US20140059963A1

Movatterモバイル変換

Info

Publication number: US20140059963A1
Application number: US14/012,163
Authority: US
Inventors: David Rogne; James Rosebrugh; Damon Larkin
Original assignee: EMERCOR Ltd
Current assignee: EMERCOR Ltd
Priority date: 2012-08-29
Filing date: 2013-08-28
Publication date: 2014-03-06
Also published as: CA2825230A1

Abstract

An insulated sheathing for use in construction is provided. The insulated sheathing comprises a sheathing having a first surface, second surface, and edges; and a backing attached to the first surface of the sheathing. The sheathing is at least one of plywood, OSB, drywall, fiberglass, concrete board, metal, and plastic. The backing may have an insulation medium, which may be at least one of polyurethane, polystyrene, and fiberglass. Methods of using the insulated sheathing in constructing sections of a building are also provided.

Description

FIELD

The invention relates to sheathing for the construction of buildings and a method for assembling a wall and/or ceiling section of a building.

BACKGROUND

In the construction industry, sheathing is generally used to construct a wall and/or ceiling section of a building. Sheathing helps protect the wall and/or ceiling structure from wind loading and shear forces, and provide a surface on which cladding may be attached. Generally, when constructing a wall or ceiling section, sheathing is attached directly on to studs in a horizontal orientation and insulation material is sometimes installed between the studs.

For concrete walls of a building, such as basement walls, insulation is generally installed on the interior side of the walls. Placing insulation on the interior side of concrete walls may not be an efficient way of insulating an interior space from the exterior temperature. For example, in a situation where interior wall insulation is installed to prevent heat from escaping from the interior space to a colder exterior space, the concrete wall would be approximately the same temperature as the colder exterior since it is exposed to the exterior space so the only barrier between the interior temperature and the exterior temperature is the insulation. Consequently, some heat from the interior space would transfer to the colder concrete wall through the insulation.

Sheathing can be used to form part of a ceiling of a room. Such sheathing is generally attached directly on to other structural elements, such as studs and trusses.

SUMMARY OF INVENTION

The present invention provides an insulated sheathing and a method for assembling a wall and/or ceiling section using the insulated sheathing.

In accordance with a broad aspect of the invention, there is provided an insulated sheathing for use in construction comprising a sheathing having a first surface, second surface, and edges; and a backing attached to the first surface of the sheathing.

In accordance with another broad aspect of the invention, there is provided a method of installing the insulated sheathing as a part of a partition between a first space and a second space, the first space and second space having partition members therebetween, the partition members each having an upper side and a lower side, the method comprising attaching the insulated sheathing to the lower side of the partition members, with the first surface of the insulated sheathing facing the partition members.

In accordance with another broad aspect of the invention, there is provided a method of assembling a wall structure extending between an upper building structure and a lower building structure, the wall structure for providing a separation between a first space and a second space, the method comprising: attaching a bottom plate to the lower building structure; attaching the first ends of a plurality of studs intermittently on the bottom plate along the length thereof; attaching a top plate to the second ends of the plurality of studs, the top plate being attached to the upper building structure; disposing an insulated sheathing over a first surface of the studs, the first surface facing the first space, the insulated sheathing comprising a sheathing having a first surface and a second surface, and a backing attached to the first surface of the sheathing, and the backing being between the plurality of studs and the sheathing; and attaching the insulated sheathing to at least one of the top plate, plurality of studs, and bottom plate.

In accordance with another broad aspect of the invention, there is provided a method of assembling a wall structure extending between an upper building structure and a lower building structure, the wall structure for providing a separation between a first space and a second space, the method comprising: attaching a bottom plate to the lower building structure; attaching the first ends of a plurality of studs intermittently on the bottom plate along the length thereof; attaching a lower top plate to the second ends of the plurality of studs; disposing an insulated sheathing over a first surface of the studs, the first surface facing the first space, the insulated sheathing comprising a sheathing having a first surface and a second surface, and a backing attached to the first surface of the sheathing, and the backing being between the plurality of studs and the sheathing; attaching an upper top plate to an upper surface of the lower top plate, the upper top plate being attached to the upper building structure; and attaching the insulated sheathing to at least one of the upper top plate, lower top plate, plurality of studs, and bottom plate.

In accordance with another broad aspect of the invention, there is provided a method of assembling a wall structure for providing a separation between a first space and a second space, the method comprising: providing a plurality of spaced-apart studs on a first side of the wall structure; providing a plurality of spaced-apart studs on a second side of the wall structure, the first and second sides forming a first angle relative to one another at the intersection therebetween; providing a corner stud at the intersection to connect the first and second sides; disposing a first insulated sheathing and a second insulated sheathing over a first surface of the studs on the first side and second sides, respectively, the first surface facing the first space, the first and second insulated sheathings each comprising a sheathing having a side edge, a first surface, and a second surface, and a backing attached to the first surface of the sheathing, and the backing being between the studs and the sheathing; aligning the side edges of the first and second insulated sheathings near the corner stud to form a second angle therebetween, the second angle substantially coinciding with the first angle; and attaching the first and second insulated sheathings to one or both of the studs and the corner stud.

In accordance with another broad aspect of the invention, there is provided a method for constructing a concrete structure for surrounding an area, the area having a perimeter, the method comprising: erecting a plurality of insulated sheathings along the perimeter to form a first form, the first form defining an interior space therein, each of the insulated sheathings comprising a first surface, second surface, and edges, and a backing attached to the first surface of the sheathing, the backing of the insulated sheathings facing the interior space; erecting a plurality of sheathings in the interior space, spaced apart from the plurality of insulated sheathings, to form a second form, and the first form and second form defining a space therebetween; bracing the first and second forms; pouring concrete into the space; and allowing the concrete to cure.

BRIEF DESCRIPTION OF THE DRAWINGS

Drawings are included for the purpose of illustrating certain aspects of the invention. Such drawings and the description thereof are intended to facilitate understanding and should not be considered limiting of the invention. Drawings are included, in which:

FIG. 1 is a front view of an insulated sheathing of the present invention;

FIG. 2 is a side view of the insulated sheathing;

FIG. 3 is an end view of the insulated sheathing;

FIG. 4 is a cross-sectional view of a section of a building with the insulated sheathing installed;

FIGS. 5ato5care side cross-sectional views of a section of a building, showing sequential stages of assembly;

FIG. 6ais a top elevation view of a prior art outside corner wall structure constructed with conventional sheathing;

FIG. 6bis a top elevation view of an outside corner wall structure constructed with the insulated sheathing of the present invention;

FIG. 6cis a top elevation view of a prior art inside corner wall structure constructed with conventional sheathing;

FIG. 6dis a top elevation view of an inside corner wall structure constructed with the insulated sheathing of the present invention;

FIG. 7ais a side cross-sectional view of a section of a building having an opening for a door;

FIG. 7bis a side cross-sectional view of a section of a building having an opening for a window;

FIG. 7cis a front exterior view of the section of the building inFIG. 7b; and

FIG. 8 is a side view of a concrete structure where the insulated sheathing is used as part of a form system.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

The detailed description set forth below in connection with the appended drawings is intended as a description of various embodiments of the present invention and is not intended to represent the only embodiments contemplated by the inventor. The detailed description includes specific details for the purpose of providing a comprehensive understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced without these specific details.

The present invention provides an insulated sheathing and a method for assembling a wall and/or ceiling section using the insulated sheathing. The insulated sheathing aims to provide an insulation layer between the outer surface of the sheathing and the studs.

The insulated sheathing of the present invention may provide an insulation layer to concrete structures. It may be desirable to install the insulated sheathing on the exterior surface of concrete walls to help keep the walls at a temperature closer to that of the interior space in order to minimize heat transfer between the interior space and the walls. Placing the insulated sheathing on the exterior surface of concrete walls also provides a multi-layer barrier (i.e. sheathing, insulation layer, and concrete wall) between the exterior and interior spaces, which may further assist in minimizing heat transfer between the two spaces. For example, the insulated sheathing can be used as part of a partition between a warm space and a cold space, such as a room over a garage or a cantilever extending over the wall below.

Referring toFIGS. 1,2 and3, an insulatedsheathing10 comprises asheathing12 and abacking14. Sheathing12 is a structural sheet having some rigidity and strength for providing some structural support. Sheathing12 also provides physical separation. Backing14 may provide insulation. Sheathing12 and backing14 may be made of various materials. Possible materials forsheathing12 include, for example, wood sheathing, such as plywood or oriented strand board (“OSB”), drywall, fiberglass, concrete board, metal, and plastic. In a preferred embodiment,backing14 is made of an insulation medium. The insulation medium may be of various materials, such as for example polyurethane foam, polystyrene, and fiberglass. Polyurethane may be made from various compounds including isocyanate, polyisocyanate, resin, and polymeric MDI (diphenylmethane diisocyanate). The insulation medium may be a pre-cut sheet of material, or may be a fluid (which includes a liquid, semi-fluid, colloid, and/or a gel-like substance) that turns into a substantially solid and stable material when dried, cured, and/or set. A semi-fluid is a substance with flow properties that are between those of solids and liquids.

Backing

14 is applied on to the first of two surfaces ofsheathing12, which may be done in various ways, including for example by adhesives (including hot and cold adhesives), chemical reaction bonding, and fasteners (e.g. screws, nails, bolts, staples, etc.). If adhesives are used for attachingbacking14 to sheathing12, the adhesives may be applied to all or some of the contact surface ofbacking14 and/or sheathing12. In one embodiment, the insulation medium is a fluid that is applied to sheathing12 and then self-adheres to sheathing12 as the fluid dries, cures, sets, and/or hardens, which may be triggered by exposure to air or by other chemical reactions.

In one embodiment,backing14 provides an insulation layer with substantially consistent thickness on the first surface ofsheathing12. Backing14 may cover a substantial portion of the first surface ofsheathing12. Sheathing12 has a first end16 and asecond end18, either of which may extend beyond the edges ofbacking14 or may be flush with the edges ofbacking14. Sheathing12 also hassides20, which may or may not be flush with the edges ofbacking14.

Sheathing

12 andbacking14 may be of various dimensions. For example, in one embodiment, sheathing12 is 8 feet long, 4 feet wide, and 7/16 inches thick. In another embodiment, backing14 is 7 feet and 8⅝ inches long, 4 feet wide, and 2 inches thick. In a further embodiment, sheathing12 extends 2¼ inches at the first end16 and 1⅛ inches at thesecond end18 beyondbacking14. In a still further embodiment, sheathing12 extends beyond backing14 at both the first and second ends by an equal distance. Of course, sheathing12 andbacking14 may be of dimensions other than those mentioned above.

When in use, two or moreinsulated sheathings10 may be installed side-by-side in a section of a building, such that the edges of adjacent sheathings abut. The edges ofinsulated sheathings10 may be shaped to form a certain interface with the edges of adjacent insulated sheathings. For example, adjacent insulated sheathings may connect with one another by overlapping an extending piece of the sheathing of one the insulated sheathing over a recessed area on the backing of the other insulated sheathing, which is sometimes referred to as a lap joint. In other embodiments, the edges ofadjacent sheathings10 may connect to each other by, for example, a miter joint, butt joint, or tongue and groove joint.Insulated sheathing10 may be installed like drywall, except that the addition of insulation during installation may not be necessary since insulation is already effected with backing14 ofinsulated sheathing10.Insulated sheathing10 may be installed on to studs, joists, and/or trusses by screws or other fasteners through the sheathing and the backing.Insulated sheathing10 may be finished like drywall by applying tape and mud. In one embodiment, the second surface of the two surfaces ofsheathing12 has a groove formed therein near and substantially parallel to one or more of its edges to provide space for tape and mud, such that after taping and mudding, the second surface ofsheathing12 is substantially level.

Referring toFIG. 4,insulated sheathing10 may be used as a component in assembling a section of a building as described hereinafter. The section of the building has alower space15 and anupper space17.Space17 may be an enclosed room or may be alfresco. A separatingstructure30 divides the lower space and the upper space. Thestructure30 comprises the insulatedsheathing10,partition members24, and afloor panel28.Partition members24 are joists and/or trusses.Structure30 may further compriseinsulation material22.Floor panel28 is attached to an upper side ofmembers24 and theinsulated sheathing10 is attached to a lower side ofmembers24.Insulated sheathing10, with its sheathing side facing down, as determined by gravity, forms the bottom ofstructure30 and is adjacent to lowerspace15.Floor panel28 is at the top ofstructure30 and is adjacent tospace17.Insulation material22 may be disposed in any empty space betweenadjacent members24.Floor panel28 may be made of various materials, including oriented strand board (OSB). Theinsulation material22 may be batt insulation, loose fill insulation, or the like.

Avapour barrier18 may be installed betweeninsulated sheathing10 and the other components ofstructure30.Vapour barrier18 may prevent any moisture fromspace15 from seeping into the space between the floor panel andinsulated sheathing10.

A method of installinginsulated sheathing10 as a part of a partition between a first space and a second space is described herein. The method of forming a partition between a first space and a second space having partition members therebetween, the partition members each having an upper side and a lower side, comprises attaching an insulated sheathing, having a backing attached to a sheathing, to the lower side of the partition members, with the outer-facing surface of the backing facing the partition members and the outer-facing surface of the sheathing facing away from the partition members. The insulated sheathing may be attached to the partition members by fasteners. The method may further comprise disposing a vapour barrier between the insulated sheathing and the partition members prior to attaching the insulated sheathing. The method may still further comprise inserting insulation material between adjacent partition members. The method may further comprise attaching a floor panel to the upper side of the partition members.

The use ofinsulated sheathing10 may enhance the insulation properties ofstructure30. Therefore,insulated sheathing10 may be useful as ceiling material, as part of a partition between a lower level room and an upper level room where there is a temperature differential between the two rooms. The lower level room may be a garage, for example, and the upper level room may be a bedroom, where it is desirable to insulate the bedroom from temperature variations in the garage. It can also be appreciated thatinsulated sheathing10 may be used as flooring, a wall, or any other structural component of a building, especially where it is desirable to minimize heat transfer between two spaces.

Insulated sheathing

10 can be used as a component in constructing a wall structure of a building as described hereinafter. The space exterior and interior to the building for which the wall structure is constructed is denoted by “out” and “in”, respectively, in the figures. Referring toFIGS. 5ato5c, a wall section generally comprises a plurality ofwall studs32 that may be spaced apart. In one embodiment,wall studs32 are 2×4 studs. The studs may be made of various materials and may be of other dimensions, including for example 2×5 or 2×6. The upper end of eachwall stud32 is attached to the bottom surface of alower top plate34. The lower end of eachwall stud32 is attached to the top surface of abottom plate36. In one embodiment, lowertop plate34 is a piece of 2×4. In a further embodiment,bottom plate36 is a 2×6. Lowertop plate34 andbottom plate36 may be of other dimensions and made of various materials.

In a preferred embodiment,bottom plate36 is thicker thanstuds32 such that the bottom plate extends beyond the exterior-facing edge ofstuds32, to form ashoulder38. The

components

32,34, and36 may be connected by fasteners, adhesives or the like.

As shown inFIGS. 5band5c,insulated sheathing10 is disposed over the exterior-facing edges ofstuds32 and

plates

34,36, with the backing side facing the studs and the sheathing side facing outwards (i.e. away from the studs). In a preferred embodiment, backing14 substantially covers the first surface ofsheathing12, except near the upper edge and lower edge of the sheathing, to provide anupper extension40 andlower extension41 where the first surface of the sheathing has less or substantially no insulation material.Lower extension41 and the lower edge of backing14 form a notch for receiving an outer-facing portion ofbottom plate36 when sheathing10 is attached tostuds32. The sheathing may be secured to the studs in various ways, including for example fasteners, adhesives, etc. Alternatively or additionally, the lower edge ofsheathing10 may be secured to the bottom plate by fasteners or the like. When sheathing10 is attached to the studs and/or the bottom plate, the lower edge of backing14 may, at least partially, rest onshoulder38.

In a preferred embodiment, an uppertop plate42 is included above lowertop plate34 and is thicker than lowertop plate34 such that the uppertop plate42 extends beyond the exterior-facing edge of lowertop plate34, to form ashoulder44. In one embodiment, uppertop plate42 is a 2×6. However, upper top plate may be of other dimensions and made of various materials.Upper extension40 and the upper edge of backing14 form a notch for receiving an outer-facing portion of the uppertop plate42 when sheathing10 is attached tostuds32. Alternatively or additionally, the upper edge ofsheathing10 may be secured to one or both of the upper and lower top plates by fasteners or the like. When sheathing10 is attached to at least one of the studs, the bottom plate, the upper top plate, and the lower top plate, the upper edge of backing14 may, at least partially, or may not abut againstshoulder44.

In one embodiment, the interior-facing edge of

plates

34,36 and40 is substantially flush with the interior-facing surface ofstuds32.

When sheathing10 is attached to only thebottom plate36 and upper top plate42 (and/or lower top plate34), backing14 or a portion thereof may or may not be in contact withstuds32. In one embodiment, the distance by which uppertop plate42 andbottom plate36 extend beyond the exterior-facing edge ofstuds32 is substantially equal to the thickness of backing14, such that when sheathing10 is attached to thebottom plate36 and upper top plate42 (and/or lower top plate34), backing14 or at least a portion thereof abuts againststuds32.

In one embodiment,upper extension40 may extend further away from backing14 thanlower extension41. The extra extension ofupper extension40 increases the contact surface area betweensheathing12 and upper and lower

top plates

42,34, which may be desirable in terms of structural integrity when uppertop plate42 is included.

Insulated sheathing

10 may be finished like drywall by applying tape and mud.

When sheathing10 is secured to one or more of the studs, the bottom plate, the upper top plate, and the lower top plate, sheathing10 may form an exterior surface of a wall section of a building. Uppertop plate42 may be attached to components of a section of the building, which may be a roof or floor. Thebottom plate36 may be attached to another section of the building, which for example as shown in the illustrated embodiment is a floor component, which may in turn be attached to the foundation of the building.

In one embodiment, either the lower top plate or the upper top plate is omitted. In another embodiment, the lower top plate and the upper top plate are a single piece of material.

Insulation material (not shown) may be disposed in the space betweenadjacent studs32, and may or may not be in contact withbacking14. The insulation material may be any loose fill insulation, such as batting, or that blown in or injected, etc. In a further embodiment, a vapour barrier (not shown) may be disposed betweeninsulated sheathing10 andstuds32 to prevent any moisture from the exterior from seeping into the interior space. Additional sheathing (not shown), such as for example plywood or drywall, may be attached to the interior-facing side ofstuds32 to partially or completely cover the insulation material and/or the space between adjacent studs.

A method of assembling a wall structure (some also referred to as a partition) between a first space and a second space is described herein. The method of assembling a wall structure extending between an upper building structure and a lower building structure, the wall structure for providing a separation between a first space and a second space, the method comprises attaching a bottom plate to the lower building structure; attaching the first ends of a plurality of studs intermittently on the bottom plate along the length thereof; attaching a lower top plate to the second ends of the plurality of studs; disposing an insulated sheathing over a first surface of the studs, the first surface facing the first space, the insulated sheathing having a backing attached to a sheathing, and the backing being between the plurality of studs and the sheathing; attaching an upper top plate to an upper surface of the lower top plate, the upper top plate being attached to the upper building structure; and attaching the insulated sheathing to at least one of the upper top plate, lower top plate, plurality of studs, and bottom plate.

The insulated sheathing may have an upper extension and a lower extension, to provide an upper notch and a lower notch, respectively. The bottom plate and the upper top plate may extend beyond the first surface of the plurality of studs, and the extensions of the bottom plate and the upper top plate being receivable in the lower notch and the upper notch, respectively. The method may further comprise attaching the upper extension and lower extension to the upper top plate and the bottom plate, respectively.

The method may further comprise disposing a vapour barrier between the insulated sheathing and the plurality of studs prior to attaching the insulated sheathing. The method may still further comprise inserting insulation material between adjacent studs. The method may further comprise attaching drywall to a second surface of the plurality of studs, the second surface facing the second space. The method may still further comprising finishing the insulated sheathing with tape and mud.

FIGS. 6aand6bcompare an outside corner wall structure of the prior art with that using the insulated sheathing of the present invention. In the prior art, a first side and a second side of the outside corner has intermittently positioned studs, S, which are usually 2×6 beams. The first side and the second side are substantially perpendicular to each other to form a substantially right angle corner. There are corner studs, C, at the corner where the first and second sides meet for connecting the two sides. The corner studs are usually a pair of 2×6s in an L-shaped configuration when viewed at the ends, and are attached to a stud on the first side by fasteners. Sheets of drywall, DW, are attached to the outer-facing surface of the studs S and corner studs C. The drywall is usually finished by applying tape and mud.

Referring toFIG. 6b,

insulated sheathings

10a,10bcan be used to form an outside corner wall structure as described hereinbelow. A first side and a second side of the outside corner has intermittently positionedstuds32, which are preferably 2×4 beams. However, other sizes of beams may be used. In the illustrated embodiment, the first side and the second side are substantially perpendicular to each other to form a substantially right angle corner. However, in other embodiments, the first and second side may form any angle therebetween, whether acute or obtuse. There are corner studs, C, at the corner where the first and second sides meet for connecting the two sides. In one embodiment, the corner studs are in an L-shaped configuration when viewed at the ends, and are attached to a stud S on the first side by fasteners. The corner studs C may be in different configurations depending on the desired angle between the two sides and may consist of one or more pieces of material. The corner studs have outer-facing portions that extend beyond the outer surface ofstuds32 on both the first and second sides. In the illustrated embodiment, the corner studs are a pair of 2×6s that are positioned substantially orthogonal to each other.

In the illustrated embodiment, a firstinsulated sheathing10ahas aside extension46awhere the first surface of the sheathing has less or substantially no insulation material.Side extension46aand the side edge of backing14aform a notch for receiving the outer-facing extended portion of the corner studs C on the first side when sheathing10ais attached to studs C and/or32 on the first side.

A secondinsulated sheathing10bhas aside extension46bwhere the first surface of the sheathing has less or substantially no insulation material.Side extension46band the side edge of backing14bform a notch for receiving the outer-facing extended portion of the corner studs C on the second side when sheathing10bis attached to studs C and/or32 on the second side.

The

sheathings

10a,10bare attached to the studs with the backing side facing the studs and the sheathing side facing the exterior. The sheathings may be secured to the studs in various ways, including for example fasteners, adhesives, etc. When

sheathings

10a,10bare secured to the studs, the side edge of backing14a,14b,

adjacent extension

46a,46b, respectively, may at least partially or may not abut against the extended portion of studs C on either side. Sheathings10a,10bmay be attached to one or more ofstuds32 and/or corner studs C, and when attached,

backings

14a,14bmay at least partially or may not be in contact with the outer-facing surface ofstuds32.

In one embodiment, the distance by which the corner studs C extend beyond the exterior-facing edge ofstuds32 on each side is substantially equal to the thickness of backing14a,14b, such that when sheathing10a,10 is attached to the studs, backing14a,14bor at least a portion thereof abuts againststuds32. In a preferred embodiment, when

sheathings

10aand10bare installed on the studs, the edges of

side extensions

46aand46bor at least a portion thereof meet to form a corner with an angle that substantially coincide with the angle formed by the two sides.

Insulated sheathings

10a,10b, including the joint therebetween, may be finished like drywall by applying tape and mud.

FIGS. 6cand6dcompare an inside corner wall structure of the prior art with that using the insulated sheathing of the present invention. In the prior art, a first side and a second side of the inside corner has intermittently positioned studs, S, which are usually 2×6 beams. In the illustrated embodiment, the first side and the second side are substantially perpendicular to each other to form two sides of a substantially right angle corner. However, in other embodiments, the first and second side may form any angle therebetween, whether acute or obtuse. There are corner studs, C, at the corner where the first and second sides meet for connecting the two sides. The corner studs are usually a pair of 2×6s in a reversed L-shaped configuration when viewed at the ends, and are attached to a stud S on the first side by fasteners. Sheets of drywall, DW, are attached to the outer-facing surface of the studs S and corner studs C. The drywall is usually finished by applying tape and mud.

Referring toFIG. 6d,

insulated sheathings

10c,10dcan be used to form an inside corner wall structure as described hereinbelow. A first side and a second side of the outside corner has intermittently positionedstuds32, which are preferably 2×4 beams. However, other sizes of beams may be used. In the illustrated embodiment, the first side and the second side are substantially perpendicular to each other to form a substantially right angle corner. However, in other embodiments, the first and second side may form any angle therebetween, whether acute or obtuse.

There are corner studs, C, at the corner where the first and second sides meet for connecting the two sides. In one embodiment, the corner studs form a generally reversed L-shape when viewed at the ends. In a further embodiment, the corner studs are three 2×6s, two of which are placed adjacent and substantially parallel to one another and to thestuds32 on the first side, and positioned substantially orthogonal to the third. The two substantially parallel corner studs are offset to form a notch for receiving a side edge of the third corner stud, in order to provide a substantially flush interior-facing surface. The corner studs C may be in different configurations depending on the desired angle between the two sides and may consist of one or more pieces of material. The corner studs have exterior-facing portions that extend beyond the outer surface ofstuds32 on both the first and second sides.

In the illustrated embodiment, a firstinsulated sheathing10chas aside extension46cwhere the first surface of the sheathing has less or substantially no insulation material.Side extension46cand the side edge of backing14cform a notch for receiving the outer-facing extended portion of the corner studs C on the first side when sheathing10cis attached to studs C and/or32 on the first side.

A secondinsulated sheathing10dhas aside extension46dwhere the first surface of the sheathing has less or substantially no insulation material.Side extension46dand the side edge of backing14dform a notch for receiving the outer-facing extended portion of the corner studs C on the second side when sheathing10dis attached to studs C and/or32 on the second side.

The

sheathings

10c,10dare attached to the studs with the backing side facing the studs and the sheathing side facing the exterior. The sheathings may be secured to the studs in various ways, including for example fasteners, adhesives, etc. When

sheathings

10c,10dare secured to the studs, the side edge of backing14c,14d,

adjacent extension

46c,46d, respectively, may at least partially or may not abut against the extended portion of studs C on either side.

Sheathings

10c,10dmay be attached to one or more ofstuds32 and/or corner studs C, and when attached,

backings

14c,14dmay at least partially or may not be in contact with the outer-facing surface ofstuds32.

In one embodiment, the distance by which the corner studs C extend beyond the exterior-facing edge ofstuds32 on each side is substantially equal to the thickness of backing14c,14d, such that when sheathing10c,10dis attached to the studs, backing14c,14dor at least a portion thereof abuts againststuds32. In a preferred embodiment, when

sheathings

10cand10dare installed on the studs, the edges of

side extensions

46cand46dor at least a portion thereof meet to form a corner with an angle that substantially coincide with the angle formed by the two sides.

Insulated sheathings

10c,10d, including the joint therebetween, may be finished like drywall by applying tape and mud.

Referring toFIGS. 6band6d, insulation material (not shown) may be disposed in thespaces45 betweenadjacent studs32, and may or may not be in contact with backing14a,14b,14c,14d. The insulation material may be any loose fill insulation, such as batting, or that blown in or injected, etc. In a further embodiment, a vapour barrier (not shown) may be disposed between each of

insulated sheathings

10a,10b,10c,10dandstuds32 to prevent any moisture from the exterior from seeping into the interior space. Additional sheathing (not shown), such as for example plywood or drywall, may be attached to the interior-facing side ofstuds32 to partially or completely cover the insulation material and/or the space between adjacent studs.

Another method of assembling a wall structure between a first space and a second space is described herein. The method of assembling a wall structure for providing a separation between a first space and a second space, the method comprises providing a plurality of spaced-apart studs on a first side of the wall structure; providing a plurality of spaced-apart studs on a second side of the wall structure, the first and second sides forming a first angle relative to one another at the intersection therebetween; providing a corner stud at the intersection to connect the first and second sides; disposing a first insulated sheathing and a second insulated sheathing over a first surface of the studs on the first side and second sides, respectively, the first surface facing the first space, the first and second insulated sheathings each having a backing attached to a sheathing, the sheathing having a side edge, and the backing being between the studs and the sheathing; aligning the side edges of the first and second insulated sheathings near the corner stud to form a second angle therebetween, the second angle substantially coinciding with the first angle; and attaching the first and second insulated sheathings to one or both of the studs and the corner stud.

The first and second insulated sheathings each may have a side extension along its edge, to provide a notch. The corner stud may extend beyond the first surface of the studs on one or both of the first and second sides, and the extension of the corner stud being receivable in one or both of the notches. The method may further comprise attaching one or both of the side extensions to the corner stud.

The method may further comprise disposing a vapour barrier between the insulated sheathing and the studs prior to attaching the insulated sheathing. The method may still further comprise inserting insulation material between adjacent studs on one or both of the first and second sides. The method may further comprise attaching drywall to a second surface of the studs on the first side and second sides, the second surface facing the second space. The method may still further comprising finishing the first and second insulated sheathings with tape and mud.

Referring toFIGS. 7ato7c,insulated sheathing10 can be used to frame an opening, such as a window, W, or door, D, in a wall structure of a building. A wall section generally comprises a plurality ofwall studs32 that are spaced apart. In one embodiment,wall studs32 are 2×4 studs. The studs may be of other dimensions, including for example 2×5 or 2×6. The upper end of eachwall stud32 is attached to the bottom surface of alower top plate34. The lower end of eachwall stud32 is attached to the top surface of abottom plate36. In one embodiment, lowertop plate34 is a piece of 2×4. In a further embodiment,bottom plate36 is a 2×6. Lowertop plate34 andbottom plate36 may be of other dimensions.

In one embodiment, an uppertop plate42 is included above lowertop plate34 and is thicker than lowertop plate34 such that the uppertop plate42 extends beyond the exterior-facing edge of lowertop plate34, to form ashoulder44e. In a further embodiment, uppertop plate42 is a 2×6. However, upper top plate may be of other dimensions.

Each of the door opening D and window opening W is framed at the top by ahead48 and at the sides byjambs50. Window opening W is additionally framed at the bottom by asill52. In one embodiment,head48,jambs50, andsill52 are 2×6 studs, but of course studs of other sizes may be used. In a further embodiment, the interior-facing edge ofhead48,jambs50, andsill52 is substantially flush with the interior-facing surface ofstuds32.

Alintel60 is provided betweenhead48 and lowertop plate34. In one embodiment,lintel60 comprises two overlapping panels with one of the side edges adjacent thehead48.Lintel60 may be made of various materials including for example OSB boards.Lintel60 has an exterior-facing surface and an interior facing surface. In a preferred embodiment, the interior-facing surface oflintel60 is flush with the interior-facing edge ofhead48 andstuds32.Head48 extends beyond the exterior-facing surface oflintel60 to provide ashoulder38e. The

components

34,42,60 and48 may be connected by fasteners, adhesives or the like.

For both the door and window openings,insulated sheathing10 is disposed over the exterior-facing surface oflintel60 and the exterior-facing edges of lower and upper

top plates

34,42 andhead48, with the backing side facing the lintel and the sheathing side facing the exterior. In a preferred embodiment, backing14 substantially covers the first surface ofsheathing12, except near the upper edge and lower edge of the sheathing, to provide anupper extension40eandlower extension41ewhere the first surface of the sheathing has less or substantially no insulation material.Lower extension41eand the lower edge of backing14 form a notch for receiving an outer-facing portion ofhead48 when sheathing10 is disposed overlintel60.Upper extension40eand the upper edge of backing14 form a notch for receiving an outer-facing portion of the uppertop plate42 when sheathing10 is disposed overlintel60.

The sheathing may be secured to the header, upper top plate, and/or lintel in various ways, including for example fasteners, adhesives, etc. In the illustrated embodiment, the insulated sheathing is attached to the header, the upper top plate, and the lintel byfasteners62. When sheathing10 is attached to at least one of the header, upper top plate, and/or lintel, the upper edge of backing14 may at least partially or may not abut againstshoulder44e, and the lower edge of backing14 may, at least partially, rest onshoulder38e. Further, backing14 or a portion thereof may or may not be in contact withlintel60.

For the window opening, with reference toFIGS. 7band7c,lower studs54 are provided which extend betweensill52 andbottom plate36.Sill52 andbottom plate36 are preferably thicker thanlower studs54 such that bothsill52 andbottom plate36 extend beyond the exterior-facing surface oflower studs54, to form

shoulders

44fand38f, respectively. The

components

52,54, and36 may be connected by fasteners, adhesives or the like. In one embodiment, the interior-facing edge oflower studs54 is substantially flush with the interior-facing surface ofstuds32.

Insulated sheathing

10 is disposed over the exterior-facing surface oflower studs54 and the exterior-facing edges ofsill52 andbottom plate36, with the backing side facing the lower studs and the sheathing side facing the exterior. In a preferred embodiment, backing14 substantially covers the first surface ofsheathing12, except near the upper edge and lower edge of the sheathing, to provide anupper extension40fandlower extension41fwhere the first surface of the sheathing has less or substantially no insulation material.Lower extension41fand the lower edge of backing14 form a notch for receiving an outer-facing portion ofbottom plate36 when sheathing10 is disposed overlower studs54.Upper extension40fand the upper edge of backing14 form a notch for receiving an outer-facing portion of thesill52 when sheathing10 is disposed overlower studs54.

The sheathing may be secured to the sill, lower studs, and/or bottom plate in various ways, including for example fasteners, adhesives, etc. In the illustrated embodiment, the insulated sheathing is attached to the sill, lower studs, and bottom plate byfasteners62. When sheathing10 is attached to at least one of the sill, lower studs, and/or bottom plate, the upper edge of backing14 may at least partially or may not abut againstshoulder44f, and the lower edge of backing14 may, at least partially, rest onshoulder38f. Further, backing14 or a portion thereof may or may not be in contact withlower studs54.

In one embodiment, the distance by whichsill52 andbottom plate36 extend beyond the exterior-facing edge oflower studs54 is substantially equal to the thickness of backing14, such that when sheathing10 is attached to thebottom plate36 andsill52, backing14 or at least a portion thereof abuts againstlower studs54.

The construction of the wall structure, including the application ofsheathings10, on either side of door and window openings may be the same as that described above, with reference toFIGS. 5ato5c,6band6d.

Adjacent insulated sheathing installed on the wall structure may be separated by a gap G. In one embodiment, gap G is approximately ⅛″. In a further embodiment, the spacing offasteners62 along the edges ofinsulated sheathing10 is smaller than that of fasteners distanced from the edges. For example, the distance between adjacent fasteners along the edges may be approximately 3″ while the distance in between other fasteners is approximately 6″. Of course, other fastener spacings are possible, in accordance with construction standards known to those skilled in the art.Insulated sheathing10 may be finished like drywall by applying tape and mud.

Insulation material (not shown) may be disposed in thespace45 between

adjacent studs

32,54, and may or may not be in contact withbacking14. The insulation material may be any loose fill insulation, such as batting, or that blown in or injected, etc. In a further embodiment, a vapour barrier (not shown) may be disposed betweeninsulated sheathing10 and

studs

32,54 to prevent any moisture from the exterior from seeping into the interior space. Additional sheathing (not shown), such as for example plywood or drywall, may be attached to the interior-facing side of

studs

32,54 to partially or completely cover the insulation material and/or the space between adjacent studs.

A method of assembling a wall structure between a first space and a second space for framing an opening in a building section is described herein. The method of assembling a part of a wall structure extending between an edge of an opening in the wall structure and a lower building structure, the wall structure for providing a partition between a first space and a second space, the method comprises attaching a bottom plate to the lower building structure; attaching the first ends of a plurality of studs intermittently on the bottom plate along the length thereof; attaching a sill to the second ends of the plurality of studs, the sill being at the edge of the opening; disposing an insulated sheathing over a first surface of the studs, the first surface facing the first space, the insulated sheathing having a backing attached to a sheathing, and the backing being between the plurality of studs and the sheathing; and attaching the insulated sheathing to at least one of the sill, plurality of studs, and bottom plate.

The insulated sheathing may have an upper extension and a lower extension, to provide an upper notch and a lower notch, respectively. The bottom plate and the sill may extend beyond the first surface of the plurality of studs, and the extensions of the bottom plate and the sill being receivable in the lower notch and the upper notch, respectively. The method may further comprise attaching the upper extension and lower extension to the sill and the bottom plate, respectively.

Insulated sheathing

10 may also be used to form at least a part of a temporary or permanent mold into which concrete or similar materials are poured. Such a mold is often referred to as a form system. Form systems may be assembled on site and may stay in place after the concrete or similar materials have cured.Sheathing10 may be used to construct form systems, or used in conjunction with other form systems, such as for example the Strip-Ease™ and the Duraform™ systems.

Insulated sheathing

10 of various sizes may be used in a form system. In one embodiment, sheathing10 having a length of 8 feet and a width of 4 feet is used for the form system. In another embodiment, sheathing10 having a length of 8 feet and a width of 2 feet is used for the form system. In yet another embodiment, sheathing12 ofinsulated sheathing10 has a thickness of ½″. It can be appreciated that sheathing10 of other dimensions may also be used.Sheathing12 may be made of preserved wood foundation type plywood, or other suitable materials as discussed above.

Insulated sheathings

10 may be used below grade and underground. For example,sheathings10 may be used in a form for constructing a concrete foundation for a building. Referring toFIG. 8,insulated sheathing10 may be used to construct aconcrete structure70 as described hereinafter. A plurality ofsheathings10 is erected substantially vertically along the perimeter of an area to form a first substantially continuous wall (hereinafter the “first form”) surrounding aninterior space72. In one embodiment,sheathings10 are positioned to have the backing side facing theinterior space72. Another set of sheathings (not shown), which may be insulatedsheathings10 or sheathings used in other form systems (e.g. plywood, timber, plastic, metal, etc.), is erected substantially vertically on the interior-facing side of the first form, to form a second substantially continuous wall (hereinafter the “second form”). The second form is erected at a distance from the first form to define a space into which concrete is poured to form a concrete structure. The distance between the forms depends on the desired thickness of the resulting concrete structure. In one embodiment, the distance between the forms range from 8 to 10 inches. The distance between the forms is preferably, but not necessarily, substantially consistent laterally and/or vertically along the surface of the forms.

Before the concrete is poured, the first and second forms are braced in place to help maintain the shape of the forms and the distance therebetween. The forms may be braced and/or reinforced in various ways to prevent them from deforming (e.g. bowing or bending outwards) as concrete is poured in between the forms.Sheathings10 may include a plurality of holes throughout its surface for receiving concrete ties, which are usually metal fasteners. In one embodiment, the first form and the second form each include a plurality of holes throughout their surfaces through which concrete ties are received in order to fasten the forms to each other at various locations to help maintain the shape of the forms and the distance therebetween, as concrete is poured between the forms. After the concrete has cured between the forms, one or both of the forms may be removed to reveal the concrete structure. Since the cured concrete can provide structural support, it is not necessary to retain the forms.

In one embodiment, the concrete structure is a wall of a building and the first form is retained while the second form is removed after the concrete has cured. It may be desirable to retain the first form, which comprisesinsulated sheathings10, in order to help insulate the concrete wall from the exterior temperature to keep the concrete wall at substantially the same temperature as the interior space. The first form also acts as a barrier, in addition to the concrete wall, between the exterior space and the interior space, which may assist in minimizing heat transfer between the two spaces. In a further embodiment,sheathings10 are used for the second form and the second form is retained to provide additional insulation between the interior space and the concrete wall. By retaining one or both forms, at least one form removal task is eliminated which helps make the construction process more time-efficient and maybe more cost-efficient.

In addition to providing thermal insulation,insulated sheathings10 may provide some acoustic insulation between the spaces for whichsheathings10 act as a partition. In a further embodiment,sheathings10 may include integrated furring strips for cladding finishes.

Waterproofing materials and/or systems that are generally applied to the outer surface of concrete walls may also be applied to the exterior-facing surface ofsheathings10.

A method for constructing a concrete structure is described hereinafter. The method of constructing a concrete structure for surrounding an area, the area having a perimeter, the method comprising erecting a plurality of insulated sheathings along the perimeter to form a first form, the first form defining an interior space therein, each of the insulated sheathings having a backing attached to a sheathing, the backing side of the insulated sheathings facing the interior space; erecting a plurality of sheathings in the interior space, spaced apart from the plurality of insulated sheathings, to form a second form, and the first form and second form defining a space therebetween; bracing the first and second forms; pouring concrete into the space; and allowing the concrete to cure. The method may further comprise removing one or both of the forms after the concrete cures. The method may still further comprise applying waterproofing materials on the sheathing of the plurality of insulated sheathings of the first form.

The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to those embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein, but is to be accorded the full scope consistent with the claims, wherein reference to an element in the singular, such as by use of the article “a” or “an” is not intended to mean “one and only one” unless specifically so stated, but rather “one or more”. All structural and functional equivalents to the elements of the various embodiments described throughout the disclosure that are know or later come to be known to those of ordinary skill in the art are intended to be encompassed by the elements of the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. For US patent properties, it is noted that no claim element is to be construed under the provisions of 35 USC 112, sixth paragraph, unless the element is expressly recited using the phrase “means for” or “step for”.

Claims

I claim:

1. An insulated sheathing for use in construction comprising a sheathing having a first surface, second surface, and edges; and a backing attached to the first surface of the sheathing.

2. The insulated sheathing ofclaim 1 wherein the backing comprises an insulation medium.

3. The insulated sheathing ofclaim 2 wherein the insulation medium comprises at least one of polyurethane, polystyrene, and fiberglass.

4. The insulated sheathing ofclaim 2 wherein the insulation medium is a pre-cut sheet of material.

5. The insulated sheathing ofclaim 4 wherein the backing is attached to the sheathing by adhesives, chemical reaction bonding, fasteners, or a combination thereof.

6. The insulated sheathing ofclaim 2 wherein the insulation medium is a fluid applied to the sheathing that self-adheres to the sheathing as the fluid dries, cures, sets or hardens.

7. The insulated sheathing ofclaim 1 wherein the sheathing comprises at least one of plywood, OSB, drywall, fiberglass, concrete board, metal, and plastic.

8. The insulated sheathing ofclaim 1 wherein the edges are configured to connect to an adjacent insulated sheathing by a lap joint, miter joint, butt joint, or tongue and groove joint.

9. A method of installing the insulated sheathing ofclaim 1 as a part of a partition between a first space and a second space, the first space and second space having partition members therebetween, the partition members each having an upper side and a lower side, the method comprising attaching the insulated sheathing to the lower side of the partition members, with the first surface of the insulated sheathing facing the partition members.

10. The method ofclaim 9 further comprising attaching the insulated sheathing to the partition members using fasteners.

11. The method ofclaim 9 further comprising disposing a vapour barrier between the insulated sheathing and the partition members prior to attaching the insulated sheathing.

12. The method ofclaim 9 further comprising inserting insulation material between adjacent partition members.

13. The method ofclaim 9 further comprising attaching a floor panel to the upper side of the partition members.

14. A method of assembling a wall structure extending between an upper building structure and a lower building structure, the wall structure for providing a separation between a first space and a second space, the method comprising:

attaching a bottom plate to the lower building structure;

attaching the first ends of a plurality of studs intermittently on the bottom plate along the length thereof;

attaching a top plate to the second ends of the plurality of studs, the top plate being attached to the upper building structure;

disposing an insulated sheathing over a first surface of the studs, the first surface facing the first space, the insulated sheathing comprising a sheathing having a first surface and a second surface, and a backing attached to the first surface of the sheathing, and the backing being between the plurality of studs and the sheathing; and

attaching the insulated sheathing to at least one of the top plate, plurality of studs, and bottom plate.

15. The method ofclaim 14 wherein the top plate is a sill below an opening in the wall structure and the upper building structure is a jamb.

16. The method ofclaim 14 wherein the insulated sheathing has an upper extension and a lower extension, to provide an upper notch and a lower notch, respectively and wherein the bottom plate and the top plate extend beyond the first surface of the plurality of studs, and the extensions of the bottom plate and the top plate being receivable in the lower notch and the upper notch, respectively.

17. The method ofclaim 16 further comprising attaching the upper extension and lower extension to the top plate and the bottom plate, respectively.

18. A method of assembling a wall structure extending between an upper building structure and a lower building structure of a building, the wall structure for providing a separation between a first space and a second space, the method comprising:

attaching a bottom plate to the lower building structure;

attaching a lower top plate to the second ends of the plurality of studs;

disposing an insulated sheathing over a first surface of the studs, the first surface facing the first space, the insulated sheathing comprising a sheathing having a first surface and a second surface, and a backing attached to the first surface of the sheathing, and the backing being between the plurality of studs and the sheathing;

attaching an upper top plate to an upper surface of the lower top plate, the upper top plate being attached to the upper building structure; and

attaching the insulated sheathing to at least one of the upper top plate, lower top plate, plurality of studs, and bottom plate.

19. The method ofclaim 18 wherein the insulated sheathing has an upper extension and a lower extension, to provide an upper notch and a lower notch, respectively, and wherein the bottom plate and the upper top plate extend beyond the first surface of the plurality of studs, and the extensions of the bottom plate and the upper top plate being receivable in the lower notch and the upper notch, respectively.

20. The method ofclaim 19 further comprising attaching the upper extension and lower extension to the upper top plate and the bottom plate, respectively.

21. The method ofclaim 18 further comprising attaching drywall to a second surface of the plurality of studs, the second surface facing the second space.

22. The method ofclaim 18 further comprising finishing the insulated sheathing with tape and mud.

23. The method ofclaim 18 wherein the bottom plate is a head above an opening in the wall structure and the lower building structure is a jamb.

24. The method ofclaim 23 wherein the first ends of the plurality of studs are attached to the bottom plate via a lintel.

25. The method ofclaim 23 wherein the plurality of studs are substituted by a lintel, such that the lintel extends between the lower top plate and the bottom plate.

26. The method ofclaim 18 wherein the first space is exterior to the building.

27. The method ofclaim 26 wherein the sheathing is OSB.

28. A method of assembling a wall structure for providing a separation between a first space and a second space, the method comprising:

providing a plurality of spaced-apart studs on a first side of the wall structure;

providing a plurality of spaced-apart studs on a second side of the wall structure, the first and second sides forming a first angle relative to one another at the intersection therebetween;

providing a corner stud at the intersection to connect the first and second sides;

disposing a first insulated sheathing and a second insulated sheathing over a first surface of the studs on the first side and second sides, respectively, the first surface facing the first space, the first and second insulated sheathings each comprising a sheathing having a side edge, a first surface, and a second surface, and a backing attached to the first surface of the sheathing, and the backing being between the studs and the sheathing;

aligning the side edges of the first and second insulated sheathings near the corner stud to form a second angle therebetween, the second angle substantially coinciding with the first angle; and

attaching the first and second insulated sheathings to one or both of the studs and the corner stud.

29. The method ofclaim 28 wherein the first and second insulated sheathings each have a side extension along its edge, to provide a notch; and wherein the corner stud extends beyond the first surface of the studs on one or both of the first and second sides, and the extension of the corner stud being receivable in one or both of the notches.

30. The method ofclaim 29 further comprising attaching one or both of the side extensions to the corner stud.

31. A method for constructing a concrete structure for surrounding an area, the area having a perimeter, the method comprising:

erecting a plurality of insulated sheathings along the perimeter to form a first form, the first form defining an interior space therein, each of the insulated sheathings comprising a first surface, second surface, and edges, and a backing attached to the first surface of the sheathing, the backing of the insulated sheathings facing the interior space;

erecting a plurality of sheathings in the interior space, spaced apart from the plurality of insulated sheathings, to form a second form, and the first form and second form defining a space therebetween;

bracing the first and second forms;

pouring concrete into the space; and

allowing the concrete to cure.

32. The method ofclaim 31 further comprising removing one or both of the forms after the concrete cures.

33. The method ofclaim 31 further comprising applying waterproofing materials on the sheathing of the plurality of insulated sheathings of the first form.