AIR BARRIER SYSTEM

Abstract

An air barrier system is provided. The air barrier system includes a plurality of framing members configured to form insulation cavities. A plurality of panels is attached to an exterior surface of the framing members and gasket material is positioned therebetween. Adjacent panels form joints. Insulative batts are positioned within the insulation cavities. Sealing material is positioned over the joints.

Description

BACKGROUND

Various housing codes require the installation of an air barrier system in the construction of structures, such as for example a house. Generally, an air barrier system is configured to “seal” the entire structure, thereby controlling the passage of air into and out of the structure.

In some instances, the air barrier system includes a continuous vapor barrier in the form of a polymeric sheet configured for application to interior walls. In other instances, the air barrier system includes a vapor barrier applied to external walls of the structure.

It would be advantageous to provide an improved air barrier system.

SUMMARY OF THE INVENTION

The above objects as well as other objects not specifically enumerated are achieved by an air barrier system. The air barrier system includes a plurality of framing members configured to form insulation cavities. A plurality of panels is attached to an exterior surface of the framing members and gasket material is positioned therebetween. Adjacent panels form joints. Insulative batts are positioned within the insulation cavities. Sealing material is positioned over the joints.

According to this invention there is also provided an air barrier system. The air barrier system includes a plurality of framing members configured to form insulation cavities. A plurality of panels is attached to an exterior surface of the framing members. Adjacent panels form joints. Insulative batts are positioned within the insulation cavities and sealing material is positioned over the joints.

According to this invention there is also provided a method of installing an air barrier system. The method includes the steps of forming insulation cavities within framing members, attaching a plurality of panels to an exterior surface of the framing members and positioning gasket material therebetween, wherein adjacent panels form joint, positioning insulative batts within the insulation cavities and sealing the joints.

Various objects and advantages of the air barrier system will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view, in elevation, of a sidewall of a building illustrating a conventional insulative structure.

FIG. 2 is a side view, in elevation, of a sidewall of a building illustrating an improved air barrier system.

FIG. 3 is an enlarged side view, in elevation, of a portion of the sidewall of FIG. 2.

FIG. 4 is a perspective view of a portion of a sidewall illustrating the improved air barrier system of FIG. 2.

FIG. 5 is a plan view of a portion of the sidewall of FIG. 4 illustrating a shiplap joint formed by the panel materials.

FIG. 6 is a side view, in elevation, of a portion of the sidewall of FIG. 4 illustrating a butt joint formed by the panel materials.

FIG. 7 is a side view, in elevation, of a portion of the sidewall of FIG. 4 illustrating a first alternate embodiment of a butt joint formed by the panel materials.

FIG. 8 is a side view, in elevation, of a portion of the sidewall of FIG. 4 illustrating a second alternate embodiment of a butt joint formed by the panel materials.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described with occasional reference to the specific embodiments of the invention. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

Unless otherwise indicated, all numbers expressing quantities of dimensions such as length, width, height, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the present invention. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements.

The description and figures disclose an improved air barrier system for application to the exterior of a residence or building. Generally, the improved air barrier system is configured to replace conventional insulation and water vapor systems with an improved system.

Referring now to FIG. 1, one example of a conventional insulative structure for a building sidewall is shown generally at 10. The sidewall 10 is configured to define interior space within the building and to support additional structural components. The sidewall 10 can be formed from various structural framing members, such as the non-limiting examples a bottom plate 12, a plurality of top plates 14a and 14b, and studs (not shown) extending therebetween. The bottom plate 12, top plates 14a and 14b and studs can be configured to provide surfaces to which additional framing members or wall panels can be attached. In certain embodiment, the bottom plate 12, top plates 14a and 14b and studs are made of wood. In other embodiments, the bottom plate 12, top plates 14a and 14b and studs can be made of other desired materials, including the non-limiting example of steel. The bottom plate 12, top plates 14a and 14b and studs can have any desired dimensions.

Referring again to FIG. 1, the exterior of the sidewall 10 is covered by an exterior sheathing 16 attached to the various structural framing members. The exterior sheathing 16 is configured to provide rigidity to the sidewall 10 and also configured to provide a surface for exterior wall coverings (not shown). In the illustrated embodiment, the exterior sheathing 16 is made of oriented strand board (OSB). In other embodiments, the exterior sheathing 16 can be made of other materials, such as for example plywood, waferboard, rigid foam or fiberboard, sufficient to provide rigidity to the sidewall 10 and to provide a surface for exterior wall coverings. The exterior sheathing 16 has an exterior surface 18 and an interior surface 19.

The exterior surface 18 of the exterior sheathing 16 is covered by a layer of house wrap material 20. The house wrap material 20 is configured to provide a water barrier between an outer cladding (not shown) of the sidewall 10 and the various framing members such as to allow water vapor to pass through, yet restrict air infiltration. One example of a commercially available house wrap material is Tyvek® manufactured and marked by Dupont, headquartered in Wilmington, Del.

The interior of the sidewall 10 can be covered by construction material 22. The construction material 22 can be any desired material or combination of materials, including the non-limiting examples of drywall and paneling. The construction material 22 has an interior surface 23.

Insulation cavities 24 can be formed in the spaces between the various structural framing members, the interior surface 19 of the exterior sheathing 16 and the interior surface 23 of the construction material 22. The term “insulation cavity” as used herein, is defined to mean any space within the building within which insulation is desired, including the non-limiting examples of a building attic or sidewalls. In certain embodiments, the insulation cavities 24 can extend from the bottom plate 12 to the top plate 14b. In other embodiments, the insulation cavities 24 can extend from the bottom plate 12 or the top plate 14b to a building fixture, such as for example a window (not shown). While the insulation cavity 24 illustrated in FIG. 1 is shown as being located in the sidewall 10 of a building, it should be appreciated that other insulation cavities can occur in other locations of the building, such as the non-limiting example of an attic space.

The insulation cavities 24 have a width W. The width W of the insulation cavities 24 corresponds to the width of the bottom plate 12 and the top plates 14a and 14b. In certain instances, the width of the bottom plate 12 and the top plates 14a and 14b is nominally 6.0 inches, which generally corresponds to an actual width of 5.5 inches. In other embodiments, the width W of the insulation cavities 24 can be in a range of from about 3.5 inches to about 5.5 inches. In still other embodiments, the width W of the insulation cavities 24 can be more about 5.5 inches.

Referring again to FIG. 1, insulative batts 26 can be positioned within the insulation cavities 24. The insulation batts 26 are typically fibrous glass having a density within the range of from about 0.3 to about 1.5 pounds per cubic foot (pcf), although other densities can be used. Also, other fibers, such as mineral fibers of rock, slag or basalt, can be used as well as organic fibers, such as the non-limiting examples of polymer fibers polypropylene and polyester. In certain embodiments, the fibers can be, but not necessarily, bonded together with a binder material, such as a urea phenol-formaldehyde commonly used with fiberglass insulation, to provide stiffness to the insulative batts 26. It will be appreciated that any binder material suitable for bonding the fibers together may be used. The insulative batts 26 can be installed in the insulation cavities 24 in any desired manner.

The insulative batts 26 are configured to provide a desired insulative value (R) to the sidewall 10. Factors contributing to the insulative value (R) include the thickness of the insulative batt 26 and the density of the material forming the insulative batts 26. In the illustrated embodiment, the insulative batt 26 has a thickness of about 5.50 inches which, when combined with the density of fibrous material forming the insulative batt 26, yields a minimum insulative value of about R20. While the illustrated embodiment of the insulative batt 26 has been described above as having a thickness of about 5.5 inches, it should be appreciated that in other embodiments, the thickness of the insulative batt 26 can be more or less than 5.5 inches, corresponding to the width W of the insulative cavities 24. Other combinations of the thickness of the insulative batt 26 and density can provide other desired insulative values (R).

The insulative batts 26 include an interior surface 27, positioned to be adjacent the interior side 23 of the construction material 22, and an exterior surface 28, positioned to be adjacent the interior surface 19 of the exterior sheathing 16.

Referring now to FIG. 2, an improved air barrier system is illustrated at 40. Generally, the improved air barrier system 40 involves replacing the exterior sheathing 16, house wrap material 20 and insulative batts 26 shown in the sidewall 10 of FIG. 1, with panel materials 42, a plurality of gasket materials 44 and insulative batts 126.

Referring again to FIG. 2, the panel materials 42 are attached to the various structural framing members, including the bottom plate 12, top plates 14a and 14b and studs (not shown). In the illustrated embodiment, the bottom plate 12, top plates 14a and 14b and studs are the same, or similar to, the bottom plate 12, top plates 14a and 14b and studs illustrated in FIG. 1 and described above. In other embodiments, the bottom plate 12, top plates 14a and 14b and studs shown in FIG. 2 can be different from the bottom plate 12, top plates 14a and 14b and studs illustrated in FIG. 1.

The panel materials 42 are configured for several purposes. First, the panel materials 42 are configured to provide rigidity to the sidewall 10. Second, the panel materials 42 are configured to provide a surface for attaching exterior wall coverings (not shown). Third, the panel materials 42 are configured to provide an insulative value to the sidewall 10. The insulative value of the panel materials 42 will be discussed in more detail below. Fourth, the panel materials 42 are configured to provide a substantially water resistant barrier that limits the penetration of liquid water through the sidewall 10. Lastly, the panel materials 42 are configured to provide a water vapor barrier between the exterior wall coverings of the sidewall 10 and the interior spaces of the building, such as to allow water vapor to pass through, yet restrict air infiltration.

In the illustrated embodiment, the panel materials 42 are formed from closed cell, moisture resistant rigid foam materials such as the non-limiting example of extruded polystyrene. One non-limiting example of a closed cell, moisture resistant rigid foam material is Foamular® 250 marketed by Owens Corning Corporation, headquartered in Toledo, Ohio. Alternatively, the panel materials 42 can be formed from other materials sufficient to provide rigidity to the sidewall 10, provide a surface for exterior wall coverings, provide an insulative value to the sidewall 10 and provide a water barrier between an outer cladding (not shown) of the sidewall 10 and the various framing members such as to allow water vapor to pass through, yet restrict air infiltration.

The foam material forming the panel materials 42 can be defined to have certain properties including thermal resistance, thermal conductivity, compressive strength, flexural strength, water absorption, water vapor permeance, dimensional stability, flame spread, smoke development, oxygen index and service temperature.

To provide effective insulative value (R), the foam material has a thermal resistance value of 5.0° F.×Ft²×h/btu @ 75° F. and a thermal resistance of 5.4° F.×Ft²×h/btu @ 40° F. as determined by thermal transmission tests, such as ASTM C518. Generally, the standard practice for Test Method ASTM C518 involves the measurement of steady state thermal transmission through flat slab specimens using a heat flow meter apparatus. The heat flow meter apparatus establishes steady state one-dimensional heat flux through a test specimen between two parallel plates at constant but different temperatures. By appropriate calibration of the heat flux transducer(s) with calibration standards and by measurement of the plate temperatures and plate separation, Fourier's law of heat conduction is used to calculate thermal conductivity, and thermal resistivity or thermal resistance and thermal conductance.

To provide effective thermal conductivity (k), the foam material has a value of 0.2 Btu×in/hr×ft²×° F. @ 75° F. and a thermal conductivity 0.18 Btu×in/hr×ft²×° F. @ 40° F. as determined by thermal transmission tests, such as ASTM C518, described above.

To provide effective compressive strength, the foam material has a minimum compressive strength value of 25.0 lb/in² as determined by compressive strength tests, such as ASTM D1621. Generally, the standard practice for Test Method ASTM D1621 involves the measurement of the compressive strength of a cellular material by applying a load to a test specimen with a square or circular cross section. The test specimens are centered between two compression platens and load is applied at a constant crosshead or actuator rate. Crosshead travel (displacement, in.) and load (lb) are recorded throughout the test. Compressive strength then can be determined by several methods depending on the characteristics of the stress-displacement curve.

To provide effective flexural strength, the foam material has a minimum flexural strength value of 75.0 lb/in² as determined by compressive strength tests, such as ASTM C203. Generally, the standard practice for Test Method ASTM C203 involves the measurement of the flexural strength of a cellular material by applying a load to a preformed block-type thermal insulation specimen having a rectangular cross section. The test specimens are positioned as a simply supported beam supported at both ends and a center load is applied to the specimen.

To provide effective water absorption, the foam material has a maximum water absorption value of 0.10% by volume as determined by water absorption tests, such as ASTM C272. Generally, the standard practice for Test Method ASTM C272 involves the measurement of the water absorption of a core foam material when immersed or in a high relatively humidity environment. In this procedure, at least five test specimen measuring 3.0 inches×3.0 inches are dried, removed from the drying oven, and allowed to cool in a desiccator. The specimens are then weighed on an analytical balance to the nearest 0.1 mg. The specimens are then immersed in deionized water or placed in the appropriate conditioning environment. The specimens are removed from the conditioning environment after 24 hours, 48 hours, or after thirty days, depending on the conditioning required.

To effectively retard the flow of air, moisture, and gases, the foam material has a maximum permeability rating of 1.1 (ng/Pa·s·m²) as determined by water vapor transmission tests, such as ASTM E96. Typical water vapor transmission tests, such as the ASTM E96, evaluate the transfer of water vapor through semi-permeable and permeable materials over a period of time.

To provide effective dimensional stability, the foam material has a maximum linear change of 2.0% as determined by dimensional stability tests, such as ASTM D 2126. Generally, the standard practice for Test Method ASTM D 2126 measures how rigid foam material responds to humidity and temperature. Test Method ASTM 2126 exposes the rigid foam material to different humidity and temperature environments. The size and shape of the rigid foam material is measured over time. A percent change in size is reported as the end result.

To provide effective flame spread, the foam material has a rating of 5 as determined by flame spread tests, such as ASTM E 84. Generally, the standard practice for Test Method ASTM E 84 measures the relative burning behavior of the material by observing the flame spread along a test specimen.

To provide effective smoke development, the foam material has a rating in a range of from about 45 to about 175 as measured by smoke development tests, such as ASTM E 84, described above.

To provide effective oxygen index, the foam material has a minimum rating of 24% by volume as determined by oxygen index tests, such as ASTM D 2863. Test Method ASTM D 2863 is a method to determine the minimum concentration of oxygen in an oxygen/nitrogen mixture that will support a flaming burn in a plastic specimen. Generally, the standard practice for Test Method ASTM D 2863 involves positioning a test specimen vertically in a glass chimney. An oxygen/nitrogen environment is established with a flow from the bottom of the chimney. The top edge of the test sample is ignited, and the oxygen concentration in the flow is decreased until the flame is no longer supported.

Referring again to FIG. 2 and as discussed above, the air barrier system 40 includes insulation cavities 24 formed in the spaces between the bottom plate 12, top plates 14a and 14b, interior surface 19 of the panel material 42 and the exterior surface 23 of the construction material 22. In the illustrated embodiment, the insulation cavities 24 are the same, or similar to, the insulation cavities 24 illustrated in FIG. 1 and described above. In other embodiments, the insulation cavities 24 shown in FIG. 2 can be different from the insulation cavities 24 illustrated in FIG. 1.

Referring again to FIG. 2, insulative batts 126 can be positioned within the insulation cavities 24. In the illustrated embodiment, the insulative batts 126 are similar to the insulative batts 26 illustrated in FIG. 1 with the exception that the density of the insulative batts 126 can be less than the density of the insulative batts 26, thereby providing a lower insulative value (R) to the sidewall 10. The insulative value (R) of the sidewall 10 will be discussed in more detail below. The insulative batts 126 include an interior surface 27, positioned to be adjacent the exterior surface 23 of the construction material 22, and an exterior surface 28, positioned to be adjacent the interior surface 19 of the panel materials 42.

Referring again to FIG. 2 and as discussed above, the panel materials 42 are attached to the various structural framing members. A gasket material 44 is positioned between the panel material 42 and the various structural framing members. The gasket material 44 is configured to seal gaps between the panel materials 42 and the faces of the various framing members, including the bottom plate 12, top plates 14a and 14b and studs. The term “seal”, as used herein, is defined to mean providing both an insulative value and a water barrier. In the illustrated embodiment, the gasket material 44 is made of a polyethylene foam material. One example of a gasket material 44 is FoamSeal® manufactured by Owens Corning Corporation headquartered in Toledo, Ohio. In other embodiments, the gasket material 44 can be made of other materials, such as for example felt or tar paper, sufficient to seal gaps between the panel materials 42 and the faces of the various framing members. In still other embodiments, the gasket material 44 can have other forms, including the non-limiting examples of foams formed from spray-on applications and elastomeric sealants.

Referring now to FIG. 3, the gasket material 44 has a width w-gm. In the illustrated embodiment, the width w-gm of the gasket material 44 is in a range of from about 1.0 inch to about 6.0 inches. In other embodiments, the width w-gm of the gasket material 44 can be less than about 1.0 inches or more than about 6.0 inches.

As shown in FIG. 3, the gasket material 44 has a nominal thickness t-gm prior to installation. In the illustrated embodiment, the nominal thickness t-gm of the gasket material 44 is 0.168 inches. In other embodiments, the nominal thickness t-gm of the gasket material 44 can be provided in a nominal thickness t-gm of more or less than 0.168 inches.

Referring now to FIGS. 4-6, the installation of the improved air barrier system 40 will now be described. Referring first to FIG. 4, a building sidewall 10 is illustrated. The building sidewall 10 includes the bottom plate 12, the plurality of top plates, 14a and 14b, the plurality of studs 46 extending therebetween and the exterior sheathing 18. The air barrier system 40 includes the panel materials 42a, 42b and 42c applied to the bottom plate 12, the plurality of top plates 14a and 14b and the plurality of studs 46 with the gasket material 44 positioned therebetween.

Panel material 42a includes longitudinal edges 42a-1 and 42a-2. Panel material 42b includes longitudinal edges 42b-1 and 42b-2 and panel material 42c includes longitudinal edges 42c-1 and 42c-2. Panel material 42a includes lateral edges 42a-3 and 42a-4. Panel material 42b includes lateral edges 42b-3 and 42b-4 and panel material 42c includes lateral edges 42c-3 and 42c-4.

Referring now to FIG. 5, the longitudinal edge 42a-2 of the panel material 42a and the longitudinal edge 42b-1 of the panel material 42b are arranged such as to form a “shiplap” joint, positioned over the gasket material 44 and a corresponding framing member, such as for example a stud 46. The term “shiplap joint”, as used herein, is defined to mean an overlapping joint in which the adjoining panel materials make a flush joint. In the embodiment illustrated in FIG. 5, the longitudinal edge 42a-2 of panel material 42a and the longitudinal edge 42b-1 of panel material 42b have cooperating recesses, with each of the recesses having a rectangular cross-sectional shape. In other embodiments, the longitudinal edge 42a-2 of panel material 42a and the longitudinal edge 42b-1 of panel material 42b can have cooperating recesses having other cross-sectional shapes, such as for example angled cross-sectional shapes. While not shown in FIG. 4, it should be understood that all of the longitudinal edges of the adjoining panel materials are arranged with cooperating shiplap joints.

Referring now to FIGS. 4 and 6, the lateral edge 42c-3 of panel material 42c and the lateral edge 42b-4 of the panel material 42b are arranged such as to form a “butt” joint, positioned over the gasket material 44 and corresponding framing members, such as for example top plates 14a and 14b. The term “butt joint”, as used herein, is defined to mean a joint in which the adjoining panel materials do not overlap. In the embodiment illustrated in FIG. 6, the lateral edge 42b-4 of panel material 42b and the lateral edge 42c-3 of panel material 42c cooperate to form a butt joint. The butt joint formed by lateral edges 42b-4 and 42c-3 are covered by a sealing material 50. While not shown in FIG. 4, it should be understood that all of the lateral edges of the adjoining panel materials are arranged with cooperating butt joints.

The sealing material 50 is configured to seal the butt joints formed between lateral edges of the panel materials. In the illustrated embodiment, the sealing material 50 is a tape formed from the combination of a pressure sensitive adhesive and a polymeric film material. One example of a sealing material 50 is BILD-R-TAPE™ manufactured by Owens Corning Corporation headquartered in Toledo, Ohio. In other embodiments, the sealing material 50 can be made from other desired materials, sufficient to seal the butt joint formed between lateral edges of the panel materials.

Referring again to FIG. 6, the sealing material 50 has a width w-sm. In the illustrated embodiment, the width w-sm of the sealing material 50 is in a range of from about 1.0 inch to about 6.0 inches. In other embodiments, the width w-sm of the sealing material 50 can be less than about 1.0 inches or more than about 6.0 inches.

As can be seen in FIG. 6, the gasket material 44 and the sealing material 50 advantageously combine to form a sealed and insulated butt joint between the panel materials 42b and 42c and the faces of the various framing members, including the top plates 14a and 14b.

Referring again to FIG. 2, as described above, the improved air barrier system 40 replaces the conventional exterior sheathing 16, house wrap material 20 and insulative batts 26 shown in the sidewall 10 of FIG. 1 with panel materials 42, gasket materials 44, insulative batts 126 and sealing materials 50. The additional insulative value (R) value of the panel members 42, compared to the conventional exterior sheathing 16, advantageously provides that the density of the insulative batts 126 can be less than the density of the conventional insulative batts 26 as shown in FIG. 1, while maintaining the overall insulative value of the building sidewall 10. In this manner, the material cost of the insulative batts 126 can be comparatively less than the material cost of the insulative batts 26. In addition, the installation of the panel materials 42 is accomplished with less installation labor than the multiple step installation process of the conventional exterior sheathing 16 and the house wrap material 20 as shown in the sidewall 10 of FIG. 1, resulting in a reduction of the installation labor costs.

One measure of the efficiency of the improved air barrier system 40 is the “airtightness” of the resulting building structure. The term “airtightness”, as used herein, is defined to mean the measure of how many times the air within a defined space (normally a room or house) is replaced for a given period of time. In certain instances, the airtightness of a building structure is measured in terms of air changes per hour (ach). A building structure having a more efficient airtightness has a lower value of air changes per hour and a building structure having a less efficient airtightness has a larger value of air changes per hour. The airtightness of a building structure can be measure by several test methods, including diagnostic tools such as for example a “blower door”. A blower door consists of a calibrated fan for measuring an airflow rate, and a pressure-sensing device to measure the air pressure created by the fan flow. The combination of pressure and fan-flow measurements is used to determine the building airtightness.

Referring again to the conventional insulation structure shown in FIG. 1, the airtightness can typically be about 3.0 air changes per hour. Advantageously, the improved air barrier system 40, illustrated in FIGS. 2 and 4 results in an improved airtightness rating within a range of from about 0.5 air changes per hour to about 2.0 air changes per hour.

While the improved air barrier system 40 has been described above as incorporating the panel materials 42, the gasket material 44, the insulative batts 126 and the sealing materials 50, it should be appreciated that in other embodiments, the air barrier system can have other configurations. A first alternate embodiment of an air barrier system is shown in FIG. 7 generally at 140. In this embodiment, the gasket material 44 is eliminated and all of the joints, whether having the shiplap configuration or the butt configuration, are covered by a sealing material 150.

Referring now to FIG. 7, lateral edges 142b-4 and 142c-3 of the panel materials 142b and 142c are arranged such as to form a butt joint as discussed above. As shown in FIG. 7, the panel materials are positioned over the corresponding framing members, such as for example top plates 114a and 114b. The butt joint formed by lateral edges 142b-4 and 142c-3 are covered by the sealing material 150.

The sealing material 150 is configured to seal the shiplap joints formed between the longitudinal edges of the panel materials and the butt joints formed between lateral edges of the panel materials, thereby providing an effective vapor barrier. In the illustrated embodiment, the sealing material 150 is a tape formed from the combination of a pressure sensitive adhesive and an acrylic-based film material. Alternatively, the sealing material 150 can be other desired materials.

While the embodiment illustrated in FIG. 7 shows a butt joint, it should be appreciated that all of the joints in this embodiment are taped in a manner similar to that shown in FIG. 7.

A second alternate embodiment of an air barrier system is shown in FIG. 8 generally at 240. In this embodiment, the gasket material 44 is eliminated and all of the joints, whether having the shiplap configuration or the butt configuration are covered with a coating 250.

Referring now to FIG. 8, lateral edge 242b-4 of panel material 242b and lateral edge 242c-3 of the panel material 242c are arranged such as to form a butt joint as discussed above. As shown in FIG. 8, the panel materials are positioned over the corresponding framing members, such as for example top plates 214a and 214b. The butt joint formed by lateral edges 242b-4 and 242c-3 are covered by the coating material 250.

The coating material 250 is configured to seal the butt joints formed between lateral edges of the panel materials thereby providing an effective vapor barrier. In the illustrated embodiment, the sealing material 250 is a spray-on coating formed from single-part or multi-part polymeric materials. In other embodiments, the sealing material 250 can be other desired materials, including materials that are applied by brush or roller. While the embodiment illustrated in FIG. 8 shows a butt joint, it should be appreciated that all of the joints in this embodiment are covered by the coating material in a manner similar to that shown in FIG. 8.

In accordance with the provisions of the patent statutes, the principle and mode of operation of the improved air barrier system have been explained and illustrated in its preferred embodiment. However, it must be understood that the improved air barrier system may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.

Claims

1. An air barrier system comprising:

a plurality of framing members, the framing members configured to form insulation cavities;

a plurality of panels attached to an exterior surface of the framing members and gasket material positioned therebetween, wherein adjacent panels form joints;

insulative batts positioned within the insulation cavities; and

sealing material positioned over the joints.

2. The air barrier system of claim 1, wherein the framing members include bottom plates, top plates and studs extending therebetween.

3. The air barrier system of claim 1, wherein the insulation cavities have a width in a range of from about 3.5 inches to about 5.5 inches.

4. The air barrier system of claim 1, wherein the panels are formed from a closed cell, moisture resistant rigid foam material.

5. The air barrier system of claim 1, wherein the panels have longitudinal edges, and wherein the longitudinal edges of adjacent panels are configured to form shiplap joints.

6. The air barrier system of claim 1, wherein the panels have lateral edges, and wherein the lateral edges of adjacent panels are configured to form butt joints.

7. The air barrier system of claim 1, wherein the gasket material is made from a polymeric foam material.

8. The air barrier system of claim 1, wherein the sealing material is a tape.

9. The air barrier system of claim 1, wherein the air barrier system has a minimum insulative value (R) of 20.

10. The air barrier system of claim 1, wherein the air barrier system provides an airtightness in a range of from about 0.5 air changes per hour to about 2.0 air changes per hour.

11. An air barrier system comprising:

a plurality of framing members, the framing members configured to form insulation cavities;

a plurality of panels attached to an exterior surface of the framing members, the adjacent panels form joints;

insulative batts positioned within the insulation cavities; and

sealing material positioned over the joints.

12. The air barrier system of claim 11, wherein the panels are formed from a closed cell, moisture resistant rigid foam material.

13. The air barrier system of claim 11, wherein the sealing material is an acrylic-based tape.

14. The air barrier system of claim 11 wherein the air barrier system has a minimum insulative value (R) of 20.

15. The air barrier system of claim 11, wherein the air barrier system provides an airtightness in a range of from about 0.5 air changes per hour to about 2.0 air changes per hour.

16. A method of installing an air barrier system comprising the steps of:

forming insulation cavities within framing members;

attaching a plurality of panels to an exterior surface of the framing members and positioning gasket material therebetween, wherein adjacent panels form joints;

positioning insulative batts within the insulation cavities; and

sealing the joints.

17. The method of claim 16, wherein the panels have longitudinal edges, and wherein the longitudinal edges of adjacent panels are configured to form shiplap joints.

18. The method of claim 16, wherein the panels have lateral edges, and wherein the lateral edges of adjacent panels are configured to form butt joints.

19. The method of claim 16, wherein the joints are sealed by a spray-on sealing material.

20. The method of claim 1, wherein the air barrier system has a minimum insulative value (R) of 20.