, and the like used in the specification and claims are to be understood as being modified in all instances by the term "about." Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and appended claims are approximations that may vary depending upon the desired properties sought to be obtained by exemplary embodiments of the invention. At the very least, each numerical parameter should be construed in light of significant digits and ordinary rounding approaches.

[0011] Unless otherwise indicated, any element, characteristic, feature, or combination of elements, characteristics, and features may be used in any embodiment disclosed herein, regardless of whether the element, characteristic, feature, or combination of elements, characteristics, and features is explicitly disclosed in the embodiment. It will be readily understood that a feature described in connection with any particular aspect described herein may be applicable to other aspects described herein, provided that the feature is compatible with that aspect.

[0012] Every numerical range given throughout this specification and the 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.

[0013] The term "R-value" is a unit used to measure the effectiveness of thermal insulation and is the inverse of thermal conductivity, which for foam board materials with substantially parallel sides is the rate of flow of thermal energy (BTU / hour or watts) per unit area (square feet, i.e., ft 2or square meters, i.e. m 2 ) / degrees of temperature difference (in degrees Fahrenheit or Kelvin) across the thickness (in inches or meters) of the slab material. The thermal performance of a polymeric insulation product is based on the insulation product's R-value, which is a measure of the product's resistance to heat flow. R-value is defined by equation (1): R=T / k where "T" is the thickness of the insulation product in inches and "k" is BTU in / hr ft 2 "R" is the thermal conductivity of the insulation product expressed in °F, hr ft 2 This is the R-value of the insulation, expressed in °F / BTU.

[0014] As used herein, the thickness (T) of an insulation product may be determined in accordance with ASTM C167-18 and may be determined by k-value and areal weight (lb / ft 2 Both the tensile strength (Tb) and the tensile strength (Tc) can be determined according to ASTM C518-21 or ASTM C177-19.

[0015] The following describes selected aspects related to cladding systems for use in constructing building structures (e.g., residential, commercial, industrial buildings). The disclosed cladding systems can include panels that can be attached to a frame of the building structure, thereby forming a cladding that encases at least a portion of the building structure. The cladding formed by the disclosed cladding systems can correspond, by way of example, to a wall portion (e.g., a vertical surface) or a roof portion of the building structure.

[0016] The multi-material coating systems disclosed herein offer various improvements over conventional coating systems. The unique assemblage of individual layers (also referred to herein as "components") utilized in manufacturing the disclosed coating systems provides stronger, thinner, and lighter coating panels with higher R-values per inch of total thickness, which offer several advantages over conventional coating systems.

[0017] The materials used in the novel cladding systems herein provide thinner structural layers that maintain or exceed the structural performance of conventional systems. As one skilled in the art can appreciate, thinner materials generally occupy less space within a building envelope, allowing for more efficient utilization of interior space. This can be particularly important in applications where maximizing usable area is essential, such as residential or commercial buildings. Thinner materials are also generally lighter in weight, which can simplify handling, transportation, and installation. Additionally, the utilization of alternative materials for cladding systems, as described, significantly reduces weight. Reduced weight can also have a positive impact on structural loads on building foundations and frames. Thinner materials offer architects and builders greater flexibility in designing and implementing various architectural elements, such as curves, angles, and intricate details. This can also result in faster construction times due to easier handling and installation. Thinner materials can subsequently result in reduced labor costs and faster project completion.

[0018] The materials utilized and described herein provide a thermal insulation coating system with a high R-value. The higher the R-value, the more effective the thermal insulation properties attributed to the coating system. More specifically, a coating system with a high R-value generally indicates that the coating system is effective at reducing heat flow through walls, roofs, and floors. This translates to lower energy consumption for heating and cooling, lower utility bills, and a smaller carbon footprint. A high R-value coating system also helps maintain a more consistent indoor temperature by reducing drafts, cold spots, and heat loss, further providing occupants with a comfortable living or working environment throughout the year. As is commonly known in the building industry, a minimum insulation R-value on the exterior of a building structure may be required by code. In this regard, conventional coating systems may require builders to add insulation after the coating panels are secured to the building structure to achieve the appropriate R-value, which further complicates the building process and leads to additional resource consumption.

[0019] 1A and 1B, an example of a cladding system for externally enveloping at least a portion of an architectural structure is illustrated, according to an exemplary embodiment of the present invention. FIG. 1A depicts a cladding system 100 bonded to a building frame structure 102. The cladding system 100 comprises a structural layer 104 and an insulating layer 106 (i.e., a "two-layer system"). As seen in FIG. 1B, the structural layer 104 includes a first surface 114 and a second surface 115 opposite the first surface 114. The structural layer 104 can have a thickness measured as the distance from the first surface 114 to the second surface 115 opposite the first surface 114. The insulating layer 106 includes a third surface 116 and a fourth surface 117 opposite the third surface 116. The thickness of the insulating layer 106 can be measured as the distance from the third surface 116 to the fourth surface 117.

[0020] The coating system 100 is formed by bonding the second surface 115 of the structural layer 104 to the third surface 116 of the thermal insulation layer 106, with the coating system 100 having an overall thickness measured from the first surface 114 to the fourth surface 117. More specifically, the structural layer 104 may be bonded to the thermal insulation layer 106 by bonding, adhering, applying, or mechanically fastening one layer to the other. By way of example, the coating system 100 may be formed by applying an adhesive layer to the second surface 115 of the structural layer 104 or the third surface 116 of the thermal insulation layer 106 to adhere one surface to the other. In some embodiments, the adhesive layer has a viscosity of about 4.885 gm / cm 2 (1 lb / MSF) ~ approx. 244.5 gm / cm 2 (50 lbs / MSF). The adhesive layer can include any of a variety of adhesives, such as, by way of non-limiting example, resins (e.g., phenol-formaldehyde, polyvinyl acetate), hot melts, isocyanate-based adhesives, tar, or other adhesives.

[0021] 2A-2B, different arrangements for coupling the covering system 100 to the building frame structure 102 are illustrated. Referring to FIG. 2A, a cross-sectional view of the covering system 100 of FIG. 1A along section line 2A (2A in FIG. 1A) is depicted. The configuration shown in FIG. 2A contemplates that the covering system 100 has an insulating layer 106 adjacent to the building frame structure 102. The configuration shown in FIG. 2B contemplates that the covering system 100 has a structural layer 104 adjacent to the building frame structure 102. The covering system 100 can be fastened to the building frame structure 102 using fasteners 210. The fasteners 210 can include any of a variety of fasteners, such as nails, screws, bolts, adhesives, anchors, rail moldings, cleats, magnets, pegboards, suction, hook and loop, or any other suitable fasteners commonly known in the art.

[0022] The fasteners 210 can be used to secure the cladding system 100 to the building frame structure 102. The cladding system 100 preferably provides resistance to prevent the fasteners 210 from being pulled out of the cladding system 100. The cladding system 100 comprises a unique layered panel system with specific materials selected for each layer. The materials selected for each layer result in the cladding system 100 meeting or exceeding current industry standard cladding systems in terms of nail pull force. For example, in an exemplary embodiment, the cladding system 100 can be constructed from panels having a 1 / 8-inch thick structural layer 104 made of polycarbonate material. The use of polycarbonate as the structural layer 104 gives the cladding system 100 the ability to resist nail pull out better than industry standard cladding systems. Referring briefly to FIG. 11A, the embodiments described herein meet or exceed industry standard products. The two-ply system shown in Figure 11A has a thickness of 7 / 8 inch and a nail pull force of over 160 or 180 lbs / inch when measured according to ASTM D1037 standard. The two-ply system consists of a polycarbonate structural layer 104 and an insulating layer 106 comprising extruded polystyrene (XPS). By comparison, the industry standard wall covering made of 7 / 16 inch thick oriented strand board (OSB) has a nail pull force of 60 or 137 lbs / inch.

[0023] With continued reference to FIGS. 2A and 2B, different thicknesses of the coating system 100 are described and can vary based on its intended use. In embodiments where better thermal insulation properties are desired, the overall thickness of the coating system 100 can be greater. For example, if the coating system 100 has an overall thickness of 2 inches, the coating system 100 can have an R-value of 10. In embodiments where lower thermal insulation properties are acceptable, the coating system 100 can have an overall thickness of 1 inch or less while still maintaining an R-value of at least 3.5. Those skilled in the art will understand that while many other thicknesses can be used (e.g., the coating system 100 can have an R-value of 7 when the overall thickness is 1.5 inches), the overall thickness of the coating system 100 is preferably within the range of 0.5 to 2 inches. It is contemplated that values beyond that range for the overall thickness can be used depending on the needs of the project partners. As with conventional coating solutions, the R-value of the coating system 100 increases with its overall thickness. Thus, the coating system 100 can have an R-value ranging from at least 3.5 to 10. In various embodiments, the total R-value of the coating system can vary depending on the ratio of the insulating layer 106 to the structural layer 104.

[0024] As noted 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 a project. For example, if greater structural strength is desired in areas prone to high wind or seismic forces, one may want to increase the relative structural thickness. As a further example, if greater insulation is desired and strength can be sacrificed, such as in cooler climates, one may want 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 approximately 3:1. As an example, a cladding system having a 3:1 ratio and a 1-inch overall thickness would have a ¼-inch structural layer 104 and a ¾-inch insulation layer 106. In other exemplary embodiments, the ratio of the thickness of the insulation layer 106 to the thickness of the structural layer 104 can be, by way of non-limiting example, 6:1, 5:1, 4:1, 2:1, 1.5:1, or 1:1. Additional ratios not disclosed herein are considered within the scope of this disclosure.

[0025] The structural layer 104 can have a variety of thicknesses based on the structural needs of the building. By way of example, the structural layer 104 can have a thickness of 1 / 8 inch. Additionally, the structural layer can have a thickness ranging from 1 / 64 inch to 1 inch. To accommodate the different insulation needs described above, the insulation layer 106 can have a thickness ranging from 1 / 4 inch to 1 1 / 2 inches. Thus, 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 configuration, the structural layer 104 and the insulation layer 106 are 1 inch or less in thickness and have an R-value of 3.5 or greater. In another exemplary configuration, the structural layer 104 and the insulation layer 106 are 1 inch or less in thickness and have an R-value of 5 or greater. Furthermore, an alternative embodiment has an R-value-to-thickness ratio of at least 5, resulting in a 2-inch system with an R-value of 10.

[0026] As described herein, the purpose of the insulation layer 106 is to provide enhanced thermal resistance. The insulation layer 106 of the cladding system 100 can include a material selected to have a high R-value. In one exemplary embodiment, the insulation layer includes extruded polystyrene (XPS). It is contemplated that the insulation layer 106 can include any insulation material, including, but not limited to, fiberglass, wood, foam, polymer, wood composite, expanded polystyrene (EPS), polyurethane foam, 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, cellulosic insulation, rock wool insulation, or any combination thereof. Polymer-based insulation materials that can also or alternatively be utilized in the insulation layer 106 include polyurethane, phenolic foam, TPO, thermoplastic polyolefin, and ethylene propylene diene monomer (EPDM), among others.

[0027] Meanwhile, the structural layer 104 provides rigidity and structural support to the architectural structure envelope. Therefore, the structural layer 104 can be constructed of any one or more materials that resist movement forces, such as polycarbonate or composites. Additional materials that can provide the rigidity and structural support required by the structural layer 104 can be one or more of materials such as polypropylene, high density polyethylene (HDPE), or wood composites. The structural layer 104 can include polymers, polycarbonate, stainless steel, glass, polyester, polypropylene, polyethylene, acrylic, acrylonitrile styrene acrylate, cyclic olefin copolymer, polycyclohexylene dimethylene terephthalate, polyether ketone, polyaryl ether ketone, polyetherimide, polyethersulfone, polymethyl methacrylate, polyvinyl chloride, polyphthalimide, polyphenylene oxide, polyphenylene sulfide, recycled HDPE, any recycled plastic or polymer, polysulfone, or syndiotactic polystyrene. The polymer may include one or more of polyvinylstyrene, plexiglass, high density polypropylene (HDPP), hard plastic, soft plastic, polyethylene terephthalate, acrylonitrile butadiene styrene, thermoplastic, thermoset, elastomer, linen, shellac, amber, wool, silk, natural rubber, cellulose, silicone, polybutylene terephthalate, styrene-butadiene rubber, or other polymers or copolymers. In a further example, recycled materials including recycled polycarbonate may be used for the structural layer 104. Additionally, other recycled materials may be considered for the structural layer 104, such as recycled plastic or composites made from recycled wood fibers and plastics.

[0028] In other embodiments, the structural layer 104 can include a polymer composite formed from a polymer and at least one filler material. The addition of a filler material can add desired physical properties to the structural layer 104, such as texture, color, strength, reduced weight, or other physical properties. The polymer composite can include a filler material added to a polymer in a weight ratio of between 1 weight percent and 90 weight percent filler material to polymer. In further embodiments, the filler material can include any amount of powder, talc, calcium carbonate, calcium carbonate pellets, cellulose, sand, silica, magnesium oxide, aluminum oxide, clay, inorganic powders, colorants, ground tire rubber, rubber, calcium sulfate, calcium silicate, barium sulfate, mica, kaolin, silicon dioxide, diatomaceous earth, minerals, glass fiber, carbon fiber, glass, polymer beads, magnesium hydroxide, fly ash, polymer foam beads, masonry filler, wollastonite, short glass fiber, long glass fiber, glass beads, coal, dolomite, carbon black, silica, magnetite, hematite, halloysite, zinc oxide, titanium dioxide, Al(OH), Mg(OH), concrete filler, gravel, stone, sand, steel, aluminum, or any other material that can be added to the polymer of structural layer 104. In alternative embodiments, organic fillers, rice hulls, nut flour, wood flour, vegetable fibers, cotton fibers, starch, synthetic organic fillers, rubber particles, chalk, quartz, granite, aluminosilicates, vermiculite, nepheline syenite, barium ferrite, barium titanate, molybdenum disulfide, potassium titanate, oxides, hydrates, powders, zinc oxide, beryllium oxide, blowing agents, PBT, ceramics, or other materials that can be added to polymers can be used as filler materials.In another embodiment, it may be contemplated to use glass fibers, carbon fibers, mineral fillers (e.g., calcium carbonate, talc, or mica), aramid fibers, glass beads, nanoclay, 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 powder), flame-retardant fillers (e.g., phosphorus-based compounds or halogenated additives) as filler materials.

[0029] In some embodiments, the filler material can have a size up to 1 mm. Polymer composites can have filler materials of various sizes, such as, but not limited to, 1 micron to 1000 microns, 1 micron to 1 centimeter, or 10 mesh to 100 mesh. In one embodiment, the filler material can be added to the polymer in a ratio of 1 weight percent to 90 weight percent of the polymer. In another embodiment, a ratio of 30 weight percent to 60 weight percent of the polymer can be used for the filler material.

[0030] The covering system 100 can be cut or molded into any desired shape or size. Formed as flat sheets (i.e., panels) of any one or more standard sizes, e.g., 4 feet by 8 feet, 4 feet by 10 feet, or 4 feet by 12 feet, the covering system 100 can be shaped or cut according to specific dimensions and / or design requirements (e.g., different geometric shapes). Cutting or shaping tools (e.g., circular saws) or precision tools (e.g., Computer Numerical Control (CNC) machines) available at the job site can be used to cut or cut each layer of the covering system 100, as appropriate.

[0031] In additional embodiments, the structural layer 104 can withstand racking forces and exceed the ASTM E72 industry standard for structural wall cladding systems. The ASTM E72 standard determines the ability of the cladding system 100 to deflect static loads (i.e., resist racking). The resistance to racking of certain embodiments is described in further detail with respect to FIG. 11B. For example, in one embodiment, the cladding system 100 can have a racking strength maximum force of greater than 640 pounds per linear foot (plf) according to the ASTM E72 test, which exceeds standard systems in the industry.

[0032] The structural layer 104 may be resistant to bulk water but permeable to water vapor. The structural layer 104 may be characterized by a water vapor transmission rate in the range of about 0.1 US perms to about 1.0 US perms, and from about 0.07 to about 7 g / m 2 / 24 hour water vapor transmission rate (per ASTM E96 Procedure A at 73°F, -50% RH). Additional embodiments of the structural layer 104 may have a water vapor transmission rate (per ASTM E96 Procedure B at 73°F, -50% RH) of about 0.1 to about 12 U.S. perms per 24 hours, per ASTM D5795, and a liquid water transmission rate (per Cobb ring grams / 100 inches) of about 1 to about 28. 2 / 24 hours).

[0033] 3A and 3B, a coating system 300 having at least three layers is illustrated. At a high level, the coating system 300 comprises the coating system 100 of FIGS. 1A-2B with the addition of a second structural layer 308; i.e., the coating system 300 comprises a first structural layer 304, a thermal insulation layer 306, and a second structural layer 308 (i.e., a "three-layer coating system"). Accordingly, the coating system 300 and each of the first structural layer 304 and the thermal insulation layer 306 can have any one or more properties of the coating system 100, the structural layer 104, and the thermal insulation layer 106, respectively, as described in connection with FIGS. 1A-2B. Additionally, the second structural layer 308 can have any one or more properties of the structural layer 104, as described in connection with FIGS. 1A-2B.

[0034] The inclusion of both the first structural layer 304 and the second structural layer 308 can be advantageous because it provides weather resistance on both sides of the insulation layer 306. Additionally, with brief reference to FIG. 11C , the first structural layer 304 and the second structural layer 308 can provide improved racking 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.

[0035] 3A and 3B , an example coating system 300 is illustrated in accordance with an exemplary embodiment of the present disclosure. As shown in FIG. 3B , the coating system 300 includes a fourth surface 317 of the thermal insulation layer 306 and a third surface 316 of the thermal insulation layer 306 opposite the fourth surface 317. The thickness of the thermal insulation layer 306 can be measured as the distance from the third surface 316 to the fourth surface 317. Furthermore, the first structural layer 304 includes a second surface 315 and a first surface 314 opposite the second surface 315. The thickness of the first structural layer 304 can be measured as the distance from the first surface 314 to the second surface 315. Additionally, the second structural layer 308 includes a sixth surface 319 and a fifth surface 318 opposite the sixth surface 319. The thickness of the second structural layer 308 can be measured as the distance from the fifth surface 318 to the sixth surface 319.

[0036] The covering system 300 is formed by bonding the second surface 315 of the first structural layer 304 to the third surface 316 of the thermal insulation layer 306. Additionally, the fourth surface 117 of the thermal insulation layer 306 is bonded to the fifth surface 318 of the second structural layer 308. More specifically, the first structural layer 304 can be bonded to the thermal insulation layer 306 by bonding, adhering, applying, or mechanically fastening one layer to the other. Additionally, the second structural layer 308 can be bonded to the thermal insulation layer 306 by bonding, adhering, applying, or mechanically fastening one of the layers to the other. By way of example, the covering system 300 can be formed by applying an adhesive layer or adhesive to the second surface 315 of the first structural layer 304 or the third surface 316 of the thermal insulation layer 306 and adhering one surface to the other. As a further example, the covering system 300 can be formed by applying an adhesive layer or adhesive to the fourth surface 317 of the thermal insulation layer 306 or the fifth surface 318 of the second structural layer 308 to bond one surface to the other.

[0037] As discussed with respect to other embodiments described herein, the ratio of the thickness of the first structural layer 304 and the second structural layer 308 to the thickness of the insulation layer 306 can vary based on the intended use of the disclosed covering system. For example, where greater structural strength is desired, such as in areas subject to high winds or seismic forces, the combined thickness of the first structural layer 304 and the second structural layer 308 can be increased as a percentage of the overall thickness of the covering system, or the thickness measured from the first surface 314 to the sixth surface 319. In a further example, where greater insulation is desired and strength can be sacrificed, such as in colder climates, the insulation layer can be a greater percentage of the overall thickness. In a preferred arrangement, the ratio of the thickness of the insulation layer 306 to the combined thickness of the first structural layer 304 and the second structural layer 308 can be approximately 3:1. In one embodiment, the coating system 300 may have a ratio of the thickness of the insulation layer 306 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. In this embodiment, the combined thickness of the first structural layer 304 and the second structural layer 308 is 14 inches, and the thickness of the insulation layer 306 is 3 / 4 inch. In some other embodiments, the ratio of the thickness of the insulation layer 306 to the combined thickness of the first structural layer 304 and the second structural layer 308 may be, by way of non-limiting example, 6:1, 5:1, 4:1, 2:1, 1.5:1, or 1:1. Additional ratios may be contemplated.

[0038] The purpose of the first structural layer 304 and the second structural layer 308 is to provide rigidity and structural support for the architectural structure envelope. Additionally, the materials used for the first structural layer 304 and the second structural layer 308 can provide other physical properties based on the intended application. For example, according to one or more design constraints, the cladding system 300 can be spaced to have a particular exterior texture, weight, or other physical property. For example, in one embodiment, the cladding system 300 may require excellent racking resistance due to high seismic activity. Additionally, the cladding system 300 may require a particular texture, nail pull, or other physical property to aid in the architectural envelope. Thus, the first structural layer 304 and the second structural layer 308 can be constructed from any one or more materials that resist racking forces, are lightweight, have one or more textures, resist nail pull, or provide other desired physical properties. In one embodiment, both the first structural layer 304 and the second structural layer 308 can comprise the same material. In an alternative embodiment, if different physical properties are desired for first structural layer 304 and second structural layer 308, they may each be formed from different materials.

[0039] As described above, the first structural layer 304 and the second structural layer 308 can have different physical requirements and, therefore, 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, can be thinner than the first structural layer 304. Accordingly, the first structural layer 304 can have a thickness ranging from 1 / 64 inch to 1 inch. The second structural layer 308 can have a thickness ranging from 1 / 64 inch to 1 inch. The insulation layer 306 can have a thickness ranging from 1 / 4 inch to 1 1 / 2 inches. The combined thickness of the first structural layer 304, insulation layer 306, and second structural layer 308 can range from 1 / 2 inch to 2 inches. In an exemplary configuration, the first structural layer 304, insulation layer 306, and second structural layer 308 are 1 inch or less in thickness and have an R-value of 5 or greater. Additionally, an alternative embodiment has an R-value to thickness ratio of at least 5, resulting in a 2 inch system with an R-value of 10.

[0040] Referring now to FIG. 4, a cross-sectional view of the covering system 300 of FIG. 3A along section line (4 in FIG. 3A) is depicted in accordance with an aspect of the present invention. The covering system 300 comprises at least a thermal insulation layer 306 adhered to a first structural layer 304 and a second structural layer 308. The covering system 300 can be fastened to the frame structure 302 through the use of fasteners 410. The fasteners 410 can include fasteners such as nails, screws, or any other suitable fasteners known in the art. In one embodiment, the distance from the exterior or outer surface of the first structural layer 304 to the interior or inner surface of the second structural layer 308 adjacent the frame structure 302 (i.e., the thickness of the covering system 300) is 1 inch or less and has an R-value of 5 or greater. In another embodiment, the distance from the exterior or outer surface of the first structural layer 304 to the inner surface adjacent 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 first structural layer 304 to the inner surface adjacent frame structure 302 is 2 inches or less.

[0041] Referring now to FIG. 5, FIG. 5 depicts a cross-sectional view of a top view of one embodiment of a coating system 500 prior to installation. The coating system 500 is illustrated with drainage channels or grooves to prevent moisture accumulation. At a high level, the coating system 500 comprises the coating system 100 of FIGS. 1A-2B with the addition of multiple drainage channels 506; i.e., the coating system 500 comprises a structural layer 502, an insulating layer 504, and multiple drainage channels 506. Thus, the coating system 500 and each of the structural layer 502 and the insulating layer 504 can have any one or more characteristics of the coating system 100, the structural layer 104, and the insulating layer 106, respectively, as described in connection with FIGS. 1A-2B. The multiple drainage channels 506 may be recessed in (or extend from) the insulating layer 504. The offset or recess distance formed by drainage groove 506 is depicted by a distance 510 extending from recess surface 516 to outer surface 514 of insulation layer 504. Distance 510 ranges from 0.01 inches to 0.1 inches. In one embodiment, distance 508 from outer structural surface 512 to outer insulation surface 514 ranges from about 1 inch to about 2 inches.

[0042] 6 similarly depicts a cross-section of a top view of a coating system 600 including a first structural layer 602, an insulating layer 604, and a second structural layer 606. Additionally, the second structural layer 606 may include drainage channels 618. The insulating layer 604, the first structural layer 602, and the second structural layer 606 may include any of the features described above with respect to, for example, FIGS. 3A, 3B, and 4. Therefore, for the sake of brevity, a detailed description of the insulating layer 604, the first structural layer 602, and the second structural layer 606 will not be repeated with respect to the coating system 600 illustrated in FIG.

[0043] The drainage grooves 618 can be recessed into (or extend from) the second structural layer 606. The offset or recessed distance formed by the drainage grooves 618 is depicted by a distance 614 extending from the recessed surface 616 to the extended surface 612 of the second structural layer 606. 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 outer first structural layer surface 610 to the extended surface 612 is 1 inch or less. In additional embodiments, the number of drainage grooves 618 per foot of the covering system 600 can range from 1 drainage groove per foot to 12 drainage grooves per foot.

[0044] Similar to the drains 508 illustrated in FIG. 5 , the drains 618 are designed on the surface of the cladding system 600 to allow gravity to drain water from the cladding system 600. The drains 618 create a path that directs water away from the cladding system 600 and the building envelope. The cladding system 600 may include a series of vertically arranged drains 618 so that when water or moisture encounters the drains 618, gravity draws the water downward and away from the building envelope. In one embodiment, the drains 618 may take the form of square gutters as depicted in FIG. 6 . In additional embodiments, the gutters 618 are V-shaped gutters, rectangular gutters, or curved gutters. Additional shapes may be contemplated for use as the gutters 618.

[0045] The placement of the drainage channels 618 can be vertical, so that water flows directly downward. Additionally, the drainage channels 618 can be oriented in a horizontal configuration or parallel to the ground when the covering system 600 is installed. In further embodiments, the drainage channels 618 can be oriented in a diagonal, radial, or serpentine configuration.

[0046] 7, which also depicts a cross-section of a top view of a coating system 700 including 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 channels 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 any of the characteristics described above with respect to, for example, FIGS. 3A, 3B, and 4. Therefore, for the sake of brevity, a detailed description of the insulating layer 704, the second structural layer 706, and the first structural layer 702 will not be repeated with respect to the coating system 700 illustrated in FIG.

[0047] Similar to the drain 618 described with respect to FIG. 6 , the drain 708 is designed as part of the cladding system 700 to allow gravity to drain water from the cladding system 700. As shown in FIG. 7 , the drain 708 is part of the insulation layer 704, which is the space between the insulation layer 704 and the second structural layer 706. The placement of the drain 708 allows for the extraction of any moisture between the insulation layer 704 and the second structural layer 706. The drain 708 creates a path that directs water away from the cladding system 700, away from the insulation layer 704, and away from the building envelope. The cladding system 700 can include a series of vertically arranged drains 708 so that when water or moisture encounters the drain 708, gravity draws the water downward and away from the insulation layer 704. In one embodiment, the drain 708 can take the form of a square groove as depicted in FIG. 7 . In additional embodiments, the drain 708 is a V-shaped groove, a rectangular groove, or a curved groove.

[0048] Continuing to refer now to FIG. 8 , a top-view cross-section of an embodiment of a coating system 800 is shown. The coating system 800 comprises a first structural layer 802, an insulating layer 804, a second structural layer 806, and drainage channels 808. The drainage channels 808 provide a varied cross-section having non-vertical surfaces. The pattern of the drainage channels 808 is designed to improve the flow of moisture adjacent to the coating system 800 for ultimate extraction from the entire coating system. The insulating layer 804, the second structural layer 806, and the first structural layer 802 may include, for example, any of the characteristics described above with respect to FIGS. 3A , 3B, and 4 . Therefore, for the sake of brevity, a detailed description of the insulating layer 804, the second structural layer 806, and the first structural layer 802 will not be repeated with respect to the coating system 800 illustrated in FIG. 8 .

[0049] Drain 808 is designed similarly to drain 618 in Figure 6. As part of cladding system 800, drain 808 allows gravity to cause water to drain from cladding system 800. Drain 808 creates a path that directs water away from cladding system 800 and the building envelope. As shown in Figure 8, drain 808 can have surfaces that deviate from the vertical.

[0050] Alternative embodiments for joining a first structural layer 902, a thermal insulation layer 906, and a second structural layer 904 are depicted in Figures 9A and 9B. With specific reference to Figure 9A, a perspective view of a covering system 900 is shown, comprising a first structural layer 902, a second structural layer 904, a thermal insulation layer 906, and one or more rods 908. The illustrative view in Figure 9A has cutout portions of the first structural layer 902 exposing the rods 908 for illustrative purposes only. In one embodiment, the rods 908 extend from the first structural layer 902, through the thermal insulation layer 906, and to the second structural layer 904. In some aspects, the rods 908 can take the form of a cylinder, a plane, a prism, a rod, or other shape capable of connecting the first structural layer 902 and the second structural layer 904 together.

[0051] 9B, which depicts a cross section of a coating system 900 incorporating a rod 908, a first structural layer 902, and a second structural layer 904. The rod 908 in the coating system 900 can be made from a high-strength, heat-resistant polymer. Depending on the specific requirements of the coating system 900, a variety of polymer materials can be utilized for the rod. For example, engineering thermoplastics such as nylon (e.g., nylon 6 or nylon 6 / 6), polypropylene, polycarbonate, or polyethylene terephthalate (PET) may be suitable choices for the rod 908.

[0052] In additional embodiments, rods 908 can be secured to the first structural layer 902 and the second structural layer 904 using a melting process to fuse the covering system 900 together. Additionally, the rods 908 can comprise a thermoplastic material, which can soften and fuse during the assembly process. The melting or fusing process can involve the application of heat to the rods 908, causing them to soften and melt slightly. The rods 908 can penetrate the first structural layer 902, the second structural layer 904, and the insulating layer 906, filling any gaps or voids therebetween. As the melted rods 908 cool and solidify, they create a strong bond, forming a fused connection and permanently securing the first structural layer 902 and the second structural layer 904 together at their ends 912 and 914.

[0053] In some embodiments, the fusing process can be accomplished by a variety of methods. One approach is to use a heated metal plate or a heated mold that is pressed against the first structural layer 902 and the second structural layer 904. Heat from the plate or mold is transferred to the rods 908 at ends 912 and 914, causing them to melt and fuse with the first structural layer 902 and the second structural layer 904. Alternatively, a localized heat source, such as hot air or infrared heat, can be directed to the specific area where the rods 908 are inserted to allow for selective melting and fusing.

[0054] In another embodiment, the cladding system 900 can 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 thermal insulation layer 906. Metal rods offer high strength, rigidity, and resistance to various environmental conditions. Metals utilized for this purpose include stainless steel alloys, aluminum alloys, or steel alloys.

[0055] In some other embodiments, rod 908 can have various diameters and lengths to accommodate different panel sizes and design requirements. The ends 914 and 912 of the rod can be threaded, allowing the rod to be easily inserted into the structural layer and securely fastened. Alternatively, rod 908 can 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.

[0056] In additional embodiments, the rod 908 can have a flanged or enlarged portion on the end 914 such that the rod 908 holds the insulation layer 906 to the second structural layer 904. The rod 908 can then be connected to the first structural layer 902 and the second structural layer 904 by melting, fusing, or other means.

[0057] Reference is now made to Figures 10A and 10B, which depict cross-sectional views of a coating system 1000. The coating system 1000 of Figures 10A and 10B comprises 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 can have any of the properties of the first structural layer 304 and the second structural layer 308, respectively, as described above in connection with Figures 3A, 3B, and 4. Therefore, for the sake of brevity, a detailed description of the first structural layer 1002 and the second structural layer 1004 will not be repeated with respect to the coating system 1000 illustrated in Figures 10A and 10B.

[0058] Between the first structural layer 1002 and the second structural layer 1004 is a support layer 1006. The support layer 1006 comprises a series of walls or structures that separate the first structural layer 1002 and the second structural layer 1004. As shown in FIG. 10A , the support layer 1006 can have a series of walls that extend vertically from the first structural layer 1002 to the second structural layer 1004. The support layer 1006 creates elongated hexagonal spaces or voids that extend from the first structural layer 1002 to the second structural layer 1004, such as the insulating void 1008. As an example, the support layer 1006 includes walls that extend from the first structural layer 1002 to the second structural layer 1004 to create the insulating void 1008. The insulating void 1008 can be oriented to extend from the first structural layer 1002 and the second structural layer 1004, for example, as shown in FIG. 10A . 10B, the support layer 1006 can have a series of structures extending from the first structural layer 1002 to the second structural layer 1004. The support layer 1006 creates elongated hexagonal spaces or voids, such as insulating voids 1008, that are parallel to the first structural layer 1002 and the second structural layer 1004. The insulating voids 1008 can be oriented parallel to the first structural layer 1002 and the second structural layer 1004, as shown in FIG.

[0059] Support layer 1006 can be constructed from any material that can be used or formed into a wall or support structure. For example, support layer 1006 can be constructed from polycarbonate, polyurethane, metal, wood, or any other structural support material as required by the intended use of support layer 1006.

[0060] The insulation void 1008 refers to the space or cavity created by the support layer 1006 of the covering system 1000. The insulation void 1008 can be filled with an insulating material to ensure the insulating material is properly contained within the panel. In some embodiments, the insulating material can include various insulating substances such as foam, fiberglass, or polymer-based insulation. The insulation void 1008 can be filled using spray foam, polyisocyanurate, EPS, recycled XPS, XPS, or other insulating materials. These materials can be sprayed, injected, or filled into the insulation void 1008. As seen in FIG. 10A , the insulation void 1008 can be filled perpendicular to the first structural layer 1002 and the second structural layer 1004 when one or more of the structural layers are not secured to the covering system 1000. However, as can be seen in FIG. 10B, the first structural layer 1002 and the second structural layer 1004 have parallel insulating gap portions 1008 that can be filled when the coating system 1000 is fully assembled.

[0061] In some embodiments, the support layer 1006 in the covering system 1000 can be designed with a honeycomb pattern, creating a series of interconnected hexagonal cells or chambers that form a regular and uniform structure throughout the support layer. The multiple hexagonal cells or chambers created by the support layer 1006 create a network of interconnected walls that distributes applied loads and stresses evenly throughout the covering system 1000, improving its structural integrity. As shown in FIG. 10A , the hexagonal cells or insulating voids 1008 can be oriented such that the openings of the insulating voids 1008 are adjacent to or face the first structural layer 1002 and the second structural layer. Additionally, as shown in FIG. 10B , the hexagonal cells or insulating voids 1008 can be oriented such that the openings of the insulating voids 1008 are perpendicular to the first structural layer 1002 and the second structural layer.

[0062] In addition to the honeycomb pattern, it is contemplated that a variety of other patterns may be used in the support layer 1006 of the covering system 1000. These patterns offer different structural characteristics and can 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 forming a grid-like structure; a triangular truss pattern consisting of interconnected triangular cells creating a truss-like framework; a diamond pattern featuring interconnected diamond-shaped cells forming a repeating pattern; or a hexagonal grid pattern consisting of interconnected hexagonal cells, similar to the honeycomb pattern. 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 with varying void sizes and shapes, providing flexibility in material distribution and load-bearing capacity.

[0063] The inventive concept has been described above both generally and with respect to various exemplary embodiments. While the general inventive concept has been described in what are believed to be exemplary illustrative embodiments, a wide variety of alternatives known to those skilled in the art can be selected within the disclosure. Additionally, the following data related to the embodiments described herein are meant to better illustrate the invention, but do not in any way limit the general inventive concept of the present invention.

[0064] 11A-13D depict data for embodiments of two-layer coating systems (i.e., a structural layer and an insulating layer) and / or three-layer coating systems (i.e., a first structural layer, an insulating layer, and a second structural layer), e.g., as described above with respect to FIGS. 1A-2B and 3A-4, respectively. In particular, FIGS. 11A-11G illustrate data for two-layer coating systems and / or three-layer coating systems, where the structural layer(s) comprise polycarbonate (PC) and the insulating layer comprises extruded polystyrene (XPS) (e.g., "1 / 16" PC / XPS 3-Layer R5"). FIGS. 12A-12D illustrate data for two-layer coating systems and / or three-layer coating systems, where the structural layer(s) comprise polycarbonate (PC) and the insulating layer comprises polyethylene terephthalate (PET) (e.g., "1 / 16" PC / PET 3-Layer R5"). 13A-13D illustrate data for a three-layer coating system, where the structural layer comprises polycarbonate (PC) and the insulating layer comprises polyurethane (PU) (eg, "1 / 32 inch PC / PU 3-Layer R5").

[0065] 11A-13D further illustrate embodiments of two-layer and / or three-layer coating systems in which the thickness or width of each structural layer can vary between 1 / 16 inch, 1 / 32 inch, or 1 / 8 inch, for a total coating system thickness or width of 1 inch or less. For example, an embodiment identified as "1 / 16 inch PC / XPS 3-Layer R5" refers to a three-layer coating system having a first structural layer and a second structural layer, each comprising polycarbonate and each having a thickness of 1 / 16 inch, and an XPS thermal insulation layer having a thickness of 3 / 4 inch.

[0066] Additionally, Figures 11A-13D include comparative data with industry standard covering systems identified as "OSB," "Product 1," "Product 2," and "Product 3." "OSB" refers to the industry standard wall covering material consisting of oriented strand board panels having a thickness of 7 / 16 inches. "Product 1" refers to a prior wall covering system including a Thermoply structural layer, a polyisocyanurate layer, a facer, and a thickness of 1 1 / 8 inches. "Product 2" and "Product 3" refer to prior wall covering systems including OSB layers and polyisocyanurate insulation layers of various thicknesses to achieve different levels of insulation.

[0067] Representative data shown in Figures 11A-13D demonstrate the superior performance of embodiments of the coating systems described herein. As is clear, the coating systems of the present disclosure outperform current industry standard products in most categories and perform better overall than the industry standard products.

[0068] 11A-11G depict data for two-layer and / or three-layer coating systems, where the thermal insulation layer comprises extruded polystyrene (XPS) and the structural layer(s) comprise polycarbonate (PC). FIG. 11A shows data for nail pull or pull tests conducted according to ASTM DI 037 standard. Nail pull tests are used to evaluate the resistance of fasteners in materials. 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. The data depicted in FIG. 11A demonstrates the superior performance of some of the embodiments described herein over current industry standard products. Coating systems of the present disclosure have nail pull forces of 20 to 200 pounds. Additionally, coating systems of the present disclosure have preferred nail pull forces of 50 to 200 pounds. In even more preferred embodiments, coating systems of the present disclosure have nail pull forces of 120 to 200 pounds. In contrast, industry standard coating systems exhibited nail pull forces of less than 60 pounds. For example, as illustrated, a 1 / 16 inch PC / XPS 3-ply R5 coating system and a 1 / 8 inch PC / XPS 2-ply R5 coating system provided average nail pull forces of 140 pounds and 165 pounds, respectively. In comparison, OSB sheathing panels, Product 2 and Product 3, each provided an average nail pull force of approximately 60 pounds. Product 1, a wall sheathing system including a Thermoply structural layer, a polyisocyanurate layer, a facer, and having a thickness of 1 1 / 8 inches, exhibited an average nail pull force of less than 15 pounds.

[0069] 11B and 11C illustrate data related to a series of tests conducted to measure structural performance and evaluate the resistance of embodied coating systems to lateral forces, such as those experienced during seismic events or high wind conditions. To measure the racking performance of each panel, FIG. 11B used the ASTM E72 standard, and FIG. 11C used the ASTM E564 standard. This data demonstrates the superior performance of the embodied panels compared to the present coating system. The disclosed coating system provides a racking strength of greater than 440 plf. In preferred embodiments, the disclosed coating system provides a racking strength of greater than 475 plf. In additional preferred embodiments, the disclosed coating system has a racking strength of greater than 700 plf. A 1 / 16-inch PC / XPS 3-ply panel has an average racking strength maximum force of 760 plf using the ASTM E72 method and 805 plf using the ASTM E564 method. The 1 / 32-inch PC / XPS 3-ply panel has an average lacquering strength peak force of 780 plf using ASTM E72. The 1 / 8-inch PC / XPS 2-ply panel has an average lacquering strength peak force of 795 plf using ASTM E72 method and 790 plf using ASTM E564 method. In comparison, each of the industry standard products exhibits significantly lower lacquering strength peak forces, demonstrating the superior lacquering performance of the present embodiment. OSB has an average lacquering strength peak force of 680 plf using ASTM E72 method and 645 plf using ASTM E564 method. Product 1 has an average lacquering strength peak force of 490 plf using ASTM E72 method and 600 plf using ASTM E564 method. Product 2 has an average lacquering strength peak force of 610 plf, and Product 3 has an average lacquering strength peak force of 400 plf using ASTM E72 method.

[0070] FIG. 11D provides data illustrating the weight of a 4-foot by 8-foot panel for each coating system tested. FIG. 11E illustrates the thickness and corresponding R-value of the disclosed coating system compared to industry standards or prior coating systems. The disclosed coating system has a weight of 5 pounds to 40 pounds, with a preferred weight of 10 pounds to 30 pounds. Further, the disclosed coating system has a thickness of 0.5 inches to 1.5 inches, with a preferred thickness of 0.8 inches to 1.06 inches. Additionally, the disclosed coating system has an R-value of 2 to 9, with a preferred R-value of 3.5 to 6. As illustrated, a 1 / 16-inch PC / XPS 3-ply R5 panel has a weight of 30 pounds and a thickness of 7 / 8 inches. Further, a 1 / 32-inch PC / XPS 3-ply R5 panel has a weight of 20 pounds and a thickness of 13 / 16 inches. Additionally, a 1 / 8-inch PC / XPS 2-ply R5 panel has a weight of 30 pounds and a thickness of 7 / 8 inches. OSB has a weight of 52 pounds and a thickness of 7 / 16 inches, Product 1 has a weight of 23 pounds and a thickness of 1 7 / 16 inches, Product 2 has a weight of 60 pounds and a thickness of 1 inch, and Product 3 has a weight of 62 pounds and a thickness of 1.5 inches. As is evident from FIGS. 11D and 11E, embodiments of the present disclosure are lighter per thickness than currently available standard products while still maintaining higher racking performance (see, e.g., FIGS. 11B-11C).

[0071] 11E and 11F provide data regarding the R-value of the disclosed coating systems compared to industry standard or prior coating systems. For each of the polycarbonate coating systems, the total thickness is less than 1 inch and the R-value is 5 or greater. A 1 / 16 inch PC / XPS 3-ply R5 panel has an R-value of 5 and an R-value / lb / in of 0.2. A 1 / 32 inch PC / XPS 3-ply R5 panel has an R-value of 5 and an R-value / lb / in of 0.32. A 1 / 8 inch PC / XPS 2-ply R5 panel has an R-value of 5 and an R-value / lb / in of 0.2. In contrast, OSB has an R-value of 0 and an R-value / lb / in of 0, Product 1 has an R-value of 6 and an R-value / lb / in of 0.24, Product 2 has an R-value of 3 and an R-value / lb / in of 0.05, and Product 3 has an R-value of 6 and an R-value / lb / in of 0.07. As shown, the covering system of the present disclosure has a higher R-value / lb / in than the industry standard covering system while maintaining racking performance. Product 1 has a comparable R-value / lb / in but significantly poorer racking performance. Thus, embodiments of the present covering system are superior to current industry standard products.

[0072] As shown in Figure 11G, the fire performance of the coating system of the present disclosure compared to industry standards or prior coating systems is shown. ASTM E84 was a test method used to evaluate the fire and smoke performance of building materials, specifically for interior wall and ceiling finishes. The E84 test, also known as the "Standard Test Method for Surface Burning Characteristics of Building Materials," is commonly used to evaluate how materials behave when exposed to flame and how they contribute to smoke generation and spread. The coating system of the present disclosure has a fire rating of 0 to 150, with a preferred fire rating being less than 20. For example, a PC / XPS 3-ply panel has a flame E84 of 0. A 3-ply 1 / 8-inch panel has a flame E84 of 10. In contrast, OSB has a flame E84 of 150. Product 1 has a flame E84 of 75. Product 2 exhibited a flame E84 of 60, and Product 3 exhibited a flame E84 of 60. The flame performance of the embodiments described herein exceeds that of industry standard products.

[0073] Moving from FIG. 12A to FIG. 12D, the depicted data show a three-layer coating system in which the thermal insulation layer comprises polyethylene terephthalate (PET) and the first and second structural layers each comprise polycarbonate (PC). FIG. 12A depicts the results of a nail pull test according to ASTM D1037, as previously described. As shown, the coating system of the present disclosure has a nail pull force of 20 pounds to 200 pounds. Additionally, the coating system of the present disclosure has a preferred nail pull force of 50 pounds to 200 pounds. In contrast, the industry standard coating system exhibited a nail pull force of approximately 60 pounds. Thus, the coating system of the present disclosure has superior nail pull performance to industry standard or prior coating systems. For example, as illustrated, a 1 / 32-inch PC / PET three-layer R4 coating system has an average nail pull force of 80 pounds. Meanwhile, OSB, Product 1, Product 2, and Product 3 all exhibit nail pulls of approximately 60 pounds.

[0074] The data shown in FIG. 12B corresponds to the weight of a 4-foot by 8-foot covering system tested. FIG. 12C shows the thickness and corresponding R-value of the three-layer covering system compared to industry standard or prior covering systems. FIG. 12D shows the R-value per inch of the disclosed three-layer covering system compared to industry standard or prior covering systems. As illustrated, the disclosed covering system can have a weight of 5 pounds to 40 pounds, with a preferred weight of 10 pounds to 30 pounds. Furthermore, the disclosed covering system provides a thickness of 0.5 inches to 1.5 inches, with a preferred thickness of 0.8 inches to 1.06 inches. Additionally, the disclosed covering system provides an R-value of 2 to 9, with a preferred R-value of 3.5 to 6. In contrast, the significantly heavier (62 pounds) prior product 2 with a 1-inch thickness provides an R-value of 3. As can be seen, the illustrated embodiment is lighter per thickness than available industry standard products while providing a high R-value while maintaining racking performance. Product 1 has a comparable R-value / lb / in but significantly poorer racking performance. Therefore, this embodiment is still far superior to the industry standard product.

[0075] Continuing with reference to FIGS. 13A-13D, the depicted data show a three-layer coating system in which the thermal insulation layer comprises polyurethane (PU) and the first and second structural layers each comprise polycarbonate (PC). As shown, the coating system has a nail pull force of 20 lbs to 200 lbs. Additionally, the coating system has a preferred nail pull force of 50 lbs to 200 lbs. FIG. 13A depicts the results of nail pull tests according to ASTM D1037, as described above. The 1 / 32-inch PC / PU 3-ply R5 panel has an average nail pull force of 58 lbs. The 1 / 32-inch PC / PET 3-ply R5 has a thickness of 13 / 16 inches, therefore the system has a required average nail pull force of 71 lbs / inch. 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 / in and Product 3 has an average nail pull force of 60 lbs / in.

[0076] The results shown in Figure 13B correspond to the weight of the 4 ft x 8 ft coating system tested. Figure 13C shows the thickness and corresponding R-value of the three-layer coating system compared to industry standard or prior coating systems. Figure 13D shows the R-value per inch of the disclosed three-layer coating system compared to industry standard or prior coating systems. As illustrated, the three-layer coating system has a weight of 20 lbs, a thickness of 13 / 16 inches, an R-value of 5, and an R-value / lb / inch of 0.32. In comparison, OSB has a weight of 52 lbs, a thickness of 7 / 16 inches, an R-value of 0, and an R-value / lb / inch of 0. Product 1 has a weight of 23 lbs, a thickness of 17 / 16 inches, an R-value of 6, and an R-value / lb / inch of 0.24. Product 2 has a weight of 60 lbs, a thickness of 1 inch, an R-value of 3, and an R-value / lb / inch of 0.05. Product 3 has a weight of 62 lbs, a thickness of 1.5 inches, an R-value of 6, and an R-value / lb / in of 0.07. This embodiment shown has a higher R-value / lb / in than the other covering systems while maintaining racking performance. Product 1 has a comparable R-value / lb / in but significantly less racking performance. Therefore, this embodiment is far superior.

[0077] It will be understood that certain features and subcombinations are of utility and can be employed without reference to other features and subcombinations, which are contemplated by and within the scope of the claims.

[0078] Although specific elements and steps are discussed in relation to one another, it is understood that any element and / or step provided herein is contemplated as being combinable with any other element and / or step, notwithstanding their express definition, while still being within the scope provided herein. Because many possible embodiments can be made from the present disclosure without departing from the scope of the present disclosure, it is to be understood that all matter set forth herein or shown in the accompanying drawings should be interpreted as illustrative and not in a limiting sense.

Claims

1. 1. A covering system for externally enveloping at least a portion of an architectural structure, the covering system comprising: a first structural layer having a first surface and a second surface opposite the first surface; an insulating layer having a third surface and a fourth surface opposite the third surface, the third surface of the insulating layer being at least partially secured to the second surface of the first structural layer; and a 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 1.5 inches or less; and the covering system has an R-value of at least 3.

5.

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

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

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

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

6. 10. The covering system of claim 1, wherein the insulating layer comprises any one or more of extruded polystyrene, expanded polystyrene, expanded polyurethane, polyisocyanurate, mineral wool, polyethylene terephthalate, polyester, phenolic foam, aerogel blanket, aerogel board, and polyurethane.

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

8. The coating system of claim 1 , wherein the coating system has a racking capacity of greater than 440 plf.

9. 10. The coating 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 1.5 inches or less, and the coating system has an R-value of at least 4.

5.

10. 10. The coating 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 1 inch or less, and the coating system has an R-value of at least 3.

5.

11. 10. The coating 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 1 inch or less, and the coating system has an R-value of at least 4.

5.

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

13. 13. The coating 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 1.5 inches or less, and the coating system has an R-value of at least 4.

5.

14. 1. A covering system for externally enveloping at least a portion of an architectural structure, prior to fixation to the architectural structure, the covering system comprising: a structural layer having a first surface and a second surface opposite the first surface; and an insulating layer having a third surface and an opposite fourth surface, the third surface of the insulating layer being at least partially fixed to the second surface of the structural layer, the covering system having a first distance from the first surface of the structural layer to the opposite fourth surface of the insulating layer of 1.5 inches or less, and the covering system having an R-value of at least 3.

5.

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

17. 15. The covering system of claim 14, wherein the insulating layer comprises any one or more of extruded polystyrene, expanded polystyrene, expanded polyurethane, polyisocyanurate, mineral wool, polyethylene terephthalate, polyester, phenolic foam, aerogel blanket, aerogel board, and polyurethane.

18. 15. The coating system of claim 14, wherein the coating system has a racking capacity of greater than 440 plf.

19. 10. The coating system of claim 1, wherein the distance from the first surface of the structural layer to the opposing fourth surface of the thermal insulation layer is 1.5 inches or less, and the coating system has an R-value of at least 4.

5.

20. 10. The coating system of claim 1, wherein the distance from the first surface of the structural layer to the opposing fourth surface of the thermal insulation layer is 1 inch or less, and the coating system has an R-value of at least 3.

5.

21. 10. The coating system of claim 1, wherein the distance from the first surface of the structural layer to the opposing fourth surface of the thermal insulation layer is 1 inch or less, and the coating system has an R-value of at least 4.

5.

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

23. 23. The coating system of claim 22, wherein the distance from the first surface of the structural layer to the opposing fourth surface of the thermal insulation layer is 1.5 inches or less, and the coating system has an R-value of at least 4.5.

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