Weather Resistant Air Barriers

Abstract

A weather resistant barrier panel includes a panel having a first side and a second side and a barrier layer. When in an installed position on a structure, the first side of the panel faces outward with respect to the structure to which the weather resistant barrier panel is coupled to. The barrier layer includes a carrier coupled to a polywoven layer. The carrier of the barrier layer is coupled to the first side of the panel so that the polywoven layer faces outward with respect to the structure. A method for manufacturing a weather resistant barrier panel includes the steps of adhering together the carrier and the polywoven layer to form the barrier layer and adhering the barrier layer to a structural wood based panel using a polyvinyl acetate adhesive mixed with an acrylic additive to form a water resistant bond. The polywoven layer may be a metalized polywoven.

Description

RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application 63 / 708,659 filed on 10 / 17 / 2024, entitled “WEATHER RESISTANT AIR BARRIER,” which is incorporated herein by reference for all purposes.TECHNICAL FIELD

[0002] This application is directed, in general, to weather resistant air barriers and more specifically to structural wood based weather and air resistant barriers and panels for construction of structures.BACKGROUND

[0003] The following discussion of the background is intended to facilitate an understanding of the present disclosure only. It should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was part of the common general knowledge at the priority date of the application.

[0004] Weather resistant barriers have been used in housing for many decades. Weather resistant barriers are used as wall coverings or components of wall covering assemblies in structures to prevent or reduce entry of air or moisture into a structure from an exterior of the structure. The weather resistant barrier may reduce cooling or heating loads of the structure by preventing or reducing air flow between an interior and the exterior of the structure. Weather resistant barriers also prevent or reduce damage caused by water or moisture entry in the structure by preventing or reducing water entry into the structure from the exterior of the structure. While weather resistant barriers have been used, improvements remain desirable.SUMMARY

[0005] According to an illustrative embodiment, a weather resistant barrier panel includes a panel having a first side and a second side and a barrier layer. When in an installed position on a structure, the first side of the panel faces outward with respect to the structure to which the weather resistant barrier panel is coupled to. The carrier of the barrier layer is coupled to the first side of the panel so that the polywoven layer faces outward with respect to the structure to which the weather resistant barrier panel is coupled to when in the installed position.

[0006] In another embodiment, a structural panel includes a wood-based panel having an exterior-facing surface and an interior-facing surface, a carrier layer laminated to the exterior-facing surface of the wood-based panel with a water resistant poly vinyl acetate resin mixed with an acrylic additive, and a polywoven layer laminated to the carrier layer. In some embodiments, the carrier layer is kraft paper. The polywoven layer includes woven synthetic polymer fibers selected from a group consisting of polypropylene fibers, polyester fibers, and combinations thereof. The polywoven layer forms an outermost surface of the structural panel on an exterior-facing side of the structural panel and has an emissivity less than 0.1 when measured from the exterior-facing side of the structural panel.

[0007] In yet another embodiment, a method of applying a weather resistant barrier to a structure includes the steps of coupling a plurality of weather resistant barrier panels to framing members of the structure to form a wall covering, coupling abutting weather resistant barriers panels by applying a tape over a gap between adjacent weather resistant barrier panels to reduce air flow through the gap between adjacent weather resistant barrier panels. Each of the plurality of weather resistant barrier panels abuts another weather resistant barrier panel of the plurality of weather resistant barrier panels. Each weather resistant barrier panel includes a panel having a first side and a second side and a barrier layer. In an installed position the first side of the panel faces outward with respect to the structure to which the weather resistant barrier panel is coupled to. The barrier layer includes a carrier coupled to a polywoven layer. The carrier of the barrier layer is coupled to the first side of the panel so that the polywoven layer faces outward with respect to the structure to which the weather resistant barrier panel is coupled to.

[0008] Other embodiments are disclosed.DESCRIPTION OF THE DRAWINGS

[0009] Illustrative embodiments of the present disclosure are described in detail below with reference to the attached drawing figures, which are incorporated by reference herein and wherein:

[0010] FIG. 1 is a schematic, perspective view of a structure, with a portion shown as a cut away, having a plurality of weather resistant barrier panels according to an illustrative embodiment;

[0011] FIG. 2 is schematic, perspective view of a weather resistant barrier panel according to an illustrative embodiment;

[0012] FIG. 3 is schematic, detailed edge view of a portion of a weather resistant barrier panel according to an illustrative embodiment;

[0013] FIG. 4 is a schematic, elevation view of a portion of wall of a structure having a weather resistant barrier panel according to an illustrative embodiment;

[0014] FIG. 5 is a flowchart illustrating an illustrative method of manufacturing weather resistant barrier panels; and

[0015] FIG. 6 is a flowchart illustrating an illustrative method of applying weather resistant barrier panels to a structure according to an illustrative embodiment.DETAILED DESCRIPTION

[0016] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is understood that other embodiments may be utilized, and that logical structural, mechanical, electrical, and chemical changes may be made without departing from the spirit or scope of the disclosure. To avoid detail not necessary to enable those skilled in the art to practice the disclosure, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present disclosure is defined only by the claims. Unless otherwise indicated, as used throughout this document, “or” does not require mutual exclusivity.

[0017] Referring now to the figures and initially to FIG. 1, a plurality of weather resistant barrier panels 100 are shown installed on a structure 104. Each of the weather resistant barrier panels 100 are coupled on an exterior side 106 of the structure 104. As shown in cutaway section 108, a plurality of framing members 112 form a structural component of the structure 104. In addition, the plurality of framing members 112 provide a point of attachment of the weather resistant barrier panels 100 to the exterior 106 of the structure 104. The weather resistant barrier panels 100 may be coupled to the exterior 106 of the structure 104 or to the framing members 112 by nails, screws, adhesives, and other methods known in the art.

[0018] It should be understood that coupling the panels 100 to the framing members 112 is illustrative, and the panels 100 may be attached to various structural elements depending on the specific construction requirements and building design. In the alternative, the weather resistant barrier panels may be coupled to the exterior 106 of the structure by coupling the weather resistant barrier panels 100 to other members of the structure 104, such as other sheathing products, intermediate wall covering products, or other structural components of the structure 104 other than framing members 112.

[0019] In the alternative, while the weather resistant barrier panels 100 are shown in the figures as forming the outermost layer of the structure 104, it should be understood that the panels 100 may be covered with additional exterior components such as siding, brick veneer, stucco, or other architectural finishes. In such installations, the weather resistant barrier panels 100 function as an intermediate weather barrier layer that provides air and moisture resistance behind the final exterior cladding system of the structure 104.

[0020] As shown in FIG. 1, when attached to the exterior 106 of the structure 104, the plurality of weather resistant barrier panels 100 are arranged so that each of the weather resistant barrier panels 100 abuts one or more other weather resistant barrier panel 100. In this manner, the array of the plurality of weather resistant barrier panels 100, when attached to the structure 104, form a complete barrier on the exterior 106 of the structure 104.

[0021] The weather resistant barrier panels 100 may be installed in various configurations depending on the specific requirements of the structure 104. Alternatively, the panels 100 may be installed in a butt-joint configuration where adjacent panels 100 abut directly against each other without overlap.

[0022] In some embodiments, the panels 100 may be installed in an overlapping configuration where adjacent panels 100 overlap by a predetermined distance, typically ranging from 1 to 6 inches, to provide enhanced weather sealing and redundant protection against air and moisture infiltration.

[0023] Alternative assembly configurations may include interlocking panel systems where the weather resistant barrier panels 100 are manufactured with complementary edge profiles, such as tongue-and-groove configurations, stepped edges, or rabbet joints, that facilitate precise alignment and enhanced sealing between adjacent panels 100. In some embodiments, the interlocking edges may incorporate gaskets, sealants, or compressible materials that create additional sealing when the panels 100 are joined together.

[0024] The installation pattern of the weather resistant barrier panels 100 may also be varied to accommodate different structural designs. For example, the panels 100 may be installed in a running bond pattern, similar to brick laying, where the vertical joints of adjacent rows are offset. In other embodiments, the panels 100 may be installed in a stack bond pattern where the vertical. The choice of installation pattern may depend on factors such as the skill level of the installation crew, local building codes, and specific performance requirements for the structure 104.

[0025] The weather resistant barrier panels 100 may also be adapted for use on different types of structures beyond residential construction. For example, the panels 100 may be suitable for commercial buildings, agricultural structures, or industrial facilities where weather resistance and energy efficiency are important considerations. The modular nature of the panels 100 allows for scalability to accommodate structures of various sizes and configurations. Additionally, the panels 100 may be manufactured in custom sizes or shapes to accommodate unique architectural features or structural requirements.

[0026] The weather resistant barrier panels 100 may be applied to various surfaces of a structure 104 beyond vertical walls. For example, the panels 100 may be installed on roof decking or sheathing to provide weather resistance for roof assemblies, where they may function as an underlayment beneath roofing materials such as shingles, metal roofing, or tiles. The panels 100 may also be suitable for installation on other structural surfaces such as foundation walls, crawl space enclosures, or attic floors, where air and moisture control are important for energy efficiency and structural protection.

[0027] Referring now primarily to FIGS. 2 and 3, which illustrate the detailed construction and layered assembly of the weather resistant barrier panels 100. FIG. 2 shows a perspective view of an illustrative embodiment of a weather resistant barrier panel 100. FIG. 3 shows a partial edge view of a weather resistant barrier panel 100.

[0028] The weather resistant barrier panel 100 includes a panel 116 having a first side 120 and a second side 124. As used herein designation of a first side and a second side is arbitrary and is provided for orientation as shown in the figures. In an installed position, as shown in FIG. 1, the first side 120 faces outward, away from the interior of the structure 104, and the second side 124 faces inward, toward the interior of the structure 104. An inner most surface 117 of the panel 100 is coincident with the second side 124 of the panel 116, and when installed, faces the interior of the structure 104.

[0029] The panel 116 may be a United States Department of Commerce Performance Standard-2 structural wood-based panel, such as veneered plywood, oriented strand board or other cross laminated structural wood panel.

[0030] A thickness 141 of the panel 116 may be in the range of 1.5" to 0.25". In some embodiments, the thickness 141 of the panel 116 is in the range of 3 / 8" to 23 / 32". In some embodiments the thickness 141 of the panel 116 is about 0.75".

[0031] In some embodiments, a length 131 of the panel 116 may be in the range of 8 to 12 feet. In some embodiments, the length 131 of the panel 116 is about 8 feet. In some embodiments, a width 133 of the panel 116 is in the range of 3 to 8 feet. In some embodiments, the width 133 of the panel 116 is about 4 feet. Other dimensions may be used as those skilled in the art will appreciate.

[0032] A barrier layer 128 is coupled or laminated to the first side 120 of the panel 116 and covers the face of the first side 120 of the panel 116. The barrier layer 128 is formed from a polywoven layer 132 and a carrier 136 (FIG. 3). The carrier 136 is coupled, on a second side 137, to the first side 120 of the panel 116. A first side 135 of the carrier 136 is coupled to a second side 129 of the polywoven layer 132. In this manner, when the panel 100 is installed on the structure 104, the polywoven layer 132 is the exterior layer of the weather resistant barrier panel 100, and the first side 127 of the polywoven layer 132 faces outward from the interior of the structure 104 when in an installed position. When the weather resistant barrier panel 100 is coupled to the structure 104, the polywoven layer 132 is the most outward facing (facing away from the interior of the structure 104) component of the weather resistant barrier panel 100.

[0033] The polywoven layer 132 is, generally, a layer formed from polymeric or plastic fibers, threads, or strands, which are woven into a sheet or fabric form. The polywoven layer 132 may be made from one or more plastic or polymeric materials such as polypropylenes, polyesters (such as PET), and other plastics and polymers, and combinations of polypropylenes, polyesters, or other plastics and polymers.

[0034] The polywoven layer 132 may be a woven fabric material constructed from synthetic polymer fibers or filaments. The polywoven material may be formed by interlacing polymer strands, threads, or tapes in a traditional weaving pattern, typically with warp and weft directions, to form a flexible sheet or fabric structure. This weaving process creates a material that combines the strength and durability of synthetic polymers with the flexibility and breathability characteristics of woven textiles.

[0035] The polywoven construction allows for controlled porosity, where the spacing between the woven fibers can be engineered to provide specific air permeability and moisture vapor transmission rates while maintaining resistance to liquid water penetration. The woven structure also provides enhanced tear resistance and dimensional stability compared to non-woven synthetic materials, making it particularly suitable for construction applications where the material may be subjected to mechanical stress during installation and service life.

[0036] In some embodiments, the polywoven is a metalized polywoven, which is a polywoven material with a metallic component added.

[0037] Metalized polywoven is a specialized variant of polywoven material that incorporates a thin metallic layer or coating applied to at least some of the polymer fibers or fabric surface. The metallization process typically involves vacuum deposition, sputtering, or lamination of metals such as aluminum, silver, or other reflective metals onto the polywoven substrate. This metallic component significantly enhances the material's reflective properties and thermal performance characteristics. The metalized surface creates a radiant barrier effect that reflects infrared radiation and heat energy, rather than absorbing it like conventional non-metalized materials. The metallization can be applied as a continuous coating across the entire surface or as discrete metallic elements integrated into the weave pattern. The thickness of the metallic layer is typically formed to provide the desired reflective properties while maintaining the flexibility and durability of the underlying polywoven structure. The metalized polywoven retains the beneficial characteristics of standard polywoven materials, including tear resistance, dimensional stability, and controlled permeability, while adding enhanced thermal management capabilities that are particularly valuable in building envelope applications.

[0038] Utilizing metallized polywoven material may greatly decrease the emissivity of the completed weather resistant barrier panel 100. Emissivity is a material property that measures how effectively a surface emits thermal radiation compared to a perfect black body radiator. It is expressed as a value between 0 and 1, where 0 represents a perfect reflector that emits no thermal radiation, and 1 represents a perfect black body that emits the maximum possible thermal radiation at a given temperature. Materials with high emissivity values efficiently radiate heat energy away from their surface, while materials with low emissivity values tend to reflect thermal radiation rather than emit it. In building applications, controlling emissivity is important for thermal management, as surfaces with low emissivity can reflect radiant heat and reduce heat transfer, while surfaces with high emissivity can effectively dissipate heat through radiation.

[0039] Decreasing the emissivity of the weather resistant barrier panel 100 by inclusion of a metalized polywoven layer 132 improves the weather resistant barrier panel's 100 ability to reflect thermal and other energies away from the structure 104. In some embodiments using the metalized polywoven, the metalized polywoven is painted or otherwise coated to change the emissivity of the weather resistant barrier panel 100.

[0040] In some embodiments, the emissivity of the weather resistant barrier panel 100 is adjusted to be within required limits of building codes or other building standards. For example, the International Energy Conservation Code (IECC) and ASHRAE Standard 90.1 specify emissivity requirements for radiant barrier materials, typically requiring emissivity values of 0.1 or less for low-emissivity surfaces and 0.9 or higher for high-emissivity surfaces. The Federal Trade Commission's R-Value Rule also establishes guidelines for reflective insulation products that incorporate emissivity considerations. Additionally, ASTM C1371 provides standard test methods for determining emissivity of materials at room temperature, while ASTM E408 covers total normal emittance of surfaces using inspection-meter techniques.

[0041] In some embodiments, the emissivity of the weather resistant barrier panel 100, when measured from the polywoven side (i.e. the outer most exterior surface of the panel 100 when installed on the structure), is in the range of 0.01 – 0.2. In some embodiments, the emissivity of the weather resistant barrier panel 100, when measured from the polywoven side, is in the range of 0.01 - 0.1. In some embodiments, the emissivity of the weather resistant barrier panel 100, when measured from the polywoven side, is in the range of 0.01-0.05. In some embodiments, the emissivity of the weather resistant barrier panel 100, when measured from the polywoven side, is less than 0.2. In some embodiments, the emissivity of the weather resistant barrier panel 100, when measured from the polywoven side, is less than 0.1.

[0042] The weather resistant barrier panel 100 may be configured to achieve emissivity values within these standardized ranges, such as maintaining low emissivity (0.05 to 0.1) when using metalized polywoven materials for enhanced radiant heat reflection, or achieving higher emissivity values (0.8 to 0.95) when thermal radiation dissipation is desired. The specific emissivity characteristics can be tailored through selection of polywoven materials, metallic coatings, and surface treatments to meet the requirements of applicable building codes, energy standards, and performance specifications for the intended application and climate zone.

[0043] The emissivity characteristics of the weather resistant barrier panel 100 may be verified through standardized testing methods to ensure compliance with building codes and performance specifications. Emissivity testing is typically conducted using ASTM C1371, which provides the standard test method for determining emittance of materials at room temperature using portable emissometers. This test method involves placing a calibrated emissometer directly on the surface of the polywoven layer 132 to measure the emissivity value at ambient temperature conditions. The emissometer uses infrared sensors to compare the thermal radiation emitted by the test surface against a reference black body standard, providing emissivity readings with accuracy typically within ±0.02 units.

[0044] The nature and type of plastic or polymer used to make the polywoven layer 132 can be varied to vary the properties of the weather resistant barrier panels 100. For example, the use of polypropylenes or polyesters results in a water resistant barrier because of the inherent hydrophobic (water-repelling) properties of these synthetic polymer materials. Polypropylene exhibits excellent chemical resistance to water and moisture due to its non-polar molecular structure, which prevents water molecules from bonding to or penetrating through the material. Similarly, polyester materials, particularly polyethylene terephthalate (PET), demonstrate superior moisture resistance due to their crystalline molecular structure and low water absorption rates, typically less than 0.1% by weight. These materials maintain their structural integrity and barrier properties even when exposed to high humidity conditions or direct water contact over extended periods. Additionally, both polypropylene and polyester fibers can be manufactured with specific surface treatments or additives that further enhance their water-repelling characteristics, such as fluoropolymer coatings or silicone-based treatments that create an even more hydrophobic surface.

[0045] The woven construction of these materials also contributes to water resistance by creating a fabric structure where water droplets are too large to pass through the interstices between the fibers, while still allowing vapor permeability for moisture management within the building envelope. In addition, the properties of the polywoven layer 132 may be varied by varying the types and sizes of plastic fibers used to manufacture the polywoven layer 132. For example, small or larger diameter or width fibers or threads may be used to vary the amount of air or water penetration through the polywoven layer 132 or tighter or looser weaves may have the same effects. In addition, the polywoven layer 132 or the starting material for manufacturing the polywoven layer 132 may include additives to alter the physical and chemical properties of the polywoven layer 132.

[0046] In some embodiments, the polywoven layer 132 may be manufactured with specific weave characteristics tailored to optimize performance for particular applications. For example, the polywoven layer 132 may utilize a plain weave construction where each warp fiber passes alternately over and under each weft fiber, creating a balanced and uniform fabric structure with consistent porosity and strength characteristics. This plain weave configuration provides predictable air permeability rates and uniform moisture vapor transmission across the entire surface area of the weather resistant barrier panel 100. In other embodiments, the polywoven layer 132 may employ a twill weave pattern where the warp fibers pass over multiple weft fibers in a diagonal pattern, creating a fabric with enhanced drape characteristics and improved conformability to irregular surface contours during installation.

[0047] The thread count and fiber spacing of the polywoven layer 132 may be specifically engineered to achieve desired performance characteristics. In some embodiments, the polywoven layer 132 may have a thread count ranging from 8 to 20 threads per inch in both the warp and weft directions, providing a balance between structural integrity and controlled permeability. Higher thread counts, such as 16 to 20 threads per inch, may be utilized when enhanced tear resistance and reduced air permeability are desired, while lower thread counts, such as 8 to 12 threads per inch, may be employed when increased breathability and moisture vapor transmission are prioritized. The fiber denier, which measures the linear mass density of the individual polymer fibers, may range from 200 to 1000 denier, with heavier denier fibers providing increased strength and durability, while lighter denier fibers offer improved flexibility and conformability.

[0048] In some embodiments, the polywoven layer 132 may incorporate a basket weave construction where multiple warp and weft fibers are grouped together and woven as single units, creating larger openings in the fabric structure while maintaining overall strength. This basket weave configuration may be particularly beneficial for applications requiring enhanced vapor permeability while still providing adequate resistance to liquid water penetration. The polywoven layer 132 may also utilize specialized weave patterns such as leno weave, where pairs of warp fibers are twisted around the weft fibers to create a more open fabric structure with improved dimensional stability and reduced tendency for fiber slippage during handling and installation.

[0049] The color of the polywoven layer 132 may also be varied to affect the reflectivity, emissivity, or general heat retention properties of the polywoven layer 132. For example, a white polywoven layer 132 will reflect more heat and energy than a black polywoven layer 132, which is more likely to absorb energy and increase in temperature as a result, as compared to the white polywoven layer 132. In this manner the overall heat retention properties of the weather resistant barrier panels 100 may be varied by varying the color of the polywoven layer 132.

[0050] The polywoven layer 132 may also be manufactured in intermediate colors such as gray, tan, brown, or green to provide balanced thermal characteristics while meeting specific architectural or aesthetic requirements.

[0051] In some embodiments, the polywoven layer 132 may incorporate combinations of the various characteristics described above to optimize performance for specific applications. For example, a single weather resistant barrier panel 100 may utilize a metalized polywoven layer 132 with white coloration to maximize both reflective properties from the metallic coating and solar reflectance from the light color, creating enhanced thermal management capabilities. Alternatively, the polywoven layer 132 may combine specific weave characteristics, such as a plain weave construction with 12-16 threads per inch, using polypropylene fibers in a gray color to provide balanced performance characteristics suitable for moderate climate applications. The polywoven layer 132 may also integrate non-metalized polyester fibers in a basket weave pattern with earth-tone coloration for applications where aesthetic integration with natural surroundings is important while maintaining adequate weather resistance properties. These combinations allow for customization of the weather resistant barrier panel 100 to meet diverse performance requirements, climate conditions, and architectural specifications. The flexibility to mix and match polymer materials, weave patterns, thread counts, metallization options, and color selections enables manufacturers to create specialized products tailored to specific market segments or unique project requirements while maintaining the fundamental weather resistance and structural integrity characteristics of the barrier system.

[0052] In one embodiment the carrier 136 is kraft paper. The carrier 136 however may be any suitable material that provides support for the polywoven layer 132.

[0053] The carrier 136 may be characterized by specific physical and performance properties that optimize its function as a support layer for the polywoven layer 132. In embodiments where the carrier 136 comprises kraft paper, the kraft paper may have a basis weight ranging from 20 to 60 pounds per 3000 square feet, with typical embodiments utilizing kraft paper having a basis weight of approximately 30 to 40 pounds per 3000 square feet. The kraft paper carrier 136 may have a thickness ranging from 0.002 to 0.008 inches, providing adequate structural support while maintaining flexibility for installation around irregular surfaces. The kraft paper may be manufactured from virgin wood fibers or recycled content, and may be treated with wet-strength additives to maintain integrity when exposed to moisture during manufacturing and installation processes. In some embodiments, the kraft paper carrier 136 may be calendered or supercalendered to achieve a smooth surface finish that promotes uniform adhesion with both the polywoven layer 132 and the panel 116. The kraft paper may also be treated with sizing agents or barrier coatings to control porosity and moisture absorption characteristics, ensuring consistent performance across varying environmental conditions.

[0054] In some embodiments, the carrier 136 may comprise alternative materials beyond kraft paper to provide different performance characteristics or manufacturing advantages. For example, the carrier 136 may be formed from a scrim fiber mesh, which is a lightweight, open-weave fabric typically made from fiberglass, polyester, or polypropylene fibers. The scrim mesh carrier provides enhanced dimensional stability and tear resistance while maintaining flexibility for installation around irregular surfaces. In other embodiments, the carrier 136 may comprise a non-woven synthetic fabric, such as spunbond polypropylene or polyester, which offers uniform thickness and consistent porosity characteristics. Non-woven carriers may provide improved adhesion properties due to their fibrous structure that allows adhesive penetration and mechanical bonding..

[0055] In alternative embodiments, the carrier 136 may be omitted entirely, with the polywoven layer 132 applied directly to the panel 116 using adhesive systems or mechanical bonding techniques. Direct application methods may reduce material costs and manufacturing complexity while potentially improving the overall thickness profile of the weather resistant barrier panel 100. When the carrier 136 is omitted, the polywoven layer 132 may be manufactured with enhanced structural properties, such as increased fiber density or specialized surface treatments, to provide adequate support and adhesion characteristics without the intermediate carrier layer. The selection of carrier material or the decision to omit the carrier 136 may depend on factors such as manufacturing capabilities, cost considerations, performance requirements, and compatibility with the chosen polywoven layer 132 and adhesive system.

[0056] In some embodiments, the barrier layer 128 is adhered to the panel 116 with a water resistant poly vinyl acetate resin mixed with an acrylic additive. This adhesive specifically addresses potential issues with weather and air resistant products to consistently pass building codes requirements. Previously used resins were not water resistant, and ambient moisture could deteriorate the bond and performance of the weather resistant barriers. The water resistant poly vinyl acetate resin with an acrylic additive adhesive formulation creates a non-permeable glue line between the barrier layer 128 and the panel 116. This formulation may create enough heat from the friction of a pneumatic mechanical fastener, that the adhesive formulation may bind to the mechanical fastener and create a better air and moisture barrier at the structural mechanical fastening point.

[0057] Poly vinyl acetate (PVA) resin is a synthetic polymer adhesive commonly known as white glue or school glue in its basic form. In construction applications, PVA resin adhesives are formulated as water-based emulsions that cure through water evaporation and coalescence of polymer particles. The water-resistant poly vinyl acetate resin with acrylic additive used in this application represents an advanced formulation specifically engineered for exterior building applications. The acrylic additive enhances the adhesive's water resistance, UV stability, and flexibility compared to standard PVA formulations. This modified PVA resin creates strong bonds with both wood substrates and synthetic materials while maintaining flexibility to accommodate thermal expansion and contraction. The adhesive cures at room temperature without requiring heat activation, making it suitable for cold-process manufacturing methods. When cured, the adhesive forms a clear, flexible bond line that resists moisture penetration and maintains adhesion strength under varying environmental conditions, which is critical for weather barrier applications where long-term durability and weather resistance are essential.

[0058] The acrylic additive incorporated into the water-resistant poly vinyl acetate resin may serve multiple functions that enhance the adhesive's performance for exterior building applications. The acrylic additive typically comprises acrylic polymer emulsions or acrylic copolymers that are blended with the base PVA resin during formulation. These acrylic components may include methyl methacrylate, ethyl acrylate, butyl acrylate, or acrylic acid derivatives that are specifically selected to improve water resistance, flexibility, and durability characteristics of the base PVA adhesive system.

[0059] In some embodiments, the acrylic additive may comprise styrene-acrylic copolymers that provide enhanced water resistance by creating a more hydrophobic polymer matrix when the adhesive cures.. The typical concentration of acrylic additive in the PVA resin formulation may range from 2% to 40% by weight. In some embodiments, the acrylic additive concentration is in the range of 2% to 10% by weight, as compared to the PVA resin. The acrylic additive may be incorporated as a pre-formed emulsion that is blended with the PVA resin, or it may be polymerized in-situ during the adhesive manufacturing process to create a more intimate blend of the polymer components.

[0060] In some embodiments, the acrylic additive may be formulated with specific functional groups that enhance adhesion to both wood substrates and synthetic materials. For example, the acrylic additive may include carboxyl groups (-COOH) or hydroxyl groups (-OH) that can form hydrogen bonds with cellulose fibers in wood, while also providing compatibility with the polywoven layer 132 materials. The acrylic additive may also incorporate silane coupling agents or titanate coupling agents that create chemical bridges between the organic polymer matrix and any inorganic fillers or substrates, further enhancing the overall bond strength and durability of the adhesive system.

[0061] The acrylic additive may also include plasticizers such as dibutyl phthalate (DBP) or dioctyl phthalate (DOP) that maintain flexibility of the cured adhesive over a wide temperature range, preventing brittle failure during thermal cycling. In cold climate applications, the acrylic additive may incorporate specialized low-temperature plasticizers such as adipate esters or citrate esters that maintain adhesive flexibility at temperatures as low as -40°F. For high-temperature applications, the acrylic additive may include heat-resistant components such as fluoroacrylate polymers or silicone-modified acrylics that maintain bond integrity at temperatures up to 200°F or higher. The specific selection and concentration of acrylic additives may be tailored to meet the performance requirements of different climate zones and building code specifications, ensuring optimal adhesive performance across diverse environmental conditions.

[0062] In alternative embodiments, the barrier layer 128 may be adhered to the panel 116 using different adhesive systems tailored to specific performance requirements or manufacturing processes. For example, the barrier layer 128 may be coupled to the panel 116 using a hot-melt adhesive system, which involves applying thermoplastic adhesive materials that are heated to a molten state during application and then solidify upon cooling to create a strong bond. Hot-melt adhesives may provide advantages in manufacturing speed and consistency, as they do not require curing time and can create immediate bonds upon cooling. The hot-melt adhesive may comprise ethylene vinyl acetate (EVA), polyamide, or polyolefin-based formulations that are specifically designed for wood-to-fabric bonding applications.

[0063] In some embodiments, the barrier layer 128 may be adhered to the panel 116 using structural acrylic adhesives that provide enhanced durability and weather resistance. Structural acrylics may offer superior bond strength and long-term performance compared to traditional PVA-based systems, particularly in applications where the weather resistant barrier panel 100 may be subjected to extreme temperature variations or high mechanical stress. The structural acrylic adhesive may be a two-component system that cures through chemical reaction, or a single-component system that cures through moisture exposure or UV radiation. These adhesive systems may provide improved resistance to creep, fatigue, and environmental degradation over extended service periods.

[0064] In some embodiments, the carrier 136 and the polywoven layer 132 are coupled together using a lamination process to form the barrier layer 128. In some embodiments, the barrier layer 128 is attached to the panel 116 through a cold process via a nip roller application, involving applying a curtain coat layer of poly vinyl acetate resin with the purpose of adhering the barrier layer 128 to the panel 116.

[0065] The lamination process for coupling the carrier 136 and polywoven layer 132 may involve several different manufacturing techniques, each offering specific advantages for different production requirements and performance characteristics. Lamination processes may include adhesive lamination, where a liquid adhesive is applied between the carrier 136 and polywoven layer 132 before they are brought together and pressed. The adhesive lamination process may utilize water-based, solvent-based, or reactive adhesive systems, with the selection depending on the specific materials being bonded and the desired performance characteristics of the finished barrier layer 128.

[0066] A nip roller application process provides a manufacturing process that may ensure uniform adhesive distribution and consistent bonding between the barrier layer 128 and the panel 116. The nip roller system typically consists of two or more precision-machined steel or rubber-covered rollers that create a controlled pressure zone through which the panel 116 and barrier layer 128 are passed. The roller pressure, typically ranging from 50 to 500 pounds per linear inch, is carefully calibrated to ensure adequate adhesive penetration and bonding without causing delamination or damage to the polywoven layer 132. The roller speed, usually maintained between 10 to 100 feet per minute, is synchronized with the adhesive application rate to ensure consistent coating thickness and prevent adhesive starvation or excess that could compromise bond quality.

[0067] The curtain coating process for adhesive application involves creating a continuous liquid curtain of poly vinyl acetate resin that falls vertically onto the moving panel 116 surface. This coating method provides uniformity and can accommodate varying panel widths without requiring mechanical adjustments. The curtain coating system typically includes a precision-engineered coating head with adjustable slot dies that control the adhesive flow rate and curtain width. The adhesive viscosity, typically maintained between 500 to 2000 centipoise, is carefully controlled through temperature regulation and solids content adjustment to ensure proper curtain formation and stability. The coating weight, usually ranging from 8 to 25 grams per square meter, is precisely controlled through pump speed and curtain height adjustments to optimize adhesive coverage while minimizing material usage and cost.

[0068] Quality control measures during the lamination and nip roller processes may include real-time monitoring of adhesive application thickness using gauges or sensors that provide continuous feedback to maintain consistent coating weights across the panel width. Temperature monitoring systems may track the panel 116 and barrier layer 128 temperatures throughout the process to ensure optimal adhesive curing conditions. Pressure monitoring systems on the nip rollers may provide immediate feedback if roller pressure deviates from specified parameters, allowing for rapid correction before defective products are produced. Additionally, the manufacturing process may incorporate automated inspection systems using machine vision technology to detect surface defects, adhesive voids, or delamination issues in the finished weather resistant barrier panels 100. The cold process nature of the nip roller application eliminates the need for energy-intensive heating systems and reduces the risk of thermal damage to the polywoven layer 132, while the smooth exterior surface created by the process provides optimal drainage characteristics and consistent emittance properties across the entire panel surface.

[0069] The layered construction shown in FIGS. 2 and 3 demonstrates the arrangement of components that enables the weather resistant barrier panel 100 to function effectively. The cross-sectional view in FIG. 3 particularly illustrates how the barrier layer 128 maintains intimate contact with the panel 116 across the entire surface area, ensuring consistent performance without delamination or air pockets that could compromise the barrier's effectiveness. The thickness relationships between the various layers are considered in the overall performance, with the relatively thin barrier layer 128 providing maximum protection while adding minimal weight or bulk to the structural panel 116.

[0070] It should be understood that the illustrative embodiments of FIGS. 2 and 3 are not drawn to scale. Certain components of the weather resistant barrier panel 100 are shown in exaggerated relative size. Therefore, the relative dimensions, as shown in the figures, are not meant to be limiting. For example, the relative thicknesses of the panels 116, the barrier layer 128, and the carrier 136 are not intended to be limiting.

[0071] Referring now primarily to FIG. 4, a schematic, elevation view of an exterior side 152 of a portion of wall 140 of a structure having a plurality weather resistant barrier panels 100 according to an illustrative embodiment is presented. In this view, one may see that the exterior side 152 of the wall 140 is covered in the plurality of weather resistant barrier panels 100, with each weather resistant barrier panel 100 abutting at least one other weather resistant barrier panel 100, as described in relation to FIG. 1. At the point of abutment of two weather resistant barrier panels 100 a gap 144 is formed. For illustration purposes the gap 144 is not shown to scale and is shown as a dashed line.

[0072] It is desirable to seal the gap 144 to prevent air flow between the exterior 106 of the structure 104 and the interior of the structure 104 to prevent air exchange which may result in cooling or heating losses and moisture entry into the structure 104. In some embodiments, the gaps 144 are sealed using scrim tape 148. The scrim tape 148 is further sealed to the weather resistant barrier panels 100 with an acrylic resin adhesive or any of the above mentioned adhesive for binding the barrier layer 128 to the panel 116.

[0073] The combination of the scrim tape 148 covering the gaps 144 along with the adhesion and sealing of the scrim tape 148 with the acrylic resin forms a weather resistant barrier over the gaps 144. In this manner, the entire exterior 152 of the wall 140 is able to resist weather or water infiltration. Other suitable materials may be used to seal the gaps 144.

[0074] The scrim tape 148 used to seal the gaps 144 between adjacent weather resistant barrier panels 100 may comprise a specialized construction designed to provide durable and weather-resistant sealing performance. The scrim tape 148 typically consists of a reinforcing scrim layer, which is an open-weave fabric mesh, combined with adhesive layers and protective facings. The scrim layer is commonly manufactured from fiberglass, polyester, or polypropylene fibers that are woven in a grid pattern to provide dimensional stability and tear resistance. The scrim mesh typically has an open area ranging from 30% to 70%, allowing for adhesive penetration while maintaining structural integrity. The individual fibers in the scrim may have diameters ranging from 0.005 to 0.020 inches, with the weave pattern creating openings that are typically 0.125 to 0.5 inches in both directions. This construction provides conformability to irregular surfaces while preventing the tape from stretching or distorting during installation.

[0075] The scrim tape 148 may be manufactured in various widths to accommodate different sealing requirements and installation preferences. Standard widths for scrim tape 148 may include 2 inches, 3 inches, 4 inches, 6 inches, and 9 inches, with the selection depending on the size of the gaps 144 and the desired overlap onto the adjacent weather resistant barrier panels 100. Narrow tapes, such as 2-inch or 3-inch widths, may be suitable for precise sealing of tight gaps where material efficiency is important, while wider tapes, such as 6-inch or 9-inch widths, may provide enhanced sealing performance and greater tolerance for installation variations. The scrim tape 148 may also be available in custom widths ranging from 1 inch to 12 inches or more, depending on specific project requirements..

[0076] The adhesive system used with the scrim tape 148 may comprise various formulations optimized for different environmental conditions and substrate materials. In some embodiments, the scrim tape 148 may utilize a pressure-sensitive adhesive that provides immediate tack upon contact with the weather resistant barrier panels 100, allowing for repositioning during installation if necessary..

[0077] In alternative embodiments, the gaps 144 between adjacent weather resistant barrier panels 100 may be sealed using materials other than scrim tape 148 to provide effective air and moisture barriers. One alternative approach involves the use of liquid-applied sealants that are dispensed directly into the gaps 144 using specialized application equipment. These liquid sealants may comprise polyurethane, silicone, or acrylic-based formulations that cure to form flexible, weather-resistant seals.

[0078] Another alternative sealing method involves the use of pre-formed gasket strips that are installed in the gaps 144 during panel installation. These gasket strips may be manufactured from closed-cell foam materials such as EPDM rubber, neoprene, or polyethylene foam that provide excellent compression recovery and weather resistance. The gasket strips are typically sized to be slightly larger than the gap 144 width, creating a compression fit that maintains sealing pressure over time. In some embodiments, the gasket strips may incorporate adhesive backing that bonds to the adjacent panel surfaces, while in other embodiments, the gaskets may be held in place purely by compression forces. The gasket material may be selected based on temperature range requirements, with EPDM gaskets suitable for extreme temperature variations and polyethylene foam gaskets providing cost-effective sealing for moderate climate applications.

[0079] Mechanical sealing systems represent another alternative approach for sealing gaps 144 between weather resistant barrier panels 100. These systems may include metal or plastic batten strips that are fastened over the gaps 144, creating a physical barrier that prevents air and moisture infiltration. The batten strips may be manufactured from aluminum, galvanized steel, or high-density polyethylene, with the material selection depending on durability requirements and aesthetic considerations. In some embodiments, the batten strips may incorporate integral gasket channels that hold compressible sealing materials against the panel surfaces. The mechanical fastening of batten strips may utilize screws, nails, or specialized clips that engage with the underlying framing members 112, providing both sealing and additional structural connection between adjacent panels 100.

[0080] To manufacture the weather resistant barrier panel 100 according to one illustrative embodiment, the panel 116, e.g., an oriented strand board (“OSB”) or plywood panel, is formed in the usual way as those skilled in the art will appreciate. For example, in the case of OSB, wood strands are oriented in specific directions and bonded together with adhesive resins under heat and pressure to form a structural panel. In the case of plywood, thin wood veneers are layered with alternating grain directions and bonded together with adhesive under heat and pressure to create a cross-laminated structural panel. The panels 116 are typically manufactured to standard dimensions and thicknesses according to industry specifications such as those established by the Engineered Wood Association (APA) or similar standards organizations.

[0081] An adhesive or glue is applied to the first side 120 of the panel 116. Then, the barrier layer 128 (e.g., the polywoven layer 132 and carrier 136) is applied to the adhesive on the panel 116. In some embodiments, the barrier layer is adhered to the panel 116 using a nip roller. In some embodiments, the adhesive may be applied to the surface of the barrier layer 128, namely the carrier 136, and then the barrier layer 128 applied onto the first side 120 of the panel 116. In other embodiments, the barrier layer 128 may be formed in the process of forming the weather resistant barrier panel 100 by adhering the carrier 136 to the panel 116 and then adhering the polywoven layer 132 to the carrier 136. In some embodiments heat or activators are not used to activate the adhesive.

[0082] Referring now to FIG. 5, an illustrative method 500 may comprise the following steps: (502) preparing the structural wood-based panel 116, for example, by sanding or ensuring proper moisture content (typically below 19%) and surface cleanliness; (504) applying the water-resistant poly vinyl acetate resin with acrylic additive to the first side 120 of the panel 116 using curtain coating application at controlled viscosity and coating weight; (506) positioning the pre-laminated barrier layer 128, consisting of carrier 136 and polywoven layer 132, above the adhesive-coated panel 116; (508) passing the assembly through the nip roller system at controlled pressure and speed to ensure uniform bonding; (510) conducting real-time quality control monitoring including adhesive thickness measurement, pressure verification, and visual inspection for defects; (512) allowing the bonded assembly to cure under controlled environmental conditions; and (514) performing final inspection and testing to verify adhesion strength, weather resistance, and dimensional accuracy and stacking completed panels 100.

[0083] FIG. 6 is a flowchart illustrating a method 600 of applying weather resistant barrier panels 100 to a structure 104 according to an illustrative embodiment. The method 600 begins at step 602 with site preparation, including inspecting framing members 112 for proper alignment and ensuring environmental conditions are within acceptable ranges. At step 604, the first weather resistant barrier panel 100 is positioned at a predetermined starting point, such as a corner of the structure 104, with the polywoven layer 132 facing outward away from the interior of the structure 104.

[0084] The method 600 continues at step 606 with securing the first panel 100 to the framing members 112 using mechanical fasteners such as galvanized nails or screws. At step 608, subsequent weather resistant barrier panels 100 are installed in sequence, maintaining proper alignment and creating consistent gaps 144 of 1 / 8 inch to 1 / 4 inch between adjacent panels to accommodate thermal expansion. Step 610 involves quality control verification during installation, including checking fastener penetration depth, verifying proper panel alignment, and inspecting for damage to the polywoven layer 132.

[0085] Following panel installation, the method 600 proceeds to step 612 with preparation of the gaps 144 between adjacent panels by cleaning debris and loose material. At step 614, scrim tape 148 is measured, cut to appropriate lengths with 2-3 inches of overlap at joints, and applied over each gap 144, centered to overlap equally onto both adjacent panels 100. Step 614 may also involve applying pressure to the scrim tape 148 using a roller or smoothing tool to ensure complete contact and eliminate air bubbles. The method 600 concludes at step 618 with applying acrylic resin adhesive over the scrim tape 148 and adjacent panel surfaces to create a weatherproof seal, followed by final inspection and quality verification to ensure the weather resistant barrier system meets performance requirements and building code compliance.

[0086] After applying the double acrylic scrim tape, building code requirements regarding the air exchange rate per hour may be met due to the overall properties of the weather resistant barriers described herein. A calculated R value can be achieved through the airspace created between the weather resistant barrier and the finished exterior wall assembly.

[0087] The weather resistant barrier panels 100 and their installation method provide significant improvements to the thermal performance and R-value of structures through multiple mechanisms that work synergistically to enhance energy efficiency. A contribution to R-value improvement comes from the creation of a continuous air barrier system that eliminates uncontrolled air infiltration and exfiltration. When the weather resistant barrier panels 100 are properly installed with sealed gaps 144 using scrim tape 148 and acrylic resin adhesive, they create an essentially airtight building envelope that forces air exchange to occur only through controlled ventilation systems.

[0088] The polywoven layer 132, particularly when manufactured with metalized materials, contributes additional R-value through its radiant barrier properties that reflect infrared thermal radiation away from the structure 104. This radiant barrier effect can provide an equivalent R-value improvement of R-2 to R-10 depending on the specific metallization characteristics, installation orientation, and climate conditions.

[0089] Although the present disclosure and its advantages have been disclosed in the context of certain illustrative, non-limiting embodiments, it should be understood that various changes, substitutions, permutations, and alterations can be made without departing from the scope of the disclosure as defined by the claims. It will be appreciated that any feature that is described in a connection to any one embodiment may also be applicable to any other embodiment.

Examples

Embodiment Construction

[0016] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is understood that other embodiments may be utilized, and that logical structural, mechanical, electrical, and chemical changes may be made without departing from the spirit or scope of the disclosure. To avoid detail not necessary to enable those skilled in the art to practice the disclosure, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present disclosure is defined only by the claims. Unless otherwise indicated, as used throughout this document, “or” does not require ...

RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application 63 / 708,659 filed on 10 / 17 / 2024, entitled “WEATHER RESISTANT AIR BARRIER,” which is incorporated herein by reference for all purposes.TECHNICAL FIELD

[0002] This application is directed, in general, to weather resistant air barriers and more specifically to structural wood based weather and air resistant barriers and panels for construction of structures.BACKGROUND

[0003] The following discussion of the background is intended to facilitate an understanding of the present disclosure only. It should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was part of the common general knowledge at the priority date of the application.

[0004] Weather resistant barriers have been used in housing for many decades. Weather resistant barriers are used as wall coverings or components of wall covering assemblies in structures to prevent or reduce entry of air or moisture into a structure from an exterior of the structure. The weather resistant barrier may reduce cooling or heating loads of the structure by preventing or reducing air flow between an interior and the exterior of the structure. Weather resistant barriers also prevent or reduce damage caused by water or moisture entry in the structure by preventing or reducing water entry into the structure from the exterior of the structure. While weather resistant barriers have been used, improvements remain desirable.SUMMARY

[0005] According to an illustrative embodiment, a weather resistant barrier panel includes a panel having a first side and a second side and a barrier layer. When in an installed position on a structure, the first side of the panel faces outward with respect to the structure to which the weather resistant barrier panel is coupled to. The carrier of the barrier layer is coupled to the first side of the panel so that the polywoven layer faces outward with respect to the structure to which the weather resistant barrier panel is coupled to when in the installed position.

[0006] In another embodiment, a structural panel includes a wood-based panel having an exterior-facing surface and an interior-facing surface, a carrier layer laminated to the exterior-facing surface of the wood-based panel with a water resistant poly vinyl acetate resin mixed with an acrylic additive, and a polywoven layer laminated to the carrier layer. In some embodiments, the carrier layer is kraft paper. The polywoven layer includes woven synthetic polymer fibers selected from a group consisting of polypropylene fibers, polyester fibers, and combinations thereof. The polywoven layer forms an outermost surface of the structural panel on an exterior-facing side of the structural panel and has an emissivity less than 0.1 when measured from the exterior-facing side of the structural panel.

[0007] In yet another embodiment, a method of applying a weather resistant barrier to a structure includes the steps of coupling a plurality of weather resistant barrier panels to framing members of the structure to form a wall covering, coupling abutting weather resistant barriers panels by applying a tape over a gap between adjacent weather resistant barrier panels to reduce air flow through the gap between adjacent weather resistant barrier panels. Each of the plurality of weather resistant barrier panels abuts another weather resistant barrier panel of the plurality of weather resistant barrier panels. Each weather resistant barrier panel includes a panel having a first side and a second side and a barrier layer. In an installed position the first side of the panel faces outward with respect to the structure to which the weather resistant barrier panel is coupled to. The barrier layer includes a carrier coupled to a polywoven layer. The carrier of the barrier layer is coupled to the first side of the panel so that the polywoven layer faces outward with respect to the structure to which the weather resistant barrier panel is coupled to.

[0008] Other embodiments are disclosed.DESCRIPTION OF THE DRAWINGS

[0009] Illustrative embodiments of the present disclosure are described in detail below with reference to the attached drawing figures, which are incorporated by reference herein and wherein:

[0010] FIG. 1 is a schematic, perspective view of a structure, with a portion shown as a cut away, having a plurality of weather resistant barrier panels according to an illustrative embodiment;

[0011] FIG. 2 is schematic, perspective view of a weather resistant barrier panel according to an illustrative embodiment;

[0012] FIG. 3 is schematic, detailed edge view of a portion of a weather resistant barrier panel according to an illustrative embodiment;

[0013] FIG. 4 is a schematic, elevation view of a portion of wall of a structure having a weather resistant barrier panel according to an illustrative embodiment;

[0014] FIG. 5 is a flowchart illustrating an illustrative method of manufacturing weather resistant barrier panels; and

[0015] FIG. 6 is a flowchart illustrating an illustrative method of applying weather resistant barrier panels to a structure according to an illustrative embodiment.DETAILED DESCRIPTION

[0016] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is understood that other embodiments may be utilized, and that logical structural, mechanical, electrical, and chemical changes may be made without departing from the spirit or scope of the disclosure. To avoid detail not necessary to enable those skilled in the art to practice the disclosure, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present disclosure is defined only by the claims. Unless otherwise indicated, as used throughout this document, “or” does not require mutual exclusivity.

[0017] Referring now to the figures and initially to FIG. 1, a plurality of weather resistant barrier panels 100 are shown installed on a structure 104. Each of the weather resistant barrier panels 100 are coupled on an exterior side 106 of the structure 104. As shown in cutaway section 108, a plurality of framing members 112 form a structural component of the structure 104. In addition, the plurality of framing members 112 provide a point of attachment of the weather resistant barrier panels 100 to the exterior 106 of the structure 104. The weather resistant barrier panels 100 may be coupled to the exterior 106 of the structure 104 or to the framing members 112 by nails, screws, adhesives, and other methods known in the art.

[0018] It should be understood that coupling the panels 100 to the framing members 112 is illustrative, and the panels 100 may be attached to various structural elements depending on the specific construction requirements and building design. In the alternative, the weather resistant barrier panels may be coupled to the exterior 106 of the structure by coupling the weather resistant barrier panels 100 to other members of the structure 104, such as other sheathing products, intermediate wall covering products, or other structural components of the structure 104 other than framing members 112.

[0019] In the alternative, while the weather resistant barrier panels 100 are shown in the figures as forming the outermost layer of the structure 104, it should be understood that the panels 100 may be covered with additional exterior components such as siding, brick veneer, stucco, or other architectural finishes. In such installations, the weather resistant barrier panels 100 function as an intermediate weather barrier layer that provides air and moisture resistance behind the final exterior cladding system of the structure 104.

[0020] As shown in FIG. 1, when attached to the exterior 106 of the structure 104, the plurality of weather resistant barrier panels 100 are arranged so that each of the weather resistant barrier panels 100 abuts one or more other weather resistant barrier panel 100. In this manner, the array of the plurality of weather resistant barrier panels 100, when attached to the structure 104, form a complete barrier on the exterior 106 of the structure 104.

[0021] The weather resistant barrier panels 100 may be installed in various configurations depending on the specific requirements of the structure 104. Alternatively, the panels 100 may be installed in a butt-joint configuration where adjacent panels 100 abut directly against each other without overlap.

[0022] In some embodiments, the panels 100 may be installed in an overlapping configuration where adjacent panels 100 overlap by a predetermined distance, typically ranging from 1 to 6 inches, to provide enhanced weather sealing and redundant protection against air and moisture infiltration.

[0023] Alternative assembly configurations may include interlocking panel systems where the weather resistant barrier panels 100 are manufactured with complementary edge profiles, such as tongue-and-groove configurations, stepped edges, or rabbet joints, that facilitate precise alignment and enhanced sealing between adjacent panels 100. In some embodiments, the interlocking edges may incorporate gaskets, sealants, or compressible materials that create additional sealing when the panels 100 are joined together.

[0024] The installation pattern of the weather resistant barrier panels 100 may also be varied to accommodate different structural designs. For example, the panels 100 may be installed in a running bond pattern, similar to brick laying, where the vertical joints of adjacent rows are offset. In other embodiments, the panels 100 may be installed in a stack bond pattern where the vertical. The choice of installation pattern may depend on factors such as the skill level of the installation crew, local building codes, and specific performance requirements for the structure 104.

[0025] The weather resistant barrier panels 100 may also be adapted for use on different types of structures beyond residential construction. For example, the panels 100 may be suitable for commercial buildings, agricultural structures, or industrial facilities where weather resistance and energy efficiency are important considerations. The modular nature of the panels 100 allows for scalability to accommodate structures of various sizes and configurations. Additionally, the panels 100 may be manufactured in custom sizes or shapes to accommodate unique architectural features or structural requirements.

[0026] The weather resistant barrier panels 100 may be applied to various surfaces of a structure 104 beyond vertical walls. For example, the panels 100 may be installed on roof decking or sheathing to provide weather resistance for roof assemblies, where they may function as an underlayment beneath roofing materials such as shingles, metal roofing, or tiles. The panels 100 may also be suitable for installation on other structural surfaces such as foundation walls, crawl space enclosures, or attic floors, where air and moisture control are important for energy efficiency and structural protection.

[0027] Referring now primarily to FIGS. 2 and 3, which illustrate the detailed construction and layered assembly of the weather resistant barrier panels 100. FIG. 2 shows a perspective view of an illustrative embodiment of a weather resistant barrier panel 100. FIG. 3 shows a partial edge view of a weather resistant barrier panel 100.

[0028] The weather resistant barrier panel 100 includes a panel 116 having a first side 120 and a second side 124. As used herein designation of a first side and a second side is arbitrary and is provided for orientation as shown in the figures. In an installed position, as shown in FIG. 1, the first side 120 faces outward, away from the interior of the structure 104, and the second side 124 faces inward, toward the interior of the structure 104. An inner most surface 117 of the panel 100 is coincident with the second side 124 of the panel 116, and when installed, faces the interior of the structure 104.

[0029] The panel 116 may be a United States Department of Commerce Performance Standard-2 structural wood-based panel, such as veneered plywood, oriented strand board or other cross laminated structural wood panel.

[0030] A thickness 141 of the panel 116 may be in the range of 1.5" to 0.25". In some embodiments, the thickness 141 of the panel 116 is in the range of 3 / 8" to 23 / 32". In some embodiments the thickness 141 of the panel 116 is about 0.75".

[0031] In some embodiments, a length 131 of the panel 116 may be in the range of 8 to 12 feet. In some embodiments, the length 131 of the panel 116 is about 8 feet. In some embodiments, a width 133 of the panel 116 is in the range of 3 to 8 feet. In some embodiments, the width 133 of the panel 116 is about 4 feet. Other dimensions may be used as those skilled in the art will appreciate.

[0032] A barrier layer 128 is coupled or laminated to the first side 120 of the panel 116 and covers the face of the first side 120 of the panel 116. The barrier layer 128 is formed from a polywoven layer 132 and a carrier 136 (FIG. 3). The carrier 136 is coupled, on a second side 137, to the first side 120 of the panel 116. A first side 135 of the carrier 136 is coupled to a second side 129 of the polywoven layer 132. In this manner, when the panel 100 is installed on the structure 104, the polywoven layer 132 is the exterior layer of the weather resistant barrier panel 100, and the first side 127 of the polywoven layer 132 faces outward from the interior of the structure 104 when in an installed position. When the weather resistant barrier panel 100 is coupled to the structure 104, the polywoven layer 132 is the most outward facing (facing away from the interior of the structure 104) component of the weather resistant barrier panel 100.

[0033] The polywoven layer 132 is, generally, a layer formed from polymeric or plastic fibers, threads, or strands, which are woven into a sheet or fabric form. The polywoven layer 132 may be made from one or more plastic or polymeric materials such as polypropylenes, polyesters (such as PET), and other plastics and polymers, and combinations of polypropylenes, polyesters, or other plastics and polymers.

[0034] The polywoven layer 132 may be a woven fabric material constructed from synthetic polymer fibers or filaments. The polywoven material may be formed by interlacing polymer strands, threads, or tapes in a traditional weaving pattern, typically with warp and weft directions, to form a flexible sheet or fabric structure. This weaving process creates a material that combines the strength and durability of synthetic polymers with the flexibility and breathability characteristics of woven textiles.

[0035] The polywoven construction allows for controlled porosity, where the spacing between the woven fibers can be engineered to provide specific air permeability and moisture vapor transmission rates while maintaining resistance to liquid water penetration. The woven structure also provides enhanced tear resistance and dimensional stability compared to non-woven synthetic materials, making it particularly suitable for construction applications where the material may be subjected to mechanical stress during installation and service life.

[0036] In some embodiments, the polywoven is a metalized polywoven, which is a polywoven material with a metallic component added.

[0037] Metalized polywoven is a specialized variant of polywoven material that incorporates a thin metallic layer or coating applied to at least some of the polymer fibers or fabric surface. The metallization process typically involves vacuum deposition, sputtering, or lamination of metals such as aluminum, silver, or other reflective metals onto the polywoven substrate. This metallic component significantly enhances the material's reflective properties and thermal performance characteristics. The metalized surface creates a radiant barrier effect that reflects infrared radiation and heat energy, rather than absorbing it like conventional non-metalized materials. The metallization can be applied as a continuous coating across the entire surface or as discrete metallic elements integrated into the weave pattern. The thickness of the metallic layer is typically formed to provide the desired reflective properties while maintaining the flexibility and durability of the underlying polywoven structure. The metalized polywoven retains the beneficial characteristics of standard polywoven materials, including tear resistance, dimensional stability, and controlled permeability, while adding enhanced thermal management capabilities that are particularly valuable in building envelope applications.

[0038] Utilizing metallized polywoven material may greatly decrease the emissivity of the completed weather resistant barrier panel 100. Emissivity is a material property that measures how effectively a surface emits thermal radiation compared to a perfect black body radiator. It is expressed as a value between 0 and 1, where 0 represents a perfect reflector that emits no thermal radiation, and 1 represents a perfect black body that emits the maximum possible thermal radiation at a given temperature. Materials with high emissivity values efficiently radiate heat energy away from their surface, while materials with low emissivity values tend to reflect thermal radiation rather than emit it. In building applications, controlling emissivity is important for thermal management, as surfaces with low emissivity can reflect radiant heat and reduce heat transfer, while surfaces with high emissivity can effectively dissipate heat through radiation.

[0039] Decreasing the emissivity of the weather resistant barrier panel 100 by inclusion of a metalized polywoven layer 132 improves the weather resistant barrier panel's 100 ability to reflect thermal and other energies away from the structure 104. In some embodiments using the metalized polywoven, the metalized polywoven is painted or otherwise coated to change the emissivity of the weather resistant barrier panel 100.

[0040] In some embodiments, the emissivity of the weather resistant barrier panel 100 is adjusted to be within required limits of building codes or other building standards. For example, the International Energy Conservation Code (IECC) and ASHRAE Standard 90.1 specify emissivity requirements for radiant barrier materials, typically requiring emissivity values of 0.1 or less for low-emissivity surfaces and 0.9 or higher for high-emissivity surfaces. The Federal Trade Commission's R-Value Rule also establishes guidelines for reflective insulation products that incorporate emissivity considerations. Additionally, ASTM C1371 provides standard test methods for determining emissivity of materials at room temperature, while ASTM E408 covers total normal emittance of surfaces using inspection-meter techniques.

[0041] In some embodiments, the emissivity of the weather resistant barrier panel 100, when measured from the polywoven side (i.e. the outer most exterior surface of the panel 100 when installed on the structure), is in the range of 0.01 – 0.2. In some embodiments, the emissivity of the weather resistant barrier panel 100, when measured from the polywoven side, is in the range of 0.01 - 0.1. In some embodiments, the emissivity of the weather resistant barrier panel 100, when measured from the polywoven side, is in the range of 0.01-0.05. In some embodiments, the emissivity of the weather resistant barrier panel 100, when measured from the polywoven side, is less than 0.2. In some embodiments, the emissivity of the weather resistant barrier panel 100, when measured from the polywoven side, is less than 0.1.

[0042] The weather resistant barrier panel 100 may be configured to achieve emissivity values within these standardized ranges, such as maintaining low emissivity (0.05 to 0.1) when using metalized polywoven materials for enhanced radiant heat reflection, or achieving higher emissivity values (0.8 to 0.95) when thermal radiation dissipation is desired. The specific emissivity characteristics can be tailored through selection of polywoven materials, metallic coatings, and surface treatments to meet the requirements of applicable building codes, energy standards, and performance specifications for the intended application and climate zone.

[0043] The emissivity characteristics of the weather resistant barrier panel 100 may be verified through standardized testing methods to ensure compliance with building codes and performance specifications. Emissivity testing is typically conducted using ASTM C1371, which provides the standard test method for determining emittance of materials at room temperature using portable emissometers. This test method involves placing a calibrated emissometer directly on the surface of the polywoven layer 132 to measure the emissivity value at ambient temperature conditions. The emissometer uses infrared sensors to compare the thermal radiation emitted by the test surface against a reference black body standard, providing emissivity readings with accuracy typically within ±0.02 units.

[0044] The nature and type of plastic or polymer used to make the polywoven layer 132 can be varied to vary the properties of the weather resistant barrier panels 100. For example, the use of polypropylenes or polyesters results in a water resistant barrier because of the inherent hydrophobic (water-repelling) properties of these synthetic polymer materials. Polypropylene exhibits excellent chemical resistance to water and moisture due to its non-polar molecular structure, which prevents water molecules from bonding to or penetrating through the material. Similarly, polyester materials, particularly polyethylene terephthalate (PET), demonstrate superior moisture resistance due to their crystalline molecular structure and low water absorption rates, typically less than 0.1% by weight. These materials maintain their structural integrity and barrier properties even when exposed to high humidity conditions or direct water contact over extended periods. Additionally, both polypropylene and polyester fibers can be manufactured with specific surface treatments or additives that further enhance their water-repelling characteristics, such as fluoropolymer coatings or silicone-based treatments that create an even more hydrophobic surface.

[0045] The woven construction of these materials also contributes to water resistance by creating a fabric structure where water droplets are too large to pass through the interstices between the fibers, while still allowing vapor permeability for moisture management within the building envelope. In addition, the properties of the polywoven layer 132 may be varied by varying the types and sizes of plastic fibers used to manufacture the polywoven layer 132. For example, small or larger diameter or width fibers or threads may be used to vary the amount of air or water penetration through the polywoven layer 132 or tighter or looser weaves may have the same effects. In addition, the polywoven layer 132 or the starting material for manufacturing the polywoven layer 132 may include additives to alter the physical and chemical properties of the polywoven layer 132.

[0046] In some embodiments, the polywoven layer 132 may be manufactured with specific weave characteristics tailored to optimize performance for particular applications. For example, the polywoven layer 132 may utilize a plain weave construction where each warp fiber passes alternately over and under each weft fiber, creating a balanced and uniform fabric structure with consistent porosity and strength characteristics. This plain weave configuration provides predictable air permeability rates and uniform moisture vapor transmission across the entire surface area of the weather resistant barrier panel 100. In other embodiments, the polywoven layer 132 may employ a twill weave pattern where the warp fibers pass over multiple weft fibers in a diagonal pattern, creating a fabric with enhanced drape characteristics and improved conformability to irregular surface contours during installation.

[0047] The thread count and fiber spacing of the polywoven layer 132 may be specifically engineered to achieve desired performance characteristics. In some embodiments, the polywoven layer 132 may have a thread count ranging from 8 to 20 threads per inch in both the warp and weft directions, providing a balance between structural integrity and controlled permeability. Higher thread counts, such as 16 to 20 threads per inch, may be utilized when enhanced tear resistance and reduced air permeability are desired, while lower thread counts, such as 8 to 12 threads per inch, may be employed when increased breathability and moisture vapor transmission are prioritized. The fiber denier, which measures the linear mass density of the individual polymer fibers, may range from 200 to 1000 denier, with heavier denier fibers providing increased strength and durability, while lighter denier fibers offer improved flexibility and conformability.

[0048] In some embodiments, the polywoven layer 132 may incorporate a basket weave construction where multiple warp and weft fibers are grouped together and woven as single units, creating larger openings in the fabric structure while maintaining overall strength. This basket weave configuration may be particularly beneficial for applications requiring enhanced vapor permeability while still providing adequate resistance to liquid water penetration. The polywoven layer 132 may also utilize specialized weave patterns such as leno weave, where pairs of warp fibers are twisted around the weft fibers to create a more open fabric structure with improved dimensional stability and reduced tendency for fiber slippage during handling and installation.

[0049] The color of the polywoven layer 132 may also be varied to affect the reflectivity, emissivity, or general heat retention properties of the polywoven layer 132. For example, a white polywoven layer 132 will reflect more heat and energy than a black polywoven layer 132, which is more likely to absorb energy and increase in temperature as a result, as compared to the white polywoven layer 132. In this manner the overall heat retention properties of the weather resistant barrier panels 100 may be varied by varying the color of the polywoven layer 132.

[0050] The polywoven layer 132 may also be manufactured in intermediate colors such as gray, tan, brown, or green to provide balanced thermal characteristics while meeting specific architectural or aesthetic requirements.

[0051] In some embodiments, the polywoven layer 132 may incorporate combinations of the various characteristics described above to optimize performance for specific applications. For example, a single weather resistant barrier panel 100 may utilize a metalized polywoven layer 132 with white coloration to maximize both reflective properties from the metallic coating and solar reflectance from the light color, creating enhanced thermal management capabilities. Alternatively, the polywoven layer 132 may combine specific weave characteristics, such as a plain weave construction with 12-16 threads per inch, using polypropylene fibers in a gray color to provide balanced performance characteristics suitable for moderate climate applications. The polywoven layer 132 may also integrate non-metalized polyester fibers in a basket weave pattern with earth-tone coloration for applications where aesthetic integration with natural surroundings is important while maintaining adequate weather resistance properties. These combinations allow for customization of the weather resistant barrier panel 100 to meet diverse performance requirements, climate conditions, and architectural specifications. The flexibility to mix and match polymer materials, weave patterns, thread counts, metallization options, and color selections enables manufacturers to create specialized products tailored to specific market segments or unique project requirements while maintaining the fundamental weather resistance and structural integrity characteristics of the barrier system.

[0052] In one embodiment the carrier 136 is kraft paper. The carrier 136 however may be any suitable material that provides support for the polywoven layer 132.

[0053] The carrier 136 may be characterized by specific physical and performance properties that optimize its function as a support layer for the polywoven layer 132. In embodiments where the carrier 136 comprises kraft paper, the kraft paper may have a basis weight ranging from 20 to 60 pounds per 3000 square feet, with typical embodiments utilizing kraft paper having a basis weight of approximately 30 to 40 pounds per 3000 square feet. The kraft paper carrier 136 may have a thickness ranging from 0.002 to 0.008 inches, providing adequate structural support while maintaining flexibility for installation around irregular surfaces. The kraft paper may be manufactured from virgin wood fibers or recycled content, and may be treated with wet-strength additives to maintain integrity when exposed to moisture during manufacturing and installation processes. In some embodiments, the kraft paper carrier 136 may be calendered or supercalendered to achieve a smooth surface finish that promotes uniform adhesion with both the polywoven layer 132 and the panel 116. The kraft paper may also be treated with sizing agents or barrier coatings to control porosity and moisture absorption characteristics, ensuring consistent performance across varying environmental conditions.

[0054] In some embodiments, the carrier 136 may comprise alternative materials beyond kraft paper to provide different performance characteristics or manufacturing advantages. For example, the carrier 136 may be formed from a scrim fiber mesh, which is a lightweight, open-weave fabric typically made from fiberglass, polyester, or polypropylene fibers. The scrim mesh carrier provides enhanced dimensional stability and tear resistance while maintaining flexibility for installation around irregular surfaces. In other embodiments, the carrier 136 may comprise a non-woven synthetic fabric, such as spunbond polypropylene or polyester, which offers uniform thickness and consistent porosity characteristics. Non-woven carriers may provide improved adhesion properties due to their fibrous structure that allows adhesive penetration and mechanical bonding..

[0055] In alternative embodiments, the carrier 136 may be omitted entirely, with the polywoven layer 132 applied directly to the panel 116 using adhesive systems or mechanical bonding techniques. Direct application methods may reduce material costs and manufacturing complexity while potentially improving the overall thickness profile of the weather resistant barrier panel 100. When the carrier 136 is omitted, the polywoven layer 132 may be manufactured with enhanced structural properties, such as increased fiber density or specialized surface treatments, to provide adequate support and adhesion characteristics without the intermediate carrier layer. The selection of carrier material or the decision to omit the carrier 136 may depend on factors such as manufacturing capabilities, cost considerations, performance requirements, and compatibility with the chosen polywoven layer 132 and adhesive system.

[0056] In some embodiments, the barrier layer 128 is adhered to the panel 116 with a water resistant poly vinyl acetate resin mixed with an acrylic additive. This adhesive specifically addresses potential issues with weather and air resistant products to consistently pass building codes requirements. Previously used resins were not water resistant, and ambient moisture could deteriorate the bond and performance of the weather resistant barriers. The water resistant poly vinyl acetate resin with an acrylic additive adhesive formulation creates a non-permeable glue line between the barrier layer 128 and the panel 116. This formulation may create enough heat from the friction of a pneumatic mechanical fastener, that the adhesive formulation may bind to the mechanical fastener and create a better air and moisture barrier at the structural mechanical fastening point.

[0057] Poly vinyl acetate (PVA) resin is a synthetic polymer adhesive commonly known as white glue or school glue in its basic form. In construction applications, PVA resin adhesives are formulated as water-based emulsions that cure through water evaporation and coalescence of polymer particles. The water-resistant poly vinyl acetate resin with acrylic additive used in this application represents an advanced formulation specifically engineered for exterior building applications. The acrylic additive enhances the adhesive's water resistance, UV stability, and flexibility compared to standard PVA formulations. This modified PVA resin creates strong bonds with both wood substrates and synthetic materials while maintaining flexibility to accommodate thermal expansion and contraction. The adhesive cures at room temperature without requiring heat activation, making it suitable for cold-process manufacturing methods. When cured, the adhesive forms a clear, flexible bond line that resists moisture penetration and maintains adhesion strength under varying environmental conditions, which is critical for weather barrier applications where long-term durability and weather resistance are essential.

[0058] The acrylic additive incorporated into the water-resistant poly vinyl acetate resin may serve multiple functions that enhance the adhesive's performance for exterior building applications. The acrylic additive typically comprises acrylic polymer emulsions or acrylic copolymers that are blended with the base PVA resin during formulation. These acrylic components may include methyl methacrylate, ethyl acrylate, butyl acrylate, or acrylic acid derivatives that are specifically selected to improve water resistance, flexibility, and durability characteristics of the base PVA adhesive system.

[0059] In some embodiments, the acrylic additive may comprise styrene-acrylic copolymers that provide enhanced water resistance by creating a more hydrophobic polymer matrix when the adhesive cures.. The typical concentration of acrylic additive in the PVA resin formulation may range from 2% to 40% by weight. In some embodiments, the acrylic additive concentration is in the range of 2% to 10% by weight, as compared to the PVA resin. The acrylic additive may be incorporated as a pre-formed emulsion that is blended with the PVA resin, or it may be polymerized in-situ during the adhesive manufacturing process to create a more intimate blend of the polymer components.

[0060] In some embodiments, the acrylic additive may be formulated with specific functional groups that enhance adhesion to both wood substrates and synthetic materials. For example, the acrylic additive may include carboxyl groups (-COOH) or hydroxyl groups (-OH) that can form hydrogen bonds with cellulose fibers in wood, while also providing compatibility with the polywoven layer 132 materials. The acrylic additive may also incorporate silane coupling agents or titanate coupling agents that create chemical bridges between the organic polymer matrix and any inorganic fillers or substrates, further enhancing the overall bond strength and durability of the adhesive system.

[0061] The acrylic additive may also include plasticizers such as dibutyl phthalate (DBP) or dioctyl phthalate (DOP) that maintain flexibility of the cured adhesive over a wide temperature range, preventing brittle failure during thermal cycling. In cold climate applications, the acrylic additive may incorporate specialized low-temperature plasticizers such as adipate esters or citrate esters that maintain adhesive flexibility at temperatures as low as -40°F. For high-temperature applications, the acrylic additive may include heat-resistant components such as fluoroacrylate polymers or silicone-modified acrylics that maintain bond integrity at temperatures up to 200°F or higher. The specific selection and concentration of acrylic additives may be tailored to meet the performance requirements of different climate zones and building code specifications, ensuring optimal adhesive performance across diverse environmental conditions.

[0062] In alternative embodiments, the barrier layer 128 may be adhered to the panel 116 using different adhesive systems tailored to specific performance requirements or manufacturing processes. For example, the barrier layer 128 may be coupled to the panel 116 using a hot-melt adhesive system, which involves applying thermoplastic adhesive materials that are heated to a molten state during application and then solidify upon cooling to create a strong bond. Hot-melt adhesives may provide advantages in manufacturing speed and consistency, as they do not require curing time and can create immediate bonds upon cooling. The hot-melt adhesive may comprise ethylene vinyl acetate (EVA), polyamide, or polyolefin-based formulations that are specifically designed for wood-to-fabric bonding applications.

[0063] In some embodiments, the barrier layer 128 may be adhered to the panel 116 using structural acrylic adhesives that provide enhanced durability and weather resistance. Structural acrylics may offer superior bond strength and long-term performance compared to traditional PVA-based systems, particularly in applications where the weather resistant barrier panel 100 may be subjected to extreme temperature variations or high mechanical stress. The structural acrylic adhesive may be a two-component system that cures through chemical reaction, or a single-component system that cures through moisture exposure or UV radiation. These adhesive systems may provide improved resistance to creep, fatigue, and environmental degradation over extended service periods.

[0064] In some embodiments, the carrier 136 and the polywoven layer 132 are coupled together using a lamination process to form the barrier layer 128. In some embodiments, the barrier layer 128 is attached to the panel 116 through a cold process via a nip roller application, involving applying a curtain coat layer of poly vinyl acetate resin with the purpose of adhering the barrier layer 128 to the panel 116.

[0065] The lamination process for coupling the carrier 136 and polywoven layer 132 may involve several different manufacturing techniques, each offering specific advantages for different production requirements and performance characteristics. Lamination processes may include adhesive lamination, where a liquid adhesive is applied between the carrier 136 and polywoven layer 132 before they are brought together and pressed. The adhesive lamination process may utilize water-based, solvent-based, or reactive adhesive systems, with the selection depending on the specific materials being bonded and the desired performance characteristics of the finished barrier layer 128.

[0066] A nip roller application process provides a manufacturing process that may ensure uniform adhesive distribution and consistent bonding between the barrier layer 128 and the panel 116. The nip roller system typically consists of two or more precision-machined steel or rubber-covered rollers that create a controlled pressure zone through which the panel 116 and barrier layer 128 are passed. The roller pressure, typically ranging from 50 to 500 pounds per linear inch, is carefully calibrated to ensure adequate adhesive penetration and bonding without causing delamination or damage to the polywoven layer 132. The roller speed, usually maintained between 10 to 100 feet per minute, is synchronized with the adhesive application rate to ensure consistent coating thickness and prevent adhesive starvation or excess that could compromise bond quality.

[0067] The curtain coating process for adhesive application involves creating a continuous liquid curtain of poly vinyl acetate resin that falls vertically onto the moving panel 116 surface. This coating method provides uniformity and can accommodate varying panel widths without requiring mechanical adjustments. The curtain coating system typically includes a precision-engineered coating head with adjustable slot dies that control the adhesive flow rate and curtain width. The adhesive viscosity, typically maintained between 500 to 2000 centipoise, is carefully controlled through temperature regulation and solids content adjustment to ensure proper curtain formation and stability. The coating weight, usually ranging from 8 to 25 grams per square meter, is precisely controlled through pump speed and curtain height adjustments to optimize adhesive coverage while minimizing material usage and cost.

[0068] Quality control measures during the lamination and nip roller processes may include real-time monitoring of adhesive application thickness using gauges or sensors that provide continuous feedback to maintain consistent coating weights across the panel width. Temperature monitoring systems may track the panel 116 and barrier layer 128 temperatures throughout the process to ensure optimal adhesive curing conditions. Pressure monitoring systems on the nip rollers may provide immediate feedback if roller pressure deviates from specified parameters, allowing for rapid correction before defective products are produced. Additionally, the manufacturing process may incorporate automated inspection systems using machine vision technology to detect surface defects, adhesive voids, or delamination issues in the finished weather resistant barrier panels 100. The cold process nature of the nip roller application eliminates the need for energy-intensive heating systems and reduces the risk of thermal damage to the polywoven layer 132, while the smooth exterior surface created by the process provides optimal drainage characteristics and consistent emittance properties across the entire panel surface.

[0069] The layered construction shown in FIGS. 2 and 3 demonstrates the arrangement of components that enables the weather resistant barrier panel 100 to function effectively. The cross-sectional view in FIG. 3 particularly illustrates how the barrier layer 128 maintains intimate contact with the panel 116 across the entire surface area, ensuring consistent performance without delamination or air pockets that could compromise the barrier's effectiveness. The thickness relationships between the various layers are considered in the overall performance, with the relatively thin barrier layer 128 providing maximum protection while adding minimal weight or bulk to the structural panel 116.

[0070] It should be understood that the illustrative embodiments of FIGS. 2 and 3 are not drawn to scale. Certain components of the weather resistant barrier panel 100 are shown in exaggerated relative size. Therefore, the relative dimensions, as shown in the figures, are not meant to be limiting. For example, the relative thicknesses of the panels 116, the barrier layer 128, and the carrier 136 are not intended to be limiting.

[0071] Referring now primarily to FIG. 4, a schematic, elevation view of an exterior side 152 of a portion of wall 140 of a structure having a plurality weather resistant barrier panels 100 according to an illustrative embodiment is presented. In this view, one may see that the exterior side 152 of the wall 140 is covered in the plurality of weather resistant barrier panels 100, with each weather resistant barrier panel 100 abutting at least one other weather resistant barrier panel 100, as described in relation to FIG. 1. At the point of abutment of two weather resistant barrier panels 100 a gap 144 is formed. For illustration purposes the gap 144 is not shown to scale and is shown as a dashed line.

[0072] It is desirable to seal the gap 144 to prevent air flow between the exterior 106 of the structure 104 and the interior of the structure 104 to prevent air exchange which may result in cooling or heating losses and moisture entry into the structure 104. In some embodiments, the gaps 144 are sealed using scrim tape 148. The scrim tape 148 is further sealed to the weather resistant barrier panels 100 with an acrylic resin adhesive or any of the above mentioned adhesive for binding the barrier layer 128 to the panel 116.

[0073] The combination of the scrim tape 148 covering the gaps 144 along with the adhesion and sealing of the scrim tape 148 with the acrylic resin forms a weather resistant barrier over the gaps 144. In this manner, the entire exterior 152 of the wall 140 is able to resist weather or water infiltration. Other suitable materials may be used to seal the gaps 144.

[0074] The scrim tape 148 used to seal the gaps 144 between adjacent weather resistant barrier panels 100 may comprise a specialized construction designed to provide durable and weather-resistant sealing performance. The scrim tape 148 typically consists of a reinforcing scrim layer, which is an open-weave fabric mesh, combined with adhesive layers and protective facings. The scrim layer is commonly manufactured from fiberglass, polyester, or polypropylene fibers that are woven in a grid pattern to provide dimensional stability and tear resistance. The scrim mesh typically has an open area ranging from 30% to 70%, allowing for adhesive penetration while maintaining structural integrity. The individual fibers in the scrim may have diameters ranging from 0.005 to 0.020 inches, with the weave pattern creating openings that are typically 0.125 to 0.5 inches in both directions. This construction provides conformability to irregular surfaces while preventing the tape from stretching or distorting during installation.

[0075] The scrim tape 148 may be manufactured in various widths to accommodate different sealing requirements and installation preferences. Standard widths for scrim tape 148 may include 2 inches, 3 inches, 4 inches, 6 inches, and 9 inches, with the selection depending on the size of the gaps 144 and the desired overlap onto the adjacent weather resistant barrier panels 100. Narrow tapes, such as 2-inch or 3-inch widths, may be suitable for precise sealing of tight gaps where material efficiency is important, while wider tapes, such as 6-inch or 9-inch widths, may provide enhanced sealing performance and greater tolerance for installation variations. The scrim tape 148 may also be available in custom widths ranging from 1 inch to 12 inches or more, depending on specific project requirements..

[0076] The adhesive system used with the scrim tape 148 may comprise various formulations optimized for different environmental conditions and substrate materials. In some embodiments, the scrim tape 148 may utilize a pressure-sensitive adhesive that provides immediate tack upon contact with the weather resistant barrier panels 100, allowing for repositioning during installation if necessary..

[0077] In alternative embodiments, the gaps 144 between adjacent weather resistant barrier panels 100 may be sealed using materials other than scrim tape 148 to provide effective air and moisture barriers. One alternative approach involves the use of liquid-applied sealants that are dispensed directly into the gaps 144 using specialized application equipment. These liquid sealants may comprise polyurethane, silicone, or acrylic-based formulations that cure to form flexible, weather-resistant seals.

[0078] Another alternative sealing method involves the use of pre-formed gasket strips that are installed in the gaps 144 during panel installation. These gasket strips may be manufactured from closed-cell foam materials such as EPDM rubber, neoprene, or polyethylene foam that provide excellent compression recovery and weather resistance. The gasket strips are typically sized to be slightly larger than the gap 144 width, creating a compression fit that maintains sealing pressure over time. In some embodiments, the gasket strips may incorporate adhesive backing that bonds to the adjacent panel surfaces, while in other embodiments, the gaskets may be held in place purely by compression forces. The gasket material may be selected based on temperature range requirements, with EPDM gaskets suitable for extreme temperature variations and polyethylene foam gaskets providing cost-effective sealing for moderate climate applications.

[0079] Mechanical sealing systems represent another alternative approach for sealing gaps 144 between weather resistant barrier panels 100. These systems may include metal or plastic batten strips that are fastened over the gaps 144, creating a physical barrier that prevents air and moisture infiltration. The batten strips may be manufactured from aluminum, galvanized steel, or high-density polyethylene, with the material selection depending on durability requirements and aesthetic considerations. In some embodiments, the batten strips may incorporate integral gasket channels that hold compressible sealing materials against the panel surfaces. The mechanical fastening of batten strips may utilize screws, nails, or specialized clips that engage with the underlying framing members 112, providing both sealing and additional structural connection between adjacent panels 100.

[0080] To manufacture the weather resistant barrier panel 100 according to one illustrative embodiment, the panel 116, e.g., an oriented strand board (“OSB”) or plywood panel, is formed in the usual way as those skilled in the art will appreciate. For example, in the case of OSB, wood strands are oriented in specific directions and bonded together with adhesive resins under heat and pressure to form a structural panel. In the case of plywood, thin wood veneers are layered with alternating grain directions and bonded together with adhesive under heat and pressure to create a cross-laminated structural panel. The panels 116 are typically manufactured to standard dimensions and thicknesses according to industry specifications such as those established by the Engineered Wood Association (APA) or similar standards organizations.

[0081] An adhesive or glue is applied to the first side 120 of the panel 116. Then, the barrier layer 128 (e.g., the polywoven layer 132 and carrier 136) is applied to the adhesive on the panel 116. In some embodiments, the barrier layer is adhered to the panel 116 using a nip roller. In some embodiments, the adhesive may be applied to the surface of the barrier layer 128, namely the carrier 136, and then the barrier layer 128 applied onto the first side 120 of the panel 116. In other embodiments, the barrier layer 128 may be formed in the process of forming the weather resistant barrier panel 100 by adhering the carrier 136 to the panel 116 and then adhering the polywoven layer 132 to the carrier 136. In some embodiments heat or activators are not used to activate the adhesive.

[0082] Referring now to FIG. 5, an illustrative method 500 may comprise the following steps: (502) preparing the structural wood-based panel 116, for example, by sanding or ensuring proper moisture content (typically below 19%) and surface cleanliness; (504) applying the water-resistant poly vinyl acetate resin with acrylic additive to the first side 120 of the panel 116 using curtain coating application at controlled viscosity and coating weight; (506) positioning the pre-laminated barrier layer 128, consisting of carrier 136 and polywoven layer 132, above the adhesive-coated panel 116; (508) passing the assembly through the nip roller system at controlled pressure and speed to ensure uniform bonding; (510) conducting real-time quality control monitoring including adhesive thickness measurement, pressure verification, and visual inspection for defects; (512) allowing the bonded assembly to cure under controlled environmental conditions; and (514) performing final inspection and testing to verify adhesion strength, weather resistance, and dimensional accuracy and stacking completed panels 100.

[0083] FIG. 6 is a flowchart illustrating a method 600 of applying weather resistant barrier panels 100 to a structure 104 according to an illustrative embodiment. The method 600 begins at step 602 with site preparation, including inspecting framing members 112 for proper alignment and ensuring environmental conditions are within acceptable ranges. At step 604, the first weather resistant barrier panel 100 is positioned at a predetermined starting point, such as a corner of the structure 104, with the polywoven layer 132 facing outward away from the interior of the structure 104.

[0084] The method 600 continues at step 606 with securing the first panel 100 to the framing members 112 using mechanical fasteners such as galvanized nails or screws. At step 608, subsequent weather resistant barrier panels 100 are installed in sequence, maintaining proper alignment and creating consistent gaps 144 of 1 / 8 inch to 1 / 4 inch between adjacent panels to accommodate thermal expansion. Step 610 involves quality control verification during installation, including checking fastener penetration depth, verifying proper panel alignment, and inspecting for damage to the polywoven layer 132.

[0085] Following panel installation, the method 600 proceeds to step 612 with preparation of the gaps 144 between adjacent panels by cleaning debris and loose material. At step 614, scrim tape 148 is measured, cut to appropriate lengths with 2-3 inches of overlap at joints, and applied over each gap 144, centered to overlap equally onto both adjacent panels 100. Step 614 may also involve applying pressure to the scrim tape 148 using a roller or smoothing tool to ensure complete contact and eliminate air bubbles. The method 600 concludes at step 618 with applying acrylic resin adhesive over the scrim tape 148 and adjacent panel surfaces to create a weatherproof seal, followed by final inspection and quality verification to ensure the weather resistant barrier system meets performance requirements and building code compliance.

[0086] After applying the double acrylic scrim tape, building code requirements regarding the air exchange rate per hour may be met due to the overall properties of the weather resistant barriers described herein. A calculated R value can be achieved through the airspace created between the weather resistant barrier and the finished exterior wall assembly.

[0087] The weather resistant barrier panels 100 and their installation method provide significant improvements to the thermal performance and R-value of structures through multiple mechanisms that work synergistically to enhance energy efficiency. A contribution to R-value improvement comes from the creation of a continuous air barrier system that eliminates uncontrolled air infiltration and exfiltration. When the weather resistant barrier panels 100 are properly installed with sealed gaps 144 using scrim tape 148 and acrylic resin adhesive, they create an essentially airtight building envelope that forces air exchange to occur only through controlled ventilation systems.

[0088] The polywoven layer 132, particularly when manufactured with metalized materials, contributes additional R-value through its radiant barrier properties that reflect infrared thermal radiation away from the structure 104. This radiant barrier effect can provide an equivalent R-value improvement of R-2 to R-10 depending on the specific metallization characteristics, installation orientation, and climate conditions.

[0089] Although the present disclosure and its advantages have been disclosed in the context of certain illustrative, non-limiting embodiments, it should be understood that various changes, substitutions, permutations, and alterations can be made without departing from the scope of the disclosure as defined by the claims. It will be appreciated that any feature that is described in a connection to any one embodiment may also be applicable to any other embodiment.

Examples

Embodiment Construction

[0016] In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown, by way of illustration, specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is understood that other embodiments may be utilized, and that logical structural, mechanical, electrical, and chemical changes may be made without departing from the spirit or scope of the disclosure. To avoid detail not necessary to enable those skilled in the art to practice the disclosure, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present disclosure is defined only by the claims. Unless otherwise indicated, as used throughout this document, “or” does not require ...

Claims

1. A weather resistant barrier panel comprising: a panel having a first side and a second side,wherein, when in an installed position on a structure, the first side of the panel faces outward with respect to the structure to which the weather resistant barrier panel is coupled to;a barrier layer;wherein the barrier layer comprises a carrier coupled to a polywoven layer; andwherein the carrier of the barrier layer is coupled to the first side of the panel so that the polywoven layer faces outward with respect to the structure to which the weather resistant barrier panel is coupled to when in the installed position.

2. The weather resistant barrier panel of claim 1, wherein the panel comprises a structural wood-based panel.

3. The weather resistant barrier panel of claim 2, wherein the structural wood-based panel is plywood or OSB.

4. The weather resistant barrier panel of claim 2, wherein the barrier layer is coupled to the first side of the panel by a waterproof PVA glue.

5. The weather resistant barrier panel of claim 1, wherein the polywoven layer comprises polypropylene fibers.

6. The weather resistant barrier panel of claim 1, wherein the polywoven layer comprises polyester fibers.

7. The weather resistant barrier panel of claim 1, wherein the polywoven layer is a metalized polywoven layer.

8. The weather resistant barrier panel of claim 1, wherein the carrier comprises kraft paper.

9. The weather resistant barrier panel of claim 1, wherein the barrier layer is adhered to the panel with a water resistant poly vinyl acetate resin mixed with an acrylic additive.

10. The weather resistant barrier panel of claim 1,wherein the panel comprises plywood or oriented strand board;wherein the barrier layer is coupled to the first side of the panel by a water resistant poly vinyl acetate resin mixed with an acrylic additive;wherein the polywoven layer comprises polypropylene fibers;wherein the polywoven layer is a metalized polywoven layer;wherein the carrier comprises kraft paper; andwherein the panel has a thickness in the range of 0.25 inches to 1.5 inches.

11. A structural panel comprising: a wood-based panel having an exterior-facing surface and an interior-facing surface;a carrier layer comprising kraft paper laminated to the exterior-facing surface of the wood-based panel with a water resistant poly vinyl acetate resin mixed with an acrylic additive;a polywoven layer laminated to the carrier layer, wherein the polywoven layer comprises woven synthetic polymer fibers selected from a group consisting of polypropylene fibers, polyester fibers, and combinations thereof;wherein the polywoven layer comprises a metalized polywoven; andwherein the polywoven layer forms an outermost surface of the structural panel on an exterior-facing side of the structural panel and has an emissivity less than 0.1 when measured from the exterior-facing side of the structural panel.

12. The structural panel of claim 11, wherein the wood-based panel is plywood or oriented strand board.

13. The structural panel of claim 11, wherein the wood-based panel has a thickness ranging from 0.25 inches to 1.5 inches.

14. The structural panel of claim 11, wherein the metalized polywoven comprises a reflective metal at least partially coating the woven synthetic polymer fibers.

15. The structural panel of claim 11, wherein the acrylic additive comprises styrene-acrylic copolymers present in a concentration ranging from 2% to 10% by weight of the poly vinyl acetate resin.

16. A method of applying a weather resistant barrier to a structure, the method comprising: coupling a plurality of weather resistant barrier panels to framing members of the structure to form a wall covering;wherein each of the plurality of weather resistant barrier panels abuts another weather resistant barrier panel of the plurality of weather resistant barrier panels;coupling abutting weather resistant barriers panels by applying a tape over a gap between adjacent weather resistant barrier panels to reduce air flow through the gap between adjacent weather resistant barrier panels; andwherein, each weather resistant barrier panel comprises: a panel having a first side and a second side, wherein in an installed position the first side of the panel faces outward with respect to the structure to which the weather resistant barrier panel is coupled to,a barrier layer,wherein, the barrier layer comprises a carrier coupled to a polywoven layer, andwherein, the carrier of the barrier layer is coupled to the first side of the panel so that the polywoven layer faces outward with respect to the structure to which the weather resistant barrier panel is coupled to.

17. The method of claim 16, further comprising sealing the tape to the weather resistant barrier panels with an acrylic resin adhesive.

18. The method of claim 16, wherein each weather resistant barrier panel has dimensions of approximately 8 feet by 4 feet.

19. The method of claim 16, wherein the weather resistant barrier panels are coupled to the framing members using mechanical fasteners selected from a group consisting of nails, screws, and combinations thereof.

20. The method of claim 16, wherein the polywoven layer comprises a metalized polywoven material.

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