INSULATED SHEATHING AND METHOD

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. 5a to 5c are side cross-sectional views of a section of a building, showing sequential stages of assembly;

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

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

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

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

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

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

FIG. 7c is a front exterior view of the section of the building in FIG. 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 to FIGS. 1, 2 and 3, an insulated sheathing 10 comprises a sheathing 12 and a backing 14. Sheathing 12 is a structural sheet having some rigidity and strength for providing some structural support. Sheathing 12 also provides physical separation. Backing 14 may provide insulation. Sheathing 12 and backing 14 may be made of various materials. Possible materials for sheathing 12 include, for example, wood sheathing, such as plywood or oriented strand board (“OSB”), drywall, fiberglass, concrete board, metal, and plastic. In a preferred embodiment, backing 14 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 of sheathing 12, 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 attaching backing 14 to sheathing 12, the adhesives may be applied to all or some of the contact surface of backing 14 and/or sheathing 12. In one embodiment, the insulation medium is a fluid that is applied to sheathing 12 and then self-adheres to sheathing 12 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, backing 14 provides an insulation layer with substantially consistent thickness on the first surface of sheathing 12. Backing 14 may cover a substantial portion of the first surface of sheathing 12. Sheathing 12 has a first end 16 and a second end 18, either of which may extend beyond the edges of backing 14 or may be flush with the edges of backing 14. Sheathing 12 also has sides 20, which may or may not be flush with the edges of backing 14.

Sheathing 12 and backing 14 may be of various dimensions. For example, in one embodiment, sheathing 12 is 8 feet long, 4 feet wide, and 7/16 inches thick. In another embodiment, backing 14 is 7 feet and 8⅝ inches long, 4 feet wide, and 2 inches thick. In a further embodiment, sheathing 12 extends 2¼ inches at the first end 16 and 1⅛ inches at the second end 18 beyond backing 14. In a still further embodiment, sheathing 12 extends beyond backing 14 at both the first and second ends by an equal distance. Of course, sheathing 12 and backing 14 may be of dimensions other than those mentioned above.

When in use, two or more insulated sheathings 10 may be installed side-by-side in a section of a building, such that the edges of adjacent sheathings abut. The edges of insulated sheathings 10 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 of adjacent sheathings 10 may connect to each other by, for example, a miter joint, butt joint, or tongue and groove joint. Insulated sheathing 10 may be installed like drywall, except that the addition of insulation during installation may not be necessary since insulation is already effected with backing 14 of insulated sheathing 10. Insulated sheathing 10 may be installed on to studs, joists, and/or trusses by screws or other fasteners through the sheathing and the backing. Insulated sheathing 10 may be finished like drywall by applying tape and mud. In one embodiment, the second surface of the two surfaces of sheathing 12 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 of sheathing 12 is substantially level.

Referring to FIG. 4, insulated sheathing 10 may be used as a component in assembling a section of a building as described hereinafter. The section of the building has a lower space 15 and an upper space 17. Space 17 may be an enclosed room or may be alfresco. A separating structure 30 divides the lower space and the upper space. The structure 30 comprises the insulated sheathing 10, partition members 24, and a floor panel 28. Partition members 24 are joists and/or trusses. Structure 30 may further comprise insulation material 22. Floor panel 28 is attached to an upper side of members 24 and the insulated sheathing 10 is attached to a lower side of members 24. Insulated sheathing 10, with its sheathing side facing down, as determined by gravity, forms the bottom of structure 30 and is adjacent to lower space 15. Floor panel 28 is at the top of structure 30 and is adjacent to space 17. Insulation material 22 may be disposed in any empty space between adjacent members 24. Floor panel 28 may be made of various materials, including oriented strand board (OSB). The insulation material 22 may be batt insulation, loose fill insulation, or the like.

A vapour barrier 18 may be installed between insulated sheathing 10 and the other components of structure 30. Vapour barrier 18 may prevent any moisture from space 15 from seeping into the space between the floor panel and insulated sheathing 10.

A method of installing insulated sheathing 10 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 of insulated sheathing 10 may enhance the insulation properties of structure 30. Therefore, insulated sheathing 10 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 that insulated sheathing 10 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 to FIGS. 5a to 5c, a wall section generally comprises a plurality of wall studs 32 that may be spaced apart. In one embodiment, wall studs 32 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 each wall stud 32 is attached to the bottom surface of a lower top plate 34. The lower end of each wall stud 32 is attached to the top surface of a bottom plate 36. In one embodiment, lower top plate 34 is a piece of 2×4. In a further embodiment, bottom plate 36 is a 2×6. Lower top plate 34 and bottom plate 36 may be of other dimensions and made of various materials.

In a preferred embodiment, bottom plate 36 is thicker than studs 32 such that the bottom plate extends beyond the exterior-facing edge of studs 32, to form a shoulder 38. The components 32, 34, and 36 may be connected by fasteners, adhesives or the like.

As shown in FIGS. 5b and 5c, insulated sheathing 10 is disposed over the exterior-facing edges of studs 32 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, backing 14 substantially covers the first surface of sheathing 12, except near the upper edge and lower edge of the sheathing, to provide an upper extension 40 and lower extension 41 where the first surface of the sheathing has less or substantially no insulation material. Lower extension 41 and the lower edge of backing 14 form a notch for receiving an outer-facing portion of bottom plate 36 when sheathing 10 is attached to studs 32. The sheathing may be secured to the studs in various ways, including for example fasteners, adhesives, etc. Alternatively or additionally, the lower edge of sheathing 10 may be secured to the bottom plate by fasteners or the like. When sheathing 10 is attached to the studs and/or the bottom plate, the lower edge of backing 14 may, at least partially, rest on shoulder 38.

In a preferred embodiment, an upper top plate 42 is included above lower top plate 34 and is thicker than lower top plate 34 such that the upper top plate 42 extends beyond the exterior-facing edge of lower top plate 34, to form a shoulder 44. In one embodiment, upper top plate 42 is a 2×6. However, upper top plate may be of other dimensions and made of various materials. Upper extension 40 and the upper edge of backing 14 form a notch for receiving an outer-facing portion of the upper top plate 42 when sheathing 10 is attached to studs 32. Alternatively or additionally, the upper edge of sheathing 10 may be secured to one or both of the upper and lower top plates by fasteners or the like. When sheathing 10 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 backing 14 may, at least partially, or may not abut against shoulder 44.

In one embodiment, the interior-facing edge of plates 34, 36 and 40 is substantially flush with the interior-facing surface of studs 32.

When sheathing 10 is attached to only the bottom plate 36 and upper top plate 42 (and/or lower top plate 34), backing 14 or a portion thereof may or may not be in contact with studs 32. In one embodiment, the distance by which upper top plate 42 and bottom plate 36 extend beyond the exterior-facing edge of studs 32 is substantially equal to the thickness of backing 14, such that when sheathing 10 is attached to the bottom plate 36 and upper top plate 42 (and/or lower top plate 34), backing 14 or at least a portion thereof abuts against studs 32.

In one embodiment, upper extension 40 may extend further away from backing 14 than lower extension 41. The extra extension of upper extension 40 increases the contact surface area between sheathing 12 and upper and lower top plates 42, 34, which may be desirable in terms of structural integrity when upper top plate 42 is included.

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

When sheathing 10 is secured to one or more of the studs, the bottom plate, the upper top plate, and the lower top plate, sheathing 10 may form an exterior surface of a wall section of a building. Upper top plate 42 may be attached to components of a section of the building, which may be a roof or floor. The bottom plate 36 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 between adjacent studs 32, and may or may not be in contact with backing 14. 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 insulated sheathing 10 and studs 32 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 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. 6a and 6b compare 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 to FIG. 6b, insulated sheathings 10a, 10b can 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 positioned studs 32, 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 of studs 32 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 first insulated sheathing 10a has a side extension 46a where the first surface of the sheathing has less or substantially no insulation material. Side extension 46a and the side edge of backing 14a form a notch for receiving the outer-facing extended portion of the corner studs C on the first side when sheathing 10a is attached to studs C and/or 32 on the first side.

A second insulated sheathing 10b has a side extension 46b where the first surface of the sheathing has less or substantially no insulation material. Side extension 46b and the side edge of backing 14b form a notch for receiving the outer-facing extended portion of the corner studs C on the second side when sheathing 10b is attached to studs C and/or 32 on the second side.

The sheathings 10a, 10b are 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, 10b are secured to the studs, the side edge of backing 14a, 14b, adjacent extension 46a, 46b, respectively, may at least partially or may not abut against the extended portion of studs C on either side. Sheathings 10a, 10b may be attached to one or more of studs 32 and/or corner studs C, and when attached, backings 14a, 14b may at least partially or may not be in contact with the outer-facing surface of studs 32.

In one embodiment, the distance by which the corner studs C extend beyond the exterior-facing edge of studs 32 on each side is substantially equal to the thickness of backing 14a, 14b, such that when sheathing 10a, 10 is attached to the studs, backing 14a, 14b or at least a portion thereof abuts against studs 32. In a preferred embodiment, when sheathings 10a and 10b are installed on the studs, the edges of side extensions 46a and 46b or 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. 6c and 6d compare 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 to FIG. 6d, insulated sheathings 10c, 10d can 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 positioned studs 32, 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 the studs 32 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 of studs 32 on both the first and second sides.

In the illustrated embodiment, a first insulated sheathing 10c has a side extension 46c where the first surface of the sheathing has less or substantially no insulation material. Side extension 46c and the side edge of backing 14c form a notch for receiving the outer-facing extended portion of the corner studs C on the first side when sheathing 10c is attached to studs C and/or 32 on the first side.

A second insulated sheathing 10d has a side extension 46d where the first surface of the sheathing has less or substantially no insulation material. Side extension 46d and the side edge of backing 14d form a notch for receiving the outer-facing extended portion of the corner studs C on the second side when sheathing 10d is attached to studs C and/or 32 on the second side.

The sheathings 10c, 10d are 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, 10d are secured to the studs, the side edge of backing 14c, 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, 10d may be attached to one or more of studs 32 and/or corner studs C, and when attached, backings 14c, 14d may at least partially or may not be in contact with the outer-facing surface of studs 32.

In one embodiment, the distance by which the corner studs C extend beyond the exterior-facing edge of studs 32 on each side is substantially equal to the thickness of backing 14c, 14d, such that when sheathing 10c, 10d is attached to the studs, backing 14c, 14d or at least a portion thereof abuts against studs 32. In a preferred embodiment, when sheathings 10c and 10d are installed on the studs, the edges of side extensions 46c and 46d or 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 to FIGS. 6b and 6d, insulation material (not shown) may be disposed in the spaces 45 between adjacent studs 32, and may or may not be in contact with backing 14a, 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, 10d and studs 32 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 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 to FIGS. 7a to 7c, insulated sheathing 10 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 of wall studs 32 that are spaced apart. In one embodiment, wall studs 32 are 2×4 studs. The studs may be of other dimensions, including for example 2×5 or 2×6. The upper end of each wall stud 32 is attached to the bottom surface of a lower top plate 34. The lower end of each wall stud 32 is attached to the top surface of a bottom plate 36. In one embodiment, lower top plate 34 is a piece of 2×4. In a further embodiment, bottom plate 36 is a 2×6. Lower top plate 34 and bottom plate 36 may be of other dimensions.

In one embodiment, an upper top plate 42 is included above lower top plate 34 and is thicker than lower top plate 34 such that the upper top plate 42 extends beyond the exterior-facing edge of lower top plate 34, to form a shoulder 44e. In a further embodiment, upper top plate 42 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 a head 48 and at the sides by jambs 50. Window opening W is additionally framed at the bottom by a sill 52. In one embodiment, head 48, jambs 50, and sill 52 are 2×6 studs, but of course studs of other sizes may be used. In a further embodiment, the interior-facing edge of head 48, jambs 50, and sill 52 is substantially flush with the interior-facing surface of studs 32.

A lintel 60 is provided between head 48 and lower top plate 34. In one embodiment, lintel 60 comprises two overlapping panels with one of the side edges adjacent the head 48. Lintel 60 may be made of various materials including for example OSB boards. Lintel 60 has an exterior-facing surface and an interior facing surface. In a preferred embodiment, the interior-facing surface of lintel 60 is flush with the interior-facing edge of head 48 and studs 32. Head 48 extends beyond the exterior-facing surface of lintel 60 to provide a shoulder 38e. The components 34, 42, 60 and 48 may be connected by fasteners, adhesives or the like.

For both the door and window openings, insulated sheathing 10 is disposed over the exterior-facing surface of lintel 60 and the exterior-facing edges of lower and upper top plates 34, 42 and head 48, with the backing side facing the lintel and the sheathing side facing the exterior. In a preferred embodiment, backing 14 substantially covers the first surface of sheathing 12, except near the upper edge and lower edge of the sheathing, to provide an upper extension 40e and lower extension 41e where the first surface of the sheathing has less or substantially no insulation material. Lower extension 41e and the lower edge of backing 14 form a notch for receiving an outer-facing portion of head 48 when sheathing 10 is disposed over lintel 60. Upper extension 40e and the upper edge of backing 14 form a notch for receiving an outer-facing portion of the upper top plate 42 when sheathing 10 is disposed over lintel 60.

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 by fasteners 62. When sheathing 10 is attached to at least one of the header, upper top plate, and/or lintel, the upper edge of backing 14 may at least partially or may not abut against shoulder 44e, and the lower edge of backing 14 may, at least partially, rest on shoulder 38e. Further, backing 14 or a portion thereof may or may not be in contact with lintel 60.

For the window opening, with reference to FIGS. 7b and 7c, lower studs 54 are provided which extend between sill 52 and bottom plate 36. Sill 52 and bottom plate 36 are preferably thicker than lower studs 54 such that both sill 52 and bottom plate 36 extend beyond the exterior-facing surface of lower studs 54, to form shoulders 44f and 38f, respectively. The components 52, 54, and 36 may be connected by fasteners, adhesives or the like. In one embodiment, the interior-facing edge of lower studs 54 is substantially flush with the interior-facing surface of studs 32.

Insulated sheathing 10 is disposed over the exterior-facing surface of lower studs 54 and the exterior-facing edges of sill 52 and bottom plate 36, with the backing side facing the lower studs and the sheathing side facing the exterior. In a preferred embodiment, backing 14 substantially covers the first surface of sheathing 12, except near the upper edge and lower edge of the sheathing, to provide an upper extension 40f and lower extension 41f where the first surface of the sheathing has less or substantially no insulation material. Lower extension 41f and the lower edge of backing 14 form a notch for receiving an outer-facing portion of bottom plate 36 when sheathing 10 is disposed over lower studs 54. Upper extension 40f and the upper edge of backing 14 form a notch for receiving an outer-facing portion of the sill 52 when sheathing 10 is disposed over lower studs 54.

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 by fasteners 62. When sheathing 10 is attached to at least one of the sill, lower studs, and/or bottom plate, the upper edge of backing 14 may at least partially or may not abut against shoulder 44f, and the lower edge of backing 14 may, at least partially, rest on shoulder 38f. Further, backing 14 or a portion thereof may or may not be in contact with lower studs 54.

In one embodiment, the distance by which sill 52 and bottom plate 36 extend beyond the exterior-facing edge of lower studs 54 is substantially equal to the thickness of backing 14, such that when sheathing 10 is attached to the bottom plate 36 and sill 52, backing 14 or at least a portion thereof abuts against lower studs 54.

The construction of the wall structure, including the application of sheathings 10, on either side of door and window openings may be the same as that described above, with reference to FIGS. 5a to 5c, 6b and 6d.

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 of fasteners 62 along the edges of insulated sheathing 10 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 sheathing 10 may be finished like drywall by applying tape and mud.

Insulation material (not shown) may be disposed in the space 45 between adjacent studs 32, 54, and may or may not be in contact with backing 14. 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 insulated sheathing 10 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. Sheathing 10 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, sheathing 10 having a length of 8 feet and a width of 4 feet is used for the form system. In another embodiment, sheathing 10 having a length of 8 feet and a width of 2 feet is used for the form system. In yet another embodiment, sheathing 12 of insulated sheathing 10 has a thickness of ½″. It can be appreciated that sheathing 10 of other dimensions may also be used. Sheathing 12 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, sheathings 10 may be used in a form for constructing a concrete foundation for a building. Referring to FIG. 8, insulated sheathing 10 may be used to construct a concrete structure 70 as described hereinafter. A plurality of sheathings 10 is erected substantially vertically along the perimeter of an area to form a first substantially continuous wall (hereinafter the “first form”) surrounding an interior space 72. In one embodiment, sheathings 10 are positioned to have the backing side facing the interior space 72. Another set of sheathings (not shown), which may be insulated sheathings 10 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. Sheathings 10 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 comprises insulated sheathings 10, 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, sheathings 10 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 sheathings 10 may provide some acoustic insulation between the spaces for which sheathings 10 act as a partition. In a further embodiment, sheathings 10 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 of sheathings 10.

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

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 of claim 1 wherein the backing comprises an insulation medium.

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

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

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

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

8. The insulated sheathing of claim 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 of claim 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 of claim 9 further comprising attaching the insulated sheathing to the partition members using fasteners.

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

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

13. The method of claim 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 of claim 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 of claim 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 of claim 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 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.

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

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

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

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

25. The method of claim 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 of claim 18 wherein the first space is exterior to the building.

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

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