Sheathing/Weather Resistive Barrier Method and System

Abstract

A sheathing product having a structural substrate with two or more edges. The sheathing product also having a weather resistive barrier attached to the structural substrate prior to securing the structural substrate to a frame of a building. A part of the weather resistive barrier extends beyond an edge of the structural substrate to create a flap that allows the weather resistive barrier to be attached to an abutting sheathing product.

1 . A sheathing product, comprising:
 a structural substrate having two sides and two or more edges; and   a weather resistive barrier, the weather resistive barrier covering and attached to one side of the structural substrate prior to securing the structural substrate to a frame of a building;   wherein a part of the weather resistive barrier extends beyond an edge of the structural substrate to form a flap that allows the weather resistive barrier to be attached to an abutting sheathing product.   
   
   
       2 . The sheathing product of  claim 1 , wherein the weather resistive barrier extends beyond at least two adjacent edges of the structural substrate creating flaps along each of the at least two adjacent edges. 
   
   
       3 . The sheathing product of  claim 1 , wherein the flap is from two inches to six inches wide. 
   
   
       4 . The sheathing product of  claim 1 , further comprising an adhesive layer carried on a surface of the flap. 
   
   
       5 . The sheathing product of  claim 4 , further comprising a releasable protective cover carried on the adhesive layer. 
   
   
       6 . The sheathing product of  claim 1 , further comprising a bonding agent attaching the weather resistive barrier to the structural substrate. 
   
   
       7 . The sheathing product of  claim 6 , wherein the bonding agent comprises a continuous layer. 
   
   
       8 . The sheathing product of  claim 7 , wherein the weather resistive barrier and the layer of bonding agent are perforated to provide a desired level of vapor permeability for the sheathing product. 
   
   
       9 . The sheathing product of  claim 6 , wherein the bonding agent comprises a discontinuous layer. 
   
   
       10 . The sheathing product of  claim 6 , wherein the weather resistive barrier and bonding agent provide increased strength to the structural substrate. 
   
   
       11 . A method of insulating a joint between two sheathing products, comprising:
 providing a first sheathing product having a weather resistive barrier attached to a structural substrate such that the weather resistive barrier of the first sheathing product overlaps the structural substrate at an edge and forms a flap along the overlapped edge;   providing a second sheathing product having a weather resistive barrier attached to a structural substrate;   securing the first sheathing product to a frame of a building;   securing the second sheathing product to the frame of the building with the flap of the first sheathing product overlapping the second sheathing product; and   adhering the flap of the first sheathing product to the weather resistive barrier of the second sheathing product;   wherein a joint formed between the first and second sheathing products is insulated by the flap extending from the first sheathing product to the second sheathing product.   
   
   
       12 . The method of  claim 11 , wherein the flap of the first sheathing product is adhered to the weather resistive barrier of the second sheathing product by using an adhesive layer that is pre-applied on the flap of the first sheathing product. 
   
   
       13 . The method of  claim 11 , wherein the flap of the first sheathing product is adhered to the weather resistive barrier of the second sheathing product by applying an adhesive layer to the flap of the first sheathing product at a job site. 
   
   
       14 . The method of  claim 13 , wherein the adhesive layer is applied to the flap of the first sheathing product using a caulking gun, a paint roller, or a roll of double-sided tape. 
   
   
       15 . The method of  claim 12 , wherein the adhesive layer acts as a vapor barrier to decrease the amount of air and moisture which could pass through the second sheathing product. 
   
   
       16 . The method of  claim 13 , wherein the adhesive layer acts as a vapor barrier to decrease the amount of air and moisture which could pass through the second sheathing product. 
   
   
       17 . The method of  claim 11 , wherein the flap of the first sheathing product is adhered to the weather resistive barrier of the second sheathing product by use of mechanical fasteners. 
   
   
       18 . A method of fabricating a sheathing product, comprising:
 providing a structural substrate having two or more edges; and   attaching a weather resistive barrier to the structural substrate such that a part of the weather resistive barrier extends beyond the structural substrate along at least one edge;   wherein the weather resistive barrier is attached to the structural substrate prior to securing the structural substrate to a frame of a building.   
   
   
       19 . The method of  claim 18 , wherein the weather resistive barrier extends beyond the structural substrate along two adjacent edges. 
   
   
       20 . The method of  claim 18 , wherein the weather resistive barrier extends beyond the edge of the structural substrate a minimum of two inches. 
   
   
       21 . The method of  claim 18 , further comprising providing the part of the weather resistive barrier which extends beyond the structural substrate with an adhesive layer. 
   
   
       22 . The method of  claim 21 , further comprising providing the adhesive layer with a protective cover. 
   
   
       23 . The method of  claim 18 , further comprising increasing the vapor permeability of the sheathing product by applying a non-continuous layer of bonding agent between the weather resistive barrier and the structural substrate. 
   
   
       24 . The method of  claim 23 , further comprising perforating the weather resistive barrier and the layer of bonding agent to provide a desired level of vapor permeability for the sheathing product. 
   
   
       25 . The method of  claim 18 , wherein the weather resistive barrier is attached to the structural substrate at a job site. 
   
   
       26 . The method of  claim 18 , wherein the weather resistive barrier is attached to the structural substrate in a factory. 
   
   
       27 . The method of  claim 18 , further comprising attaching a weather resistive barrier to the structural substrate with vapor permeable glue.