USRE39761EExpiredUtility

Laminate wall structure

66
Assignee: NAT SHELTER PRODUCTS INCPriority: Dec 2, 1997Filed: Jul 23, 2004Granted: Aug 7, 2007
Est. expiryDec 2, 2017(expired)· nominal 20-yr term from priority
Inventors:John Cahill
E04C 2/296B32B 5/18B32B 5/26Y10T442/3634Y10T442/3667Y10T442/3545Y10T428/31899Y10T442/365Y10T442/3594Y10T442/3561Y10T442/3325Y10T442/3642Y10T442/3528Y10T442/3569Y10T442/3854Y10T442/3537Y10T428/3188Y10T428/249982Y10T442/3707Y10T442/647Y10T442/674Y10T428/31786Y10T428/249981Y10T428/249921Y10T428/249953Y10T428/31895
66
PatentIndex Score
10
Cited by
23
References
54
Claims

Abstract

A laminate wall structure which can be used as an exterior wall in manufactured housing and site built construction is made up of a low density layer having a density of from about one-half pound to three pounds per cubic foot, a second, reinforcing layer laminated to the low density layer and, optionally, a cellulosic layer laminated to the second, reinforcing layer. The low density layer is preferably a foamed polymer layer, the second, reinforcing layer is a polymer fabric, a biaxially oriented polymeric film or a fiberglass reinforced material and the cellulosic layer can be impregnated with an adhesive and/or resin in order to strengthen the laminate structure. This laminate wall structure has a low weight and yet is strong enough to meet wind zone wall diaphragm requirements for housing construction.

Claims

exact text as granted — not AI-modified
1. In a wall structure that is contained in a building structure exposed to transverse wind loading, the improvement comprising said wall structure containing a first layer comprising a foamed material having a density of about 0.5-3 lb./ft. 3  and a second, reinforcing layer of a woven polymer fabric directly bonded to the first layer, said wall structure meeting the Ultimate Load Test criteria set forth in  24  C.F.R §  3280 . 401 ( b ) .    
     
     
       2. The wall structure of  claim 1 , additionally comprising a third layer comprising a cellulostic  cellulosic material laminated to said second, reinforcing layer. 
     
     
       3. The wall structure of  claim 2 , wherein the cellulosic layer has a plastic film formed thereon. 
     
     
       4. The wall structure of  claim 2 , wherein the cellulosic layer is impregnated with a member selected from the group consisting of a resin, an adhesive and mixtures thereof. 
     
     
       5. The wall structure of  claim 4 , wherein said cellulosic layer is impregnated with a urethane. 
     
     
       6. The wall structure of  claim 4 , wherein said cellulosic layer is impregnated with a polyester. 
     
     
       7. The wall structure of  claim 4 , wherein said cellulosic layer is impregnated with a urethane,and a polyester. 
     
     
       8. The wall structure of  claim 4  wherein said cellulosic layer is impregnated to a degree of saturation of from about 3 to 100%. 
     
     
       9. The wall structure of  claim 4 , wherein said cellulosic layer is impregnated to a degree of saturation of from about 25 to 50%. 
     
     
       10. The wall structure of  claim 4 , wherein said cellulosic layer is impregnated to a degree of saturation of about 35%. 
     
     
       11. The wall structure of  claim 1 , wherein said first layer comprises a foamed material. 
     
     
       12. The wall structure of  claim 11    claim 1 , wherein said foamed material is an organic material. 
     
     
       13. The wall structure of  claim 12 , wherein said organic material is selected from the group consisting of polystyrene and polyurethane. 
     
     
       14. The wall structure of  claim 1 , wherein said first layer comprises a fiberboard material. 
     
     
       15. The wall structure of  claim 1 , wherein said second, reinforcing layer is made of a thermoplastic material. 
     
     
       16. The wall structure of  claim 15 , wherein said thermoplastic material is selected from the group consisting of polyethylene and propylene. 
     
     
       17. The wall structure of  claim 15 , wherein the polymer fabric is unwoven. 
     
     
       18. The wall structure of  claim 1 , wherein a cellulosic layer is laminated to the second, reinforcing layer, an exterior layer is laminated to the cellulosic layer and an interior layer is laminated to the first layer. 
     
     
       19. The wall structure of  claim 18 , wherein said second, reinforcing layer is a biaxially oriented polymeric film. 
     
     
       20. In a wall structure that is contained in a building structure exposed to transverse wind loading, the improvement comprising said wall structure containing a first layer comprising a foamed material having a density of about 0.5-3 lb./ft. 3 , a second, reinforcing layer selected from the group  consisting of a polymer fabric and a biaxially oriented polymeric film  directly bonded to the first layer and a cellulosic layer selected from the group consisting of paper, paper fiberboard, plastic-coated paper and plastic-coated paper fiberboard laminated to the second, reinforcing layer, said wall structure meeting the Ultimate Load Test criteria set forth in  24  C.F.R §  3280 . 401 ( b ) .    
     
     
       21. The wall structure of  claim 20 , wherein an exterior layer is laminated to the cellulosic layer and an interior layer is laminated to the first layer. 
     
     
       22. The wall structure of  claim 21 , wherein said second, reinforcing layer is a biaxially oriented polymeric film. 
     
     
       23. The wall structure of  claim 20 , wherein said first layer comprises a foamed material. 
     
     
       24. The wall structure of  claim 23 , wherein said foamed material is an organic material. 
     
     
       25. The wall structure of  claim 24 , wherein said organic material is selected from the group consisting of polystyrene and polyurethane. 
     
     
       26. The wall structure of  claim 20 , wherein said first cellulosic layer comprises a fiberboard material. 
     
     
       27. The wall structure of  claim 20 , wherein said second, reinforcing layer is a polymer fabric made of a thermoplastic material. 
     
     
       28. The wall structure of  claim 27 , wherein said thermoplastic material is selected from the group consisting of polyethylene and polypropylene. 
     
     
       29. The wall structure of  claim 27 , wherein the polymer fabric is woven. 
     
     
       30. The wall structure of  claim 20 , wherein said second, reinforcing layer is a biaxially oriented polymeric film made of a thermoplastic resin. 
     
     
       31. The wall structure of  claim 30 , wherein the thermoplastic material is a polyolefin or a polyester. 
     
     
       32. The wall structure of  claim 20 , wherein the cellulosic layer has a plastic film formed thereon. 
     
     
       33. The wall structure of  claim 20 , wherein the cellulosic layer is impregnated with a member selected from the group consisting of a resin, an adhesive and mixtures thereof. 
     
     
       34. The wall structure of  claim 33 , wherein said cellulosic layer is impregnated with a urethane. 
     
     
       35. The wall structure of  claim 33 , wherein said cellulosic layer is impregnated with a polyester. 
     
     
       36. The wall structure of  claim 33 , wherein said cellulosic layer is impregnated with a urethane and a polyester. 
     
     
       37. The wall structure of  claim 33 , wherein said cellulosic layer is impregnated to a degree of saturation of from about 3 to 100%. 
     
     
       38. The wall structure of  claim 20 , wherein said cellulosic layer is Kraft paper. 
     
     
       39. The wall structure of  claim 20 , wherein the second, reinforcing layer is directly bonded to the first layer through the use of an adhesive.  
     
     
       40. In a wall structure that is contained in a building structure exposed to transverse wind loading, the improvement comprising said wall structure containing a first layer comprising a foamed material having a density of about  0 . 5 - 3  lb./ft. 3    and a second, reinforcing layer of a woven polymer fabric directly bonded to the first layer through the use of an adhesive, said wall structure meeting the Ultimate Load Test criteria set forth in  24  C.F.R §  3280 . 401   ( b ) .    
     
     
       41. The wall structure of  claim 40 , wherein said foamed material is an organic material.  
     
     
       42. The wall structure of  claim 41 , wherein said organic material is polystyrene.  
     
     
       43. The wall structure of  claim 40 , wherein the second, reinforcing layer is made of a thermoplastic material.  
     
     
       44. The wall structure of  claim 43 , wherein the thermoplastic material is a polyolefin.  
     
     
       45. The wall structure of  claim 44 , wherein the polyolefin is polyethylene or polypropylene.  
     
     
       46. A laminate wall structure for use in wall sheathing applications in manufactured housing and site built construction, the laminate wall structure comprising:
   a first layer comprising a foamed plastic material having a density of about  0 . 5 - 3  lb/ft.   3   , and        a second, reinforcing layer of a woven polymer fabric directly bonded to the first layer,        wherein said laminate wall structure meets the Ultimate Load Test criteria set forth in  24  C.F.R. § 3280 . 401   ( b )  for a design wind load of ± 46  PSF.      
     
     
       47. The laminate wall structure according to  claim 46 , wherein the laminate wall structure meets the Ultimate Load Test criteria set forth in  24  C.F.R. § 3280 . 401 ( b )  for a design wind load of ± 38  PSF.    
     
     
       48. The laminate wall structure according to  claim 46 , wherein the foamed plastic material is selected from the group consisting of polystyrene and polyurethane.  
     
     
       49. The laminate wall structure according to  claim 47 , wherein the foamed plastic material is selected from the group consisting of polystyrene and polyurethane.  
     
     
       50. The laminate wall structure according to  claim 46 , wherein the second, reinforcing layer is directly bonded to the first layer through the use of an adhesive.  
     
     
       51. The laminate wall structure according to  claim 47 , wherein the second, reinforcing layer is directly bonded to the first layer through the use of an adhesive.  
     
     
       52. The laminate wall structure according to  claim 46  further comprising:
   a cellulosic layer selected from the group consisting of paper, paper fiberboard, plastic - coated paper and plastic - coated paper fiberboard laminated to the second, reinforcing layer.      
     
     
       53. The laminate wall structure according to  claim 47 , further comprising:
   a cellulosic layer selected from the group consisting of paper, paper fiberboard, plastic - covered paper and plastic - coated paper fiberboard laminated to the second, reinforcing layer.      
     
     
       54. The wall structure of  claim 20 , wherein the polymer fabric is unwoven.

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