Structural insulated wall and roof sheathing systems for use in building construction designed to provide a structural building envelope that is moisture permeable but protects from bulk water, excess air, and thermal transfer.

Building materials such as structural panels, beams, roof decking, and flooring panels, are packaged within a protective layer including a sublayer of a polymeric material that can be applied at the factory. The protective layer protects the underlying building materials from exposure to weather and potential damage due to handling during shipping, at a job site, and which can be left in place during construction, thus eliminating the need for temporary protective measures covering the building materials. The protective layer may have additional properties such as breathability, fire resistance, and sound absorption. The protective layer also may provide an underlayment such as for flooring and roofing.

A non-wicking underlayment board and methods for forming the same. The non-wicking underlayment board includes a foam core formed of closed cell foam with reinforcement layers encapsulated within the foam core. Outer facings formed of mineral coated nonwoven fibers are positioned on opposite faces of the non-wicking underlayment panel. The non-wicking underlayment board is useful for efficient and cost effective installation of barriers and surfaces in water-resistant and waterproof environments.

A backing layer (10) of a multilayer thermal insulation panel (100) for building constructions includes a glass fiber reinforcement layer (1) having a first surface (F1) and an opposite second surface (F2). The reinforcement layer is interposed between a first coating layer (2) attached to the first surface (F1) of the reinforcement layer and a second coating layer (3) attached to the second surface (F2) of the reinforcement layer (1). The first (2) and second (3) coating layers are manufactured by a mixture including an organic binder.

Fiber-reinforced coated mats and fiber-reinforced coated mat-faced panels are provided herein, along with methods for making the same. Fiber-reinforced coated mats include a mat with a fiber-reinforced coating on one surface. Fiber-reinforced coated mat-faced panels include a fiber-coated mat and a panel material in contact with a surface of the mat opposite the fiber-reinforced coating. Methods include applying a fiber-reinforced coating to a surface of a mat to form a coated mat and drying the coated mat to cure the fiber-reinforced coating. Some methods also include combining the mat with a panel material to form a mat-faced panel.

Insulated wall and roof sheathing systems for use in building construction designed to provide moisture permeable wall panels that protect from bulk water, excess air, and thermal transfer.

A process for producing a smooth-sided strand-based siding or wood structural panel using a pre-telegraphing process. The pre-telegraphing is performed after the primary process completes pressing and consolidation of the substrate/board. The pre-telegraphing process applies a water spray on the hot board immediately out of the primary process press, and before overlay application. The application of the water spray causes the surface of the board to swell and cure. A settling period follows to allow the top surface particles and strands to swell along with absorption and evaporation of the moisture. This is followed by surface sanding to remove the telegraphing and produce a smooth surface. This may then be followed by lamination of overlay(s). The process is completed by post-lamination treatment and coating of the board.

The panel includes a water resistant barrier layer secured atop its outward facing surface. The water resistant barrier layer includes a skid resistant surface. The panels are made of lignocellulosic material. The water resistant and skid resistant surface may include indicia for aligning strips of tape or for aligning fasteners. A method for manufacturing the water resistant building panels is also disclosed and includes the steps of feeding paper onto a forming belt, depositing lignocellulosic material and the binding agent onto the forming belt so as to form a lignocellulosic mat, applying heat and pressure so as to impart the skid resistant surface on the paper, and cutting panels to predetermined sizes.

The present invention relates to an improved formaldehyde-free coated fibrous substrate. The coating includes a crosslinked binder system which forms three dimensional networks when heat cured. After the coating is applied to the back of fibrous substrate and cured, the coating is capable of hygroscopic expansion which imparts excellent anti-sag properties. The coating is compatible with other coating systems with neutral or mild alkaline pH. The improvement being the binding system is neutralized with a volatile base so that it evaporates quickly so as not to hinder the cross-linking reaction.

Apparatus and methods for constructing a shower pan. The shower pan is constructed from wedge panels having a foam core and facers on major surfaces of the wedge panels. The wedge panels are cut into portions that fit regions of the shower pan area. The wedge panel portions are placed in the regions such that the sloped upper surfaces of the wedge panel portions collectively form a continuous surface that at all locations slopes downward toward the drain of the shower. Pans for a wide variety of shower shapes and sizes can be constructed. The shower pan may be efficiently constructed on-site, often using common tools and techniques.