CA2254442C - Laminated wall structure - Google Patents
Laminated wall structure Download PDFInfo
- Publication number
- CA2254442C CA2254442C CA002254442A CA2254442A CA2254442C CA 2254442 C CA2254442 C CA 2254442C CA 002254442 A CA002254442 A CA 002254442A CA 2254442 A CA2254442 A CA 2254442A CA 2254442 C CA2254442 C CA 2254442C
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- CA
- Canada
- Prior art keywords
- layer
- water
- resistant
- adhesive
- wall structure
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 68
- 239000000853 adhesive Substances 0.000 claims abstract description 46
- 230000001070 adhesive effect Effects 0.000 claims abstract description 46
- 238000009413 insulation Methods 0.000 claims abstract description 44
- 239000010410 layer Substances 0.000 claims description 73
- 230000004888 barrier function Effects 0.000 claims description 18
- 239000012790 adhesive layer Substances 0.000 claims description 15
- 239000011152 fibreglass Substances 0.000 claims description 12
- 239000000203 mixture Substances 0.000 claims description 12
- 230000003014 reinforcing effect Effects 0.000 claims description 9
- 239000011230 binding agent Substances 0.000 claims description 8
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 claims description 4
- 230000005540 biological transmission Effects 0.000 claims description 4
- 230000009477 glass transition Effects 0.000 claims description 3
- 239000000463 material Substances 0.000 claims description 3
- HRPVXLWXLXDGHG-UHFFFAOYSA-N Acrylamide Chemical compound NC(=O)C=C HRPVXLWXLXDGHG-UHFFFAOYSA-N 0.000 claims description 2
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 claims description 2
- JIGUQPWFLRLWPJ-UHFFFAOYSA-N Ethyl acrylate Chemical group CCOC(=O)C=C JIGUQPWFLRLWPJ-UHFFFAOYSA-N 0.000 claims description 2
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 claims description 2
- 150000001252 acrylic acid derivatives Chemical class 0.000 claims description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 2
- 125000000217 alkyl group Chemical group 0.000 claims description 2
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical group CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 claims description 2
- 239000000178 monomer Substances 0.000 claims description 2
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 claims description 2
- 238000000034 method Methods 0.000 description 10
- 239000011248 coating agent Substances 0.000 description 6
- 238000000576 coating method Methods 0.000 description 6
- 239000011120 plywood Substances 0.000 description 6
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 239000010440 gypsum Substances 0.000 description 4
- 229910052602 gypsum Inorganic materials 0.000 description 4
- 238000010276 construction Methods 0.000 description 3
- 230000032798 delamination Effects 0.000 description 3
- 238000009472 formulation Methods 0.000 description 3
- 239000012528 membrane Substances 0.000 description 3
- 239000004793 Polystyrene Substances 0.000 description 2
- 239000013530 defoamer Substances 0.000 description 2
- 235000014113 dietary fatty acids Nutrition 0.000 description 2
- 239000004794 expanded polystyrene Substances 0.000 description 2
- 239000000194 fatty acid Substances 0.000 description 2
- 229930195729 fatty acid Natural products 0.000 description 2
- 239000004615 ingredient Substances 0.000 description 2
- -1 polyethylene Polymers 0.000 description 2
- 229920002223 polystyrene Polymers 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N titanium dioxide Inorganic materials O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- DAFHKNAQFPVRKR-UHFFFAOYSA-N (3-hydroxy-2,2,4-trimethylpentyl) 2-methylpropanoate Chemical compound CC(C)C(O)C(C)(C)COC(=O)C(C)C DAFHKNAQFPVRKR-UHFFFAOYSA-N 0.000 description 1
- 229920005789 ACRONAL® acrylic binder Polymers 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- 229920005822 acrylic binder Polymers 0.000 description 1
- 125000002877 alkyl aryl group Chemical group 0.000 description 1
- 239000010426 asphalt Substances 0.000 description 1
- 229960000892 attapulgite Drugs 0.000 description 1
- DQXBYHZEEUGOBF-UHFFFAOYSA-N but-3-enoic acid;ethene Chemical compound C=C.OC(=O)CC=C DQXBYHZEEUGOBF-UHFFFAOYSA-N 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000011093 chipboard Substances 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 239000004567 concrete Substances 0.000 description 1
- 238000009833 condensation Methods 0.000 description 1
- 230000005494 condensation Effects 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 239000002270 dispersing agent Substances 0.000 description 1
- 239000005038 ethylene vinyl acetate Substances 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 239000002655 kraft paper Substances 0.000 description 1
- 239000002736 nonionic surfactant Substances 0.000 description 1
- 229910052625 palygorskite Inorganic materials 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 1
- 229920000867 polyelectrolyte Polymers 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 239000011387 rubberized asphalt concrete Substances 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 159000000000 sodium salts Chemical class 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 229920003048 styrene butadiene rubber Polymers 0.000 description 1
- 229920001909 styrene-acrylic polymer Polymers 0.000 description 1
- 239000002562 thickening agent Substances 0.000 description 1
- GPRLSGONYQIRFK-MNYXATJNSA-N triton Chemical compound [3H+] GPRLSGONYQIRFK-MNYXATJNSA-N 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
- E04B2/70—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood
- E04B2/706—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood with supporting function
- E04B2/707—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of wood with supporting function obturation by means of panels
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/762—Exterior insulation of exterior walls
- E04B1/7625—Details of the adhesive connection of the insulation to the wall
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/762—Exterior insulation of exterior walls
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Acoustics & Sound (AREA)
- Building Environments (AREA)
- Finishing Walls (AREA)
- Laminated Bodies (AREA)
Abstract
A laminated wall structure, suitable for use in an exterior insulation finish system, comprises the following layers in the order provided:
i) a layer of building sheathing;
ii) a layer of water-resistant adhesive which substantially completely covers and adheres to said building sheathing; and iii) a layer of thermal insulation adhered to said building sheathing by said water-resistant adhesive. The laminated wall structure, which can be used with all conventional building sheathings, can require less time to construct than known structures.
i) a layer of building sheathing;
ii) a layer of water-resistant adhesive which substantially completely covers and adheres to said building sheathing; and iii) a layer of thermal insulation adhered to said building sheathing by said water-resistant adhesive. The laminated wall structure, which can be used with all conventional building sheathings, can require less time to construct than known structures.
Description
Laminated Wall Structure This invention concerns laminated wall structures for building exteriors.
Particularly, though not exclusively, the present invention relates to laminated wall structures for an exterior insulation finish system A building exterior constructed with an exterior insulation and finish system typically includes a laminated wall structure comprising a) a layer of building sheathing, such as wood board, plyboard, chip board, gypsum board, level masonry or concrete; and b) a layer of thermal insulation, such as expanded polystyrene, secured to the exterior surface of the building sheathing. To complete the system, the exterior surface of the thermal insulation is coated first with c) a base coat with a fibreglass reinforcing mesh embedded therein and then with d) a finish coat.
To obviate problems such as delamination and loss of integrity of the laminated wall structure, which can result from either exterior water or condensation penetrating into the building sheathing, especially when a wood- or gypsum-based building sheathing is employed, a water-resistant layer is inserted between the building sheathing and the thermal insulation.
In one embodiment, the water-resistant layer can be a water-resistant membrane, such as asphalt saturated Kraft paper and rag felt, or, as described in US-A-5027572, a polyethylene laminated rubberised asphalt sheet. The water-resistant membrane and thermal insulation layer are secured to the exterior surface of the building sheathing by mechanical fasteners which penetrate through the thermal insulation layer and water-resistant membrane into the building sheathing layer. The process of building this wall can be slow because it requires the use of many mechanical fasteners, each of which must be fitted and secured manually.
Particularly, though not exclusively, the present invention relates to laminated wall structures for an exterior insulation finish system A building exterior constructed with an exterior insulation and finish system typically includes a laminated wall structure comprising a) a layer of building sheathing, such as wood board, plyboard, chip board, gypsum board, level masonry or concrete; and b) a layer of thermal insulation, such as expanded polystyrene, secured to the exterior surface of the building sheathing. To complete the system, the exterior surface of the thermal insulation is coated first with c) a base coat with a fibreglass reinforcing mesh embedded therein and then with d) a finish coat.
To obviate problems such as delamination and loss of integrity of the laminated wall structure, which can result from either exterior water or condensation penetrating into the building sheathing, especially when a wood- or gypsum-based building sheathing is employed, a water-resistant layer is inserted between the building sheathing and the thermal insulation.
In one embodiment, the water-resistant layer can be a water-resistant membrane, such as asphalt saturated Kraft paper and rag felt, or, as described in US-A-5027572, a polyethylene laminated rubberised asphalt sheet. The water-resistant membrane and thermal insulation layer are secured to the exterior surface of the building sheathing by mechanical fasteners which penetrate through the thermal insulation layer and water-resistant membrane into the building sheathing layer. The process of building this wall can be slow because it requires the use of many mechanical fasteners, each of which must be fitted and secured manually.
In another embodiment, the water-resistant layer can be a water-resistant barrier. For example, as described in US-A-4882888, a laminated wall construction for building exteriors comprises a gypsum-based building sheathing having a non-woven fibreglass layer covering at least one surface thereof, a water-resistant barrier in the form of a coating which completely covers the fibreglass layer, a cementitious adhesive applied on the coated fibreglass sheathing by a conventional ribbon and dab method or notched trowel method for receiving and securing an insulating layer, to the sheathing. The process of building this wall can also be slow because it requires the water-resistant coating to be applied and allowed to dry before the adhesive can be applied and the insulating layer attached. Further, the process relies upon the use of a gypsum board of peculiar construction.
It is the object of this invention to provide a laminated wall structure for an exterior insulation finish system which can require less time to construct than previously described structures and which can be used with all conventional building sheathings.
In accordance with the present invention there is provided a laminated wall structure, suitable for use in an exterior insulation finish system, comprising the following layers in the order provided:
i) a layer of building sheathing;
ii) a barrier layer of water-resistant adhesive which substantially covers and adheres to said building sheathing; and iii) a layer of thermal insulation adhered to said building sheathing by said water-resistant adhesive, wherein said barrier layer of water-resistant adhesive further comprises a water-based, water-resistant, non-cementitious adhesive having sufficient tack to rapidly secure the layer of thermal insulation to the building sheathing.
The laminated wall structure of the present invention does not suffer delamination or loss of integrity since the layer of adhesive, which substantially completely covers the surface of the building sheathing to which is adheres, forms a water-resistant layer between the building sheathing and thermal insulation. Further, the laminated wall structure of the present invention does not essentially require the use of mechanical fasteners to secure the thermal insulation to the building sheathing, and so it may be constructed relatively more quickly than wall structures which rely upon the use of mechanical fasteners. Furthermore, the laminated wall structure of the present invention, by effectively combining the functions of water-resistant barrier and adhesive, can be constructed relatively more quickly than a wall structure which relies upon a process involving the separate steps of applying a water-resistant coating, allowing the coating to dry and finally applying the adhesive to which the thermal insulation is secured.
Moreover, the laminated wall structure of the present invention can be employed with all conventional building sheathings and is not reliant upon use of a building sheathing of peculiar construction.
In another aspect, the present invention provides an exterior insulation and finish system comprising the following layers in the order provided:
i) a layer. of building sheathing;
ii) a continuous barrier layer of water-based, water-resistant, non-cementitious adhesive which substantially covers and adheres to said building sheathing, said adhesive having sufficient tack to rapidly secure a layer of thermal insulation to said building sheathing;
iii) said layer of thermal insulation adhered to said building sheathing by said adhesive;
iv) a continuous layer of base coat composition having embedded within it a fibreglass reinforcing mesh; and v) a continuous layer of finish coat composition.
In yet another aspect, the present invention provides a building exterior, constructed with an exterior insulation and finish system, and including in the following order: a layer of building sheathing, a continuous barrier layer of a water-based, water-resistant, non-cementitious adhesive, a layer of thermal insulation, a layer of base coat composition having a fiberglass reinforcing mesh embedded therein, and a layer of finish coat composition, said adhesive having sufficient tack to rapidly secure said layer of thermal insulation to said building sheathing.
In yet another aspect of the present invention, there is provided a method of preventing delamination and loss of integrity of a building exterior constructed with an exterior insulation and finish system including a laminated structure wall structure comprising a) layer of building sheathing; b) a layer of thermal insulation secured to the exterior surface of the building sheathing; c) a base coat with a fibreglass reinforcing mesh embedded therein adhered to an covering the exterior surface of said thermal insulation layer; and d) a finish coat covering the exterior surface of the base coat, wherein the method comprises coating the exterior surface of the base coat, wherein the method comprises coating the exterior surface of said building sheathing with a 4 (a) continuous layer of water-based, water-resistant, non-cementitious adhesive before securing said insulating layer thereto.
In yet another aspect of the present invention, a water-based, water-resistant, non-cementitious adhesive is used to provide a continuous water-resistant layer between the external surface of a building sheathing and the internal surface of a thermal insulation layer thereto.
In yet another aspect of the present invention, a water-based, water-resistant, non-cementitious adhesive is used to provide a continuous water-resistant layer between the external surface of a building sheathing and the internal surface of a thermal insulation of a building exterior constructed with an exterior insulation and finish system including a laminated wall structure comprising a) a layer of building sheathing; b) a layer of thermal insulation adhered to the exterior surface of the building sheathing; c) a base coat with a fibreglass reinforcing mesh embedded therein applied over the external surface of said insulating layer; and d) a finish coat applied over the external surface of said base coat.
The water-resistant adhesive layer is preferably water-resistant for a minimum of 10 minutes, more preferably for a minimum of 30 minutes and most preferably for a minimum of 60 minutes, as measured in accordance with ASTM D-779. The adhesive layer may be so water-resistant that, for all practical purposes, it can be considered as being water-proof.
4 (b) The water-resistant adhesive layer preferably has a moisture vapour transmission rate of from about 4 grams, more preferably from about 5 grams, up to about 35 grams per square metre per 24 hours, as measured in accordance with ASTM E-96 Proc B.
r The water-resistant adhesive layer preferably consists of a water-based, water resistant, non-cementitious adhesive. Preferably the adhesive is acrylic, although other water-based, water-resistant adhesives may be useful, such as vinyl acrylic, ethylene vinyl acetate, styrene acrylic, styrene butadiene rubber, and vinyl chloride acrylic. Such adhesives are generally available and the skilled person will know, or will readily be able to determine, which of these will be most suited for use in the present invention. For example, water-based, water-resistant, non-cementitious adhesives comprising one or more of the following commercially available polymeric binders are suitable for use in the present invention: "Rhoplex"*
20198, "Rhoplex"* EI2000, "Rhoplex"* 2200, "Rhoplex"* EC2848 and "Rhoplex"* A-920 available from Rohm and Haas Company; "Acronal"* 567V available from BASF AG; and UCAR* 123 available from Union Carbide Corp.
Although these commercially available binders are all capable of being formulated into water-resistant adhesives suitable for use in the present invention, it is preferred to use a styrene-free binder, such as "Rhoplex"*
EI2000, "Rhoplex"* EC2848 or "Rhoplex"* A-920, as these tend to give higher moisture vapour transmission rates.
Preferably, the water-resistant adhesive layer consists of a water-based adhesive comprising a polymeric binder comprising units of one or more of the following monomers: (Cl to C$)alkyl(meth)acrylates, preferably ethyl acrylate and/or butyl acrylate; styrene; acrylonitrile; acrylamide and (meth)acrylic acid. The polymeric binder preferably has a glass transition temperature (Tg) in the range -50°C to +30°C, more preferably -35°C to 10°C, to give the adhesive formulation a good balance of flexibility and crack bridging, to accommodate expansion, contraction and other movements normally found in building structures. The adhesive formulation may comprise other components such as tackifiers or other ingredients to give the adhesive "quick grab" properties, to prevent slippage of the thermal insulating layer and minimize the time required to rasp/sand the thermal insulating layer to receive the base coat layer.
* Trademark.
The adhesive may be applied to the building sheathing by any appropriate method. For example, it may be applied by brush, roller, trowel or by spraying.
The invention is now further exemplified with reference to the accompanying drawing, in which:
FIG 1 is a schematic, fragmentary, perspective view, partially in cross section, of a building exterior, including a laminated wall structure of the present invention showing various layers and their relationship to one another.
A building exterior 1, constructed with an exterior insulation and finish system, includes a laminated wall structure, in accordance with the present invention, comprising a plywood building sheathing 2, a continuous layer of water-resistant adhesive 3 and a layer of expanded polystyrene thermal insulation 4. The building exterior also includes a base coat composition 5, which in turn is coated with a finish coat 6.
Embedded within the base coat 5 is a fibreglass reinforcing mesh 7.
The building exterior 1 is constructed as follows:
The inner surface 8 of a 2.5 cm thick plywood board 2 is secured to a building framework 9 by any conventional means. Once secured, a water-resistant adhesive, having the formulation listed in Table 1, is troweled over the exterior surface 10 of the plywood board 2 to form a continuous water-resistant layer 3, approximately 1.5 mm thick, which completely covers and adheres to the exterior surface of the plywood board. The adhesive has sufficient tack such that immediately or shortly after it has been applied to the exterior surface 10 of the plywood board 2 to form the water-resistant adhesive layer 3, the inner surface 11 of a 5 cm thick sheet of polystyrene thermal insulation 4 can be pressed into contact with the exterior surfacel2 of the adhesive layer 3, thereby to securely adhere the .. i 7 thermal insulation into position. The adhesive is sufficiently strong such that, in use, no other means of securing the thermal insulation to the plywood board 2 is essentially required.
Once the polystyrene insulation layer 4 has been adhered into position, a conventional base coat material (such as "Primus"*/Adhesive from Dryvit, ,, RFP from Sto, 3.01 Basecoat & adhesive from Parex, ABC from Finestone or "Alpha Base"* from Senergy) is applied to the outer surface of the insulating layer and a woven fibreglass reinforcing mesh 7 is positioned and embedded therein, thereby adhering the mesh 7 to the insulating layer 4. A conventional finish coat material 6 (such as "Quarz Putz"* from Dryvit, "StoLit R"* 1.5 from Sto, 3.20 and 500 Series Finishes from Parex, "Swirl Texture Finish"* from Finestone or "Classic Finish"* from Senergy) is then applied to the external surface of the base coat 5.
Table 1 Water-resistant Adhesive Ingredient Kg litres PVC Wt ~/
250 ,um Silica Sand 170 63.2 25.78 27.04 um CaCOa 205.5 76.2 30.9 32.78 Colloidal Attapulgite 5.85 2.5 1.01 0.93 Clay Rutile Ti02 2.9 0.75 0.31 0.47 Acrylic Binder "Rhoplex"* 181.5 174 - 28.95 Fatty acid defoamer "Nopco~NXZ 0.45 0.49 - 0.07 water 4.5 4.5 - 0.72 Alkylaryl polyether, "Triton"* 0.45 0.42 - 0.07 nonionic surfactant Sodium salt of a "Tamol"* 731 1.84 1.66 - 0.29 A
carboxylated polyelectrolyte, dispersant * Trademark.
. . v Thickener Wl-iT-100 2.26 2.16 - 0.36 water 50.5 50.5 - 8.05 2,2,4-Trimethyl-1,3- "Texanol"* 3.33 3.52 - 0.53 pentanediol monoisobutyrate Fatty acid defoamer "Nopco"* NXZ 0.9 1 - 0.14 Totals 627 378.5 Volume solids 65 Wt solids % 79 Viscosity 120 Paste Units (Brookfield Model KU-1 paste paddle) pH 9.25 * Trademark.
It is the object of this invention to provide a laminated wall structure for an exterior insulation finish system which can require less time to construct than previously described structures and which can be used with all conventional building sheathings.
In accordance with the present invention there is provided a laminated wall structure, suitable for use in an exterior insulation finish system, comprising the following layers in the order provided:
i) a layer of building sheathing;
ii) a barrier layer of water-resistant adhesive which substantially covers and adheres to said building sheathing; and iii) a layer of thermal insulation adhered to said building sheathing by said water-resistant adhesive, wherein said barrier layer of water-resistant adhesive further comprises a water-based, water-resistant, non-cementitious adhesive having sufficient tack to rapidly secure the layer of thermal insulation to the building sheathing.
The laminated wall structure of the present invention does not suffer delamination or loss of integrity since the layer of adhesive, which substantially completely covers the surface of the building sheathing to which is adheres, forms a water-resistant layer between the building sheathing and thermal insulation. Further, the laminated wall structure of the present invention does not essentially require the use of mechanical fasteners to secure the thermal insulation to the building sheathing, and so it may be constructed relatively more quickly than wall structures which rely upon the use of mechanical fasteners. Furthermore, the laminated wall structure of the present invention, by effectively combining the functions of water-resistant barrier and adhesive, can be constructed relatively more quickly than a wall structure which relies upon a process involving the separate steps of applying a water-resistant coating, allowing the coating to dry and finally applying the adhesive to which the thermal insulation is secured.
Moreover, the laminated wall structure of the present invention can be employed with all conventional building sheathings and is not reliant upon use of a building sheathing of peculiar construction.
In another aspect, the present invention provides an exterior insulation and finish system comprising the following layers in the order provided:
i) a layer. of building sheathing;
ii) a continuous barrier layer of water-based, water-resistant, non-cementitious adhesive which substantially covers and adheres to said building sheathing, said adhesive having sufficient tack to rapidly secure a layer of thermal insulation to said building sheathing;
iii) said layer of thermal insulation adhered to said building sheathing by said adhesive;
iv) a continuous layer of base coat composition having embedded within it a fibreglass reinforcing mesh; and v) a continuous layer of finish coat composition.
In yet another aspect, the present invention provides a building exterior, constructed with an exterior insulation and finish system, and including in the following order: a layer of building sheathing, a continuous barrier layer of a water-based, water-resistant, non-cementitious adhesive, a layer of thermal insulation, a layer of base coat composition having a fiberglass reinforcing mesh embedded therein, and a layer of finish coat composition, said adhesive having sufficient tack to rapidly secure said layer of thermal insulation to said building sheathing.
In yet another aspect of the present invention, there is provided a method of preventing delamination and loss of integrity of a building exterior constructed with an exterior insulation and finish system including a laminated structure wall structure comprising a) layer of building sheathing; b) a layer of thermal insulation secured to the exterior surface of the building sheathing; c) a base coat with a fibreglass reinforcing mesh embedded therein adhered to an covering the exterior surface of said thermal insulation layer; and d) a finish coat covering the exterior surface of the base coat, wherein the method comprises coating the exterior surface of the base coat, wherein the method comprises coating the exterior surface of said building sheathing with a 4 (a) continuous layer of water-based, water-resistant, non-cementitious adhesive before securing said insulating layer thereto.
In yet another aspect of the present invention, a water-based, water-resistant, non-cementitious adhesive is used to provide a continuous water-resistant layer between the external surface of a building sheathing and the internal surface of a thermal insulation layer thereto.
In yet another aspect of the present invention, a water-based, water-resistant, non-cementitious adhesive is used to provide a continuous water-resistant layer between the external surface of a building sheathing and the internal surface of a thermal insulation of a building exterior constructed with an exterior insulation and finish system including a laminated wall structure comprising a) a layer of building sheathing; b) a layer of thermal insulation adhered to the exterior surface of the building sheathing; c) a base coat with a fibreglass reinforcing mesh embedded therein applied over the external surface of said insulating layer; and d) a finish coat applied over the external surface of said base coat.
The water-resistant adhesive layer is preferably water-resistant for a minimum of 10 minutes, more preferably for a minimum of 30 minutes and most preferably for a minimum of 60 minutes, as measured in accordance with ASTM D-779. The adhesive layer may be so water-resistant that, for all practical purposes, it can be considered as being water-proof.
4 (b) The water-resistant adhesive layer preferably has a moisture vapour transmission rate of from about 4 grams, more preferably from about 5 grams, up to about 35 grams per square metre per 24 hours, as measured in accordance with ASTM E-96 Proc B.
r The water-resistant adhesive layer preferably consists of a water-based, water resistant, non-cementitious adhesive. Preferably the adhesive is acrylic, although other water-based, water-resistant adhesives may be useful, such as vinyl acrylic, ethylene vinyl acetate, styrene acrylic, styrene butadiene rubber, and vinyl chloride acrylic. Such adhesives are generally available and the skilled person will know, or will readily be able to determine, which of these will be most suited for use in the present invention. For example, water-based, water-resistant, non-cementitious adhesives comprising one or more of the following commercially available polymeric binders are suitable for use in the present invention: "Rhoplex"*
20198, "Rhoplex"* EI2000, "Rhoplex"* 2200, "Rhoplex"* EC2848 and "Rhoplex"* A-920 available from Rohm and Haas Company; "Acronal"* 567V available from BASF AG; and UCAR* 123 available from Union Carbide Corp.
Although these commercially available binders are all capable of being formulated into water-resistant adhesives suitable for use in the present invention, it is preferred to use a styrene-free binder, such as "Rhoplex"*
EI2000, "Rhoplex"* EC2848 or "Rhoplex"* A-920, as these tend to give higher moisture vapour transmission rates.
Preferably, the water-resistant adhesive layer consists of a water-based adhesive comprising a polymeric binder comprising units of one or more of the following monomers: (Cl to C$)alkyl(meth)acrylates, preferably ethyl acrylate and/or butyl acrylate; styrene; acrylonitrile; acrylamide and (meth)acrylic acid. The polymeric binder preferably has a glass transition temperature (Tg) in the range -50°C to +30°C, more preferably -35°C to 10°C, to give the adhesive formulation a good balance of flexibility and crack bridging, to accommodate expansion, contraction and other movements normally found in building structures. The adhesive formulation may comprise other components such as tackifiers or other ingredients to give the adhesive "quick grab" properties, to prevent slippage of the thermal insulating layer and minimize the time required to rasp/sand the thermal insulating layer to receive the base coat layer.
* Trademark.
The adhesive may be applied to the building sheathing by any appropriate method. For example, it may be applied by brush, roller, trowel or by spraying.
The invention is now further exemplified with reference to the accompanying drawing, in which:
FIG 1 is a schematic, fragmentary, perspective view, partially in cross section, of a building exterior, including a laminated wall structure of the present invention showing various layers and their relationship to one another.
A building exterior 1, constructed with an exterior insulation and finish system, includes a laminated wall structure, in accordance with the present invention, comprising a plywood building sheathing 2, a continuous layer of water-resistant adhesive 3 and a layer of expanded polystyrene thermal insulation 4. The building exterior also includes a base coat composition 5, which in turn is coated with a finish coat 6.
Embedded within the base coat 5 is a fibreglass reinforcing mesh 7.
The building exterior 1 is constructed as follows:
The inner surface 8 of a 2.5 cm thick plywood board 2 is secured to a building framework 9 by any conventional means. Once secured, a water-resistant adhesive, having the formulation listed in Table 1, is troweled over the exterior surface 10 of the plywood board 2 to form a continuous water-resistant layer 3, approximately 1.5 mm thick, which completely covers and adheres to the exterior surface of the plywood board. The adhesive has sufficient tack such that immediately or shortly after it has been applied to the exterior surface 10 of the plywood board 2 to form the water-resistant adhesive layer 3, the inner surface 11 of a 5 cm thick sheet of polystyrene thermal insulation 4 can be pressed into contact with the exterior surfacel2 of the adhesive layer 3, thereby to securely adhere the .. i 7 thermal insulation into position. The adhesive is sufficiently strong such that, in use, no other means of securing the thermal insulation to the plywood board 2 is essentially required.
Once the polystyrene insulation layer 4 has been adhered into position, a conventional base coat material (such as "Primus"*/Adhesive from Dryvit, ,, RFP from Sto, 3.01 Basecoat & adhesive from Parex, ABC from Finestone or "Alpha Base"* from Senergy) is applied to the outer surface of the insulating layer and a woven fibreglass reinforcing mesh 7 is positioned and embedded therein, thereby adhering the mesh 7 to the insulating layer 4. A conventional finish coat material 6 (such as "Quarz Putz"* from Dryvit, "StoLit R"* 1.5 from Sto, 3.20 and 500 Series Finishes from Parex, "Swirl Texture Finish"* from Finestone or "Classic Finish"* from Senergy) is then applied to the external surface of the base coat 5.
Table 1 Water-resistant Adhesive Ingredient Kg litres PVC Wt ~/
250 ,um Silica Sand 170 63.2 25.78 27.04 um CaCOa 205.5 76.2 30.9 32.78 Colloidal Attapulgite 5.85 2.5 1.01 0.93 Clay Rutile Ti02 2.9 0.75 0.31 0.47 Acrylic Binder "Rhoplex"* 181.5 174 - 28.95 Fatty acid defoamer "Nopco~NXZ 0.45 0.49 - 0.07 water 4.5 4.5 - 0.72 Alkylaryl polyether, "Triton"* 0.45 0.42 - 0.07 nonionic surfactant Sodium salt of a "Tamol"* 731 1.84 1.66 - 0.29 A
carboxylated polyelectrolyte, dispersant * Trademark.
. . v Thickener Wl-iT-100 2.26 2.16 - 0.36 water 50.5 50.5 - 8.05 2,2,4-Trimethyl-1,3- "Texanol"* 3.33 3.52 - 0.53 pentanediol monoisobutyrate Fatty acid defoamer "Nopco"* NXZ 0.9 1 - 0.14 Totals 627 378.5 Volume solids 65 Wt solids % 79 Viscosity 120 Paste Units (Brookfield Model KU-1 paste paddle) pH 9.25 * Trademark.
Claims (12)
1. A laminated wall structure, suitable for use in an exterior insulation finish system, comprising the following layers in the order provided:
i) a layer of building sheathing;
ii) a layer of water-resistant adhesive which substantially completely covers and adheres to said building sheathing; and iii) a layer of thermal insulation adhered to said building sheathing by said water-resistant adhesive, wherein said barrier layer of water-resistant adhesive further comprises a water-based, water-resistant, non-cementitious adhesive having sufficient tack to rapidly secure said layer of thermal insulation to said building sheathing.
i) a layer of building sheathing;
ii) a layer of water-resistant adhesive which substantially completely covers and adheres to said building sheathing; and iii) a layer of thermal insulation adhered to said building sheathing by said water-resistant adhesive, wherein said barrier layer of water-resistant adhesive further comprises a water-based, water-resistant, non-cementitious adhesive having sufficient tack to rapidly secure said layer of thermal insulation to said building sheathing.
2. A laminated wall structure as claimed in claim 1, wherein said barrier adhesive layer is an acrylic-based material.
3. A laminated wall structure as claimed in claim 1, wherein said barrier adhesive layer comprises a polymeric binder comprising units of at least one of the following monomers: (C1 to C8)alkyl(meth)acrylates;
styrene; acrylonitrile; acrylamide and (meth)acrylic acid.
styrene; acrylonitrile; acrylamide and (meth)acrylic acid.
4. A laminated wall structure as claimed in claim 1, wherein said barrier adhesive layer comprises a polymeric binder having a glass transition temperature (Tg) in the range of -50°C to +30°C.
5. A laminated wall structure as claimed in claim 1, wherein said water resistant barrier adhesive layer is water-resistant for a minimum of 30 minutes, as measured in accordance with ASTM D-779.
6. A laminated wall structure as claimed in claim 1, wherein said water-resistant barrier adhesive layer has a moisture vapor transmission rate of from 4 to 35 grams per square meter per 24 hours, as measured in accordance with ASTM E-96 Proc B.
7. An exterior insulation and finish system comprising the following layers in the order provided:
i) a layer of building sheathing;
ii) a continuous barrier layer of water-based, water-resistant, non-cementitious adhesive which substantially covers and adheres to said building sheathing, said adhesive having sufficient tack to rapidly secure a layer of thermal insulation to said building sheathing;
iii) said layer of thermal insulation adhered to said building sheathing by said adhesive;
iv) a continuous layer of base coat composition having embedded within it a fibreglass reinforcing mesh;
and v) a continuous layer of finish coat composition.
i) a layer of building sheathing;
ii) a continuous barrier layer of water-based, water-resistant, non-cementitious adhesive which substantially covers and adheres to said building sheathing, said adhesive having sufficient tack to rapidly secure a layer of thermal insulation to said building sheathing;
iii) said layer of thermal insulation adhered to said building sheathing by said adhesive;
iv) a continuous layer of base coat composition having embedded within it a fibreglass reinforcing mesh;
and v) a continuous layer of finish coat composition.
8. A building exterior, constructed with an exterior insulation and finish system, and including in the following order: a layer of building sheathing, a continuous barrier layer of a water-based, water-resistant, non-cementitious adhesive, a layer of thermal insulation, a layer of base coat composition having a fiberglass reinforcing mesh embedded therein, and a layer of finish coat composition, said adhesive having sufficient tack to rapidly secure said layer of thermal insulation to said building sheathing.
9. A laminated wall structure as claimed in claim 3, wherein said barrier adhesive layer comprises units of ethyl acrylate or butyl acrylate.
10. A laminated wall structure as claimed in claim 4, wherein said polymeric binder has a glass transition temperature (Tg) in the range of -35°C to +10°C.
11. A laminated wall structure as claimed in claim 5, wherein said water-resistant barrier adhesive layer is water-resistant for a minimum of 60 minutes, as measured in accordance with ASTM D-779.
12. A laminated wall structure as claimed in claim 6, wherein said water-resistant barrier adhesive layer has a moisture vapor transmission rate of from 5 to 35 grams per square meter per 24 hours, as measured in accordance with ASTM E-96 Proc. B.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US6857297P | 1997-12-23 | 1997-12-23 | |
| US60/068,572 | 1997-12-23 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2254442A1 CA2254442A1 (en) | 1999-06-23 |
| CA2254442C true CA2254442C (en) | 2005-03-22 |
Family
ID=22083408
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002254442A Expired - Lifetime CA2254442C (en) | 1997-12-23 | 1998-11-23 | Laminated wall structure |
Country Status (10)
| Country | Link |
|---|---|
| EP (1) | EP0926303A3 (en) |
| JP (1) | JPH11241423A (en) |
| KR (1) | KR19990063312A (en) |
| AU (1) | AU751815B2 (en) |
| BR (1) | BR9805611A (en) |
| CA (1) | CA2254442C (en) |
| ID (1) | ID24019A (en) |
| IL (1) | IL127377A0 (en) |
| PL (1) | PL330493A1 (en) |
| ZA (1) | ZA9810711B (en) |
Families Citing this family (15)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR20000030201A (en) * | 2000-02-07 | 2000-06-05 | 윤문옥 | The adiabatic construction method of outwall |
| DE20012405U1 (en) * | 2000-07-18 | 2000-12-07 | Jester Manfred | External wall composite element for residential buildings |
| EP1431470A1 (en) * | 2002-12-20 | 2004-06-23 | Rhino Exterior Coating Inc. | System and method for coating of dimensionally stable building material |
| GB0401065D0 (en) * | 2004-01-17 | 2004-02-18 | Blue Flag Ltd | Building system |
| US8051611B2 (en) | 2005-06-24 | 2011-11-08 | Dryvit Systems, Inc. | Exterior insulation and finish system and method and tool for installing same |
| EP2331761A4 (en) * | 2008-09-22 | 2013-01-23 | Dow Global Technologies Llc | Composite structure for exterior insulation applications |
| SE1050258A1 (en) * | 2010-03-19 | 2011-09-20 | Sto Scandinavia Ab | Building system for walls above ground |
| US8769891B2 (en) * | 2011-04-05 | 2014-07-08 | Ian Kelly | Building method using multi-storey panels |
| CN105155735A (en) * | 2015-08-18 | 2015-12-16 | 西安建筑科技大学 | Wall based on raw bamboo framework |
| CN105781043A (en) * | 2016-03-03 | 2016-07-20 | 中天联合节能建设发展(天津)股份有限公司 | Window four-corner double strengthening net process for outer wall heat preservation construction |
| CN105696731B (en) * | 2016-03-29 | 2018-04-03 | 威力（烟台）木业技术有限公司 | A kind of timber structure bearing diagonal shear wall |
| CN107448004B (en) * | 2017-08-18 | 2019-04-12 | 宜昌永东建设工程有限公司 | A kind of exterior wall anti-dropout filled type internal repair ball |
| US11913227B2 (en) * | 2020-03-25 | 2024-02-27 | Charles H. Leahy | High R-value insulated building panel with integrated weather resistant barrier |
| EP4053195A1 (en) * | 2021-03-02 | 2022-09-07 | Termo Organika Sp. z o.o. | Coating product for insulation boards and coated insulation board |
| CA3176921A1 (en) * | 2022-09-28 | 2024-03-28 | Karlta Trading Inc. | A building panel assembly |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3389518A (en) * | 1964-06-09 | 1968-06-25 | Horbach Edwin | Resilient cellular wall covering and applying it |
| US4882888A (en) | 1988-11-14 | 1989-11-28 | Dryvit System, Inc. | Laminated wall construction |
| US5027572A (en) | 1989-08-17 | 1991-07-02 | W. R. Grace & Co.-Conn. | Moisture and vapor barrier in exterior insulation finish systems |
-
1998
- 1998-11-23 CA CA002254442A patent/CA2254442C/en not_active Expired - Lifetime
- 1998-11-23 AU AU94088/98A patent/AU751815B2/en not_active Ceased
- 1998-11-24 ZA ZA9810711A patent/ZA9810711B/en unknown
- 1998-12-03 IL IL12737798A patent/IL127377A0/en unknown
- 1998-12-07 EP EP98309993A patent/EP0926303A3/en not_active Withdrawn
- 1998-12-16 ID IDP981636A patent/ID24019A/en unknown
- 1998-12-17 JP JP10358798A patent/JPH11241423A/en not_active Withdrawn
- 1998-12-21 BR BR9805611-5A patent/BR9805611A/en not_active Application Discontinuation
- 1998-12-22 KR KR1019980057124A patent/KR19990063312A/en not_active Application Discontinuation
- 1998-12-22 PL PL98330493A patent/PL330493A1/en not_active Application Discontinuation
Also Published As
| Publication number | Publication date |
|---|---|
| EP0926303A3 (en) | 2001-07-04 |
| EP0926303A2 (en) | 1999-06-30 |
| JPH11241423A (en) | 1999-09-07 |
| ID24019A (en) | 2000-06-29 |
| AU9408898A (en) | 1999-07-15 |
| CA2254442A1 (en) | 1999-06-23 |
| BR9805611A (en) | 1999-11-09 |
| KR19990063312A (en) | 1999-07-26 |
| ZA9810711B (en) | 1999-06-23 |
| PL330493A1 (en) | 1999-07-05 |
| AU751815B2 (en) | 2002-08-29 |
| IL127377A0 (en) | 1999-10-28 |
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