WEATHERIZATION PANEL AND METHODS FOR SAME

Abstract

A sheathing panel including a cementitious substrate having a first side and a second side. The first side faces an interior of a building and the second side faces towards an exterior of the building. The sheathing panel includes a moisture-resistant fabric having a first surface and a second surface opposing the first surface. The first surface is joined with the second side of the cementitious substrate and the second surface faces an exterior. The moisture-resistant fabric includes an adhesive layer disposed on the first surface.

Claims

1. A sheathing panel comprising: a cementitious substrate having a first side and a second side; wherein the first side faces an interior of a building; wherein the second side faces towards an exterior of the building; a moisture-resistant fabric having a first surface and a second surface opposing the first surface; wherein the first surface is joined with the second side of the cementitious substrate; wherein the second surface faces the exterior; and an adhesive layer disposed on the first surface of the moisture-resistant fabric.

2. The sheathing panel of claim 1, wherein the cementitious substrate includes magnesium oxide.

3. The sheathing panel of claim 1, wherein the cementitious substrate is at least one of moisture-resistant or fire resistant.

4. The sheathing panel of claim 1, wherein the moisture-resistant fabric includes a nonwoven fabric.

5. The sheathing panel of claim 4, wherein the adhesive layer is configured to be applied to the cementitious substrate; wherein the moisture-resistant fabric including the adhesive layer is configured to form a self-adhesive moisture-resistant fabric.

6. The sheathing panel of claim 1, including an insulation material disposed between the cementitious substrate and the moisture-resistant fabric.

7. A sheathing panel comprising: a cementitious substrate including magnesium oxide, the cementitious substrate having a first side and a second side; wherein the first side is configured to be coupled with a frame of a building; wherein the second side faces towards an exterior of the building; a moisture-resistant fabric having a first surface and a second surface opposing the first surface; wherein the first surface is joined with the second side of the cementitious substrate; wherein the second surface faces the exterior; and an adhesive applied to the first surface of the moisture-resistant fabric; wherein the moisture-resistant fabric with the adhesive applied is configured to form a self-adhesive moisture-resistant fabric.

8. The sheathing panel of claim 7, including: an insulation material positioned between the first surface of the moisture-resistant fabric and the second side of the cementitious substrate.

9. The sheathing panel of claim 7, wherein the cementitious substrate is a first moisture-resistant substrate, the sheathing panel including: a second substrate; and an insulation material having a first side and a second side, the first side of the insulation material coupled with a first side of the second substrate and the second side of the insulation material coupled with the first moisture-resistant substrate.

10. The sheathing panel of claim 9, wherein the insulation material includes at least one of graphite polystyrene or polystyrene.

11. The sheathing panel of claim 7, wherein the adhesive includes an acrylic.

12. The sheathing panel of claim 7, wherein the cementitious substrate is at least one of moisture-resistant or fire-resistant.

13. The sheathing panel of claim 7, wherein the cementitious substrate is mold and mildew resistant.

14. The sheathing panel of claim 7, wherein the cementitious substrate includes polymer filaments.

15. A method of forming a moisture-resistant sheathing panel comprising: forming a cementitious substrate; wherein the cementitious substrate has a first side and a second side; forming a moisture-resistant fabric; wherein the moisture-resistant fabric has a first surface and an opposing second surface; converting the moisture-resistant fabric to a self-adhesive moisture-resistant fabric, including: applying an adhesive to the first surface of the moisture-resistant fabric; and joining the first surface of the moisture-resistant fabric with one of the first side or the second side of the cementitious substrate.

16. The method of forming the moisture-resistant sheathing panel of claim 15, wherein the cementitious substrate is moisture-resistant and includes magnesium oxide.

17. The method of forming the moisture-resistant sheathing panel of claim 15, wherein the moisture-resistant fabric is a nonwoven fabric.

18. The method of forming the moisture-resistant sheathing panel of claim 15, includes: coupling a layer of insulation between the self-adhesive moisture-resistant fabric and the cementitious substrate.

19. The method of forming the moisture-resistant sheathing panel of claim 15, wherein the moisture-resistant fabric includes a polymer.

20. The method of forming the moisture-resistant sheathing panel of claim 15, wherein the adhesive includes one or more of neoprene, epoxies, polyurethanes, acrylics, silicones, modified silane (MS) polymers.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

[0020] FIG. 1 is a structure with several sheathing panels coupled to a face of the structure according to at least one example of the present disclosure.

[0021] FIG. 2 is a perspective view of a sheathing panel with a weather resistant barrier according to at least one example of the present disclosure.

[0022] FIG. 3 is a bottom view of a sheathing panel with a weather resistant barrier according to at least one example of the present disclosure.

[0023] FIG. 4 is a perspective view of a sheathing panel with a weather resistant barrier according to at least one example of the present disclosure.

[0024] FIG. 5 is a close-up cross section of a sheathing panel with a weather resistant barrier according to at least one example of the present disclosure.

[0025] FIG. 6 is close-up cross section of a sheathing panel with a weather resistant barrier and insulation according to at least one example of the present disclosure.

[0026] FIG. 7 is a method of forming a sheathing panel according to at least one example of the present disclosure.

DETAILED DESCRIPTION

[0027] In building construction, the structural components such as the frame, electrical and mechanical systems, insulation, and the like are protected from environmental conditions with additional structural components or materials. An example of an additional structural component or material includes sheathing. Sheathing is, for example, an outer layer or casing that is designed to protect at least one of the floors, ceilings, roofs, or walls of the building. In examples, sheathing is coupled (e.g., attached, fastened, or joined) to a frame of a building and is, in some examples, externally facing when coupled to a frame or a wall of a building. For example, at least a surface of a sheathing panel faces towards outdoor environmental conditions.

[0028] In examples, sheathing is supplied as panels. Each of the panels is, for example, coupled to a frame of a building. For example, at least two sheathing panels are coupled to a frame of a building such that each of the at least two sheathing panels are coupled to the frame and positioned adjacent to each other to provide a continuous surface. In examples, a continuous surface decreases environmental conditions from penetrating from the outside environment to inside structures of the building. For example, sheathing minimizes water or moisture from penetrating into a building, or the structural components of a building.

[0029] Optionally, sheathing is an insulation material that enhances thermal efficiency or energy efficiency of a building. In examples, sheathing minimizes outside environmental conditions from seeping to the inside and interior environmental conditions from escaping to the outside. For example, sheathing assists in maintaining stable temperature or moisture conditions within a building.

[0030] In other examples, sheathing minimizes fire from spreading throughout a building, should the structure or a component of a building catch on fire. For instance, sheathing is formed from materials that present fire-resistant characteristics. Sheathing presenting fire-resistant characteristics is optionally include gypsum, or cementitious materials such as magnesium oxide or the like.

[0031] One example of a moisture-resistant substrate includes using a cementitious material such as magnesium oxide (MgO). A MgO panel is moisture-resistant in so far as it does not quickly decay or deform when exposed to moisture. However, a MgO panel may retain moisture in proximity to other less moisture-resistant components (e.g., lumber, wood-based products). In some examples, a magnesium oxide (MgO) panel is coated with a liquid product that subsequently sets or dries. The coating decreases moisture absorption of the magnesium oxide.

[0032] To resist moisture absorption, weather resistant barriers are coupled or applied to protective structures. In one example, a weather resistant barrier includes coatings that are applied to the surfaces of composite materials or lumber. The coating, in some examples, reduces absorption of moisture into the protective structure. In examples, coatings include resin coatings. In other examples, liquid polymers are applied to surfaces of a composite material or lumber to minimize absorption of moisture. In examples, a weather resistant barrier is applied with a sprayed substance such as a polyurethane coating, a ceramic infused coating, a silicon dioxide coating, or the like.

[0033] In an example, the moisture-resistant fabric includes a weather resistant barrier that minimizes infiltration of environmental elements into the interior structures of a building. An example of a moisture-resistant fabric includes nonwoven or woven fabrics. The moisture-resistant fabric, for instance, is a nonwoven or woven polypropylene. Nonwoven fabrics include those similar to house wraps made by TAMLYN under the brand name such as TAMLYNWRAP or TAMLYNWRAP ELITE and those described in U.S. Pat. Nos. 11,408,142; and 11,274,437 incorporated by reference herein in their entirety. In other examples, the nonwoven fabric includes fibrous materials that are bonded together by, for example, chemical, mechanical, heat or solvent treatments. In other examples, the moisture-resistant fabric includes woven fabrics or spunbonded fabrics.

[0034] In some examples, the moisture-resistant fabric is joined to the moisture-resistant substrate, such as a magnesium oxide panel, with an intermediate component disposed between the moisture-resistant fabric and the panel. For instance, a layer of insulation is installed between the moisture-resistant fabric and the moisture-resistant substrate. The resulting composite product, in this example, includes each of the fabric, insulation layer and the substrate (and one or more adhesive layers). The layer of insulation optionally includes graphite polystyrene, polystyrene, polyisocyanurate, expanded polystyrene or other insulation materials. In other examples, the insulation is sandwiched (e.g., laminated) between two moisture-resistant substrate panels, such as two magnesium oxide panels. In an example, the moisture-resistant fabric is joined to the exterior facing panel of the two panels.

[0035] Illustrated in FIG. 1 is an example of a building 10 having a frame 20. The building 10 is, for example, a house, residential building, commercial building, storage building or the like. In some examples, such as outdoor locations, the building 10 benefits from resisting the penetration of outside environmental conditions through the frame including, but not limited to, moisture, draft, heat transfer or the like between the interior and exterior of the building 10. In some examples, protective materials are coupled to the frame 20 of the building 10 to provide separate layers having different functions. The protective materials include plywood, oriented strand board (OSB) to decrease heat transfer, interrupt drafts, provide sheeting for siding, stucco, or the like. In other examples, one or more of a wrap, tar paper or painted on (or sprayed on) coatings are separately applied to the plywood or OSB to decrease moisture permeation.

[0036] As described herein, alternatives to separately installed components for the building 10 are described. For instance, one or more sheathing panels 100 are installed to the frame 20. Each of the one or more sheathing panels 100 includes a robust substrate (e.g., plywood, OSB, MgO or the like) having an integrated moisture-resistant layer, such as a fabric or the like that decreases or prevents the likelihood of moisture penetration to the underlying substrate (and interior of the building 10). The one or more sheathing panels 100 are coupled (e.g., attached, fastened, joined) to the frame 20 or similar structure of the building 10 in a unitary manner that installs the substrate and moisture-resistant layer at the same time and in the same step.

[0037] Illustrated in FIG. 1, a first sheathing panel 100a, of the one or more sheathing panels 100, is positioned adjacent to a second sheathing panel 100b, of the one or more sheathing panels 100. In an example, the first sheathing panel 100a is at least partially in contact with the second sheathing panel 100b, for instance abut at a joint overlying a stud. In another example, the one or more sheathing panels 100 are optionally arranged in an abutting arrangement. For example, a first sheathing panel 100a abuts an adjacent, second sheathing panel 100b. In yet another example, the first sheathing panel 100a and the second sheathing panel 100b have a specified space between. The one or more sheathing panels 100 are positioned in a continuous arrangement around the exterior of the frame 20 of the building 10.

[0038] Illustrated in FIG. 2 is an example of a sheathing panel 200. In this example, the sheathing panel 200 is a rectangular panel having a specified length, width, and depth according to the specifications of the sheathing panel 200, building codes or the like. The sheathing panel 200 includes a first face 204 and an opposing second face 202. The first face 204 is optionally an exterior facing side of the sheathing panel 200 and the opposing second face 202 is an interior facing side of the sheathing panel 200. For example, the sheathing panel 200 is coupled to the frame of a building with the opposing second face 202 directed toward the inside of the building and the first face 204 is directed toward the exterior of the building.

[0039] In examples, the sheathing panel 200 includes a substrate 210, also referred to as a base layer or a foundational layer. The substrate 210 is an example of a foundation layer onto which other materials are joined (e.g., adhered, bonded, coupled, welded or the like) as part of the construction of the sheathing panel 200 to provide a composite panel having the various functions described herein. For example, the substrate 210 is formed from a robust material that supports additional layers. For example, the substrate 210 of the sheathing panel 200 is formed from a cementitious material that is durable and has lower moisture permeability than materials such as plywood, composite woods, or the like.

[0040] The substrate 210 is, for example, a foundational layer formed from a cementitious material. In an example, the substrate 210 has a first side 214 and a second side 212. The first side 214 of the substrate 210 faces, for example, the exterior of a building and the second side 212 of the substrate 210 faces, for example, the interior of a building, when the sheathing panel 200 is coupled to a frame of a building. In an example, one or more functional layers 220 are coupled (e.g., adhered, joined, bonded, welded or the like) to one or more of the first side 214 or second sides 212 of the substrate 210. In the present example, the one or more functional layers 220 face the exterior of the building. In some examples described herein, the one or more functional layers 220 decrease the permeability of the sheathing panel 200, and thereby limit moisture infiltrating into the substrate 210 and/or the interior of the building.

[0041] As shown in FIG. 2, the sheathing panel 200 is a composite building material having layers (e.g., substrate, fabric, insulation) coupled with the substrate 210 and the additional layers with one or more of more of fasteners, adhesives, bonding, or the like. As described herein, the one or more functional layers 220 optionally includes a moisture-resistant material 230. A moisture-resistant material 230 includes components that minimize or prevent moisture from penetrating though the moisture-resistant material 230. A moisture-resistant material 230 includes components such as, but not limited to, polyphenylene ether (PPE), polyethylene (PE), high density polyethylene (HDPE) or the like. In an example, the moisture-resistant material 230 is coupled as a membrane or sheet with the first side 214 of the substrate 210.

[0042] Coupling or joining the moisture-resistant material 230 to the substrate 210 is an example of a way to decrease the moisture permeability of the sheathing panel 200. For instance, the moisture-resistant material 230 decreases moisture penetration to the substrate 210. In another example, the moisture-resistant material 230 decreases moisture penetration to the frame or other internal features of the building. Moisture or fluctuations in temperature, in certain conditions, deform substrate materials and associated functional layers. In some examples, the substrate 210 is a moisture-resistant material that maintains the integrity, adhesion, or other properties of the one or more functional layers 220 coupled to the substrate 210. Optionally, the substrate 210 and the moisture-resistant material 230 cooperate to resist moisture penetration to building internal features.

[0043] The example sheathing panel 300 shown in FIG. 3 includes a durable, structurally sound, substrate 310. The sheathing panel 300 is, for instance, more durable than wood-based products, OSB, gypsum or the like.

The substrate 310, for instance, is a durable layer that supports one or more functional layers, for example the one or more functional layers 220 illustrated in FIG. 2. The one or more functional layers 220 are optionally joined or coupled to one or more of a first side 314 or a second side 312 of the substrate 310. In some examples, the first side 314 is an exterior side (the illustrated surface of FIG. 2) and the second side 312 is an interior side (the surface shown in FIG. 3). The substrate 310, in examples, supports the one or more functional layers 220 and is resistant to deforming, decaying, or degrading, for instance, due to environmental conditions, applied loads, or the like. For example, the substrate 310 is resistant to warping, cracking or the like in response to environmental conditions, installation activities (e.g., nails, screws, mounting of siding, stacking, or the like). In some examples, environmental conditions include, but are not limited to, moisture, temperature fluctuations or the like.

[0044] In some examples, the substrate 310 includes a cementitious material having cement-like properties. For example, materials that set, harden, and bind formative materials together. The cementitious material includes, for example, structural properties that promote durability. For instance, a cementitious material is resistant to swelling, deformation or degradation when exposed to moisture. In some examples, cementitious materials are more resistant to decay compared to wood-based materials (e.g., OSB or plywood). Plaster or gypsum are other examples of durable materials for the substrate 310 that are resistant to decay in comparison to wood-based materials. In other examples cementitious substrates, plaster-based substrates, or gypsum substrates, include fire resistant materials. In still other examples, cementitious materials are robust to support loads including, but not limited to, nails, screws, fasteners, cutting, mounting of siding, trim, stacking, layering, or the like.

[0045] Optionally, the cementitious material of the substrate 310 includes magnesium oxide (MgO) as example durable material for the one or more sheathing panels 100, 200, 300. MgO is a durable substrate that is resistant to environmental conditions that precipitate degrading, decaying, cracking, warping, shrinking, expanding or the like. For instance, MgO is more robust than wood-based materials, OSB, gypsum or the like. MgO is a more robust material because it, for example, presents greater shear strength in comparison to wood-based products, OSB, gypsum or the like.

[0046] In addition to the benefits of MgO as a structurally durable substrate, MgO is resistant to environmental conditions such as moisture, pests, and other environmental elements that promote degradation of a material. For example, MgO is moisture-resistant and thereby resists (including full resistance or enhanced resistance relative to wood base products), or reduces swelling, deformation, or degrading when exposed to moisture. In some examples, MgO is also resistant to mold, mildew or other environmental hazards that are prevalent in other materials, such as wood-based materials (e.g., OSB, plywood, particle board or the like). MgO is also fire-resistant material (e.g., in some examples non-combustible) in comparison to wood-based materials.

[0047] MgO, while having increased structurally durable characteristics as compared to wood-based products, OSB, gypsum or the like, does not include chemicals or additives that are toxic or harmful to humans. Optionally, MgO combined with one or more other constituents for the substrate 310 including, but not limited to, magnesium chloride, water, and other fillers like perlite, wood chips, or fiberglass to enhance properties of the substrate. Enhanced properties with these additives include, but are not limited to, stress reduction, hardness, or fire rating.

[0048] When forming a substrate 310 from MgO as a sheathing panel special tools are not required to modify the substrate 310 and it can be modified using commonly available construction tools such as a circular saw, band saw, or even scoring and snapping. In some examples, MgO is a weight bearing foundational substrate that supports components fastened (e.g., screwed, nailed, stapled or the like) to the MgO.

[0049] In examples, the substrate 310 has a first side 314 and a second side 312 where the first side 314 optionally faces the exterior of a building and the second side 312 faces the interior of the building. In other examples, the second side 312 faces the exterior of the building and the first side 314 faces the interior of the building. Illustrated in FIG. 3 is the second side 312, for example, similar to the second side 312 of the substrate 210 coupled with the frame of the building 10 (illustrated in FIG. 1). A first side 314 of the sheathing panel 300 as an example of the exterior facing side of the substrate 310. As illustrated in the example of FIG. 3, the substrate 310 is formed as a rectangular panel, for instance having dimension corresponding to a sheet of plywood (e.g., four feet by eight feet). As described herein, the substrate 310, includes a cementitious material and optionally, other materials to enhance properties, such as, but not limited to, durability or other performance properties (e.g., moisture resistance, resistance to temperature variations, thermal insulation, or the like).

[0050] In examples, the one or more other materials include a mesh 320 (e.g., fibers, fabrics, or the like) that increases the structural characteristics of the cementitious material. For instance, the mesh 320 includes a fiberglass mesh. The mesh 320 is optionally added as either of an open-weave or a closed-weave sheet to a slurry or mixture of the cementitious material during manufacturing of the sheathing panel 300.

[0051] In one example, at least one layer of mesh 320 is positioned in a mold, container, on a flexible tape or carrier film, or the like. In examples, a slurry of cementitious material administered to at least partially cover the mesh 320. Optionally, one or more layers of mesh 320 are embedded or positioned proximate to outer surfaces of the slurry. The mesh 320, in examples, is coupled with the remainder of the substrate 310 (e.g., adhered, fastened or the like) and the coupled mesh enhances the maintenance of the shape, profile or form of the substrate 310. In an example, the mesh 320 is proximate to one or more of the first side 314 and the second side 312. In other examples, the mesh 320 is positioned to be on one of the first side 314 or the second side 312. After the mesh 320 sets with the slurry, the mesh 320 enhances the structural durability of the sheathing panel 300 shape, profile, or the like.

[0052] FIG. 4 is a perspective view of another example of the sheathing panel 400. In an example, the sheathing panel 400 includes features described herein (e.g., in FIGS. 2 and 3). For instance, the sheathing panel 400 includes a cementitious substrate 410, and one or more functional layers 420 coupled (e.g., joined, bonded, adhered or the like) to one or more of the first side 414 or the second side 412. In the example shown in FIG. 4 the one or more functional layers 420 are coupled with the first side 414 of the cementitious substrate 410. The first side 414 of the cementitious substrate 410 is, for example, the exterior facing side of the cementitious substrate 410. For instance, the first side 414 is exposed to weather-related conditions in comparison to the second side 412, the interior facing side. In examples, the sheathing panel 400 is coupled to the frame of a building (e.g., frame 20 in FIG. 1), and the first side 414 faces away from the frame of the building. In some examples, when the second side 412 of the sheathing panel 400 is coupled with the frame of a building, the first side 414 is covered with siding, brick, stucco, a supplemental membrane (in addition to the sheathing panel 400) or other faade examples.

[0053] In an example, the one or more functional layers 420 provide (including enhancing) one or more functional characteristics to the cementitious substrate 410. Including the one or more functional layers 420 enhances moisture resistance and thereby decreases moisture penetration of the cementitious substrate 410. For example, the one or more functional layers 420 decreases absorption (e.g., infiltrating, penetrating, or the like) of moisture or other environmental matter into the cementitious substrate 410. The one or more functional layers 420 that enhance moisture resistance are examples of one or more barrier layers. In examples, the one or more functional layers 420 includes at least one barrier layer that enhances moisture resistance of the cementitious substrate 410.

[0054] The one or more functional layers 420 include a moisture-resistant material, as described herein. The moisture-resistant fabric 430 is a weather resistant barrier that decreases infiltration of environmental elements into the cementitious substrate 410 and interior of buildings. In one example, the moisture-resistant material includes a fabric or a fabric-like material. For instance, the moisture-resistant material (an example of one or more functional layers 420) is a moisture-resistant material including one or more of woven, non-woven or synthetic materials. In other examples, the moisture-resistant fabric 430 includes laminates of woven or non-woven filaments and a sheet or membrane material. In other examples, the moisture-resistant fabric 430 includes polymer-based materials, such as plastic sheets or the like.

[0055] The moisture-resistant fabric, for instance, is a woven or nonwoven polypropylene. Moisture-resistant fabric, wraps, wraps including fabrics or the like, include house wraps made by R. H. Tamlyn & Sons, LP under brand names such as TAMLYNWRAP or TAMLYNWRAP ELITE, wraps described in U.S. Pat. Nos. 11,408,142, and 11,274,437 each incorporated by reference herein in their entirety.

[0056] In other examples, the moisture-resistant fabric 430 includes laminated materials, such as polymer membranes or the like. In other examples, the moisture-resistant fabric 430 includes a nonwoven fabric including fibers, filaments, strands or the like that are bonded together one or more of chemical, mechanical, thermal, adhesive processes, or the like. In other examples, the moisture-resistant fabric 430 includes woven fabrics or spunbonded fabrics. In other examples, the moisture-resistant fabric 430 optionally includes a breathable film.

[0057] In still other examples, the moisture-resistant fabric 430 includes a polymer material or fabric positioned between one or more layers of a fabric (woven, non-woven or the like). For instance, the moisture-resistant fabric 430 includes a polyethylene gas breathable film (while also moisture resistant) laminated with the woven or non-woven fabric. The moisture-resistant fabric 430 includes more than one layer of material (e.g., woven fabric, non-woven fabric, films, plastics, or the like) stacked, laminated, coupled or the like. In examples, at least one of the layers resists moisture penetration to the cementitious substrate 410. Materials and arrangements have been discussed herein for the moisture-resistant fabric 430, other materials include moisture permeating to the cementitious substrate 410 are suitable.

[0058] In various examples, the moisture-resistant fabric 430 extends across the cementitious substrate 410. For instance, the moisture-resistant fabric 430 covers (e.g., spans, continuously extends along, covers, covers from edge to edge of the sheathing panel 400 or the like) the cementitious substrate 410. The moisture-resistant fabric 430 is coupled (e.g., joined, adhered, bonded or the like) to the cementitious substrate 410. For instance, the moisture-resistant fabric 430 is joined with the first side 414 of the cementitious substrate 410 such that the first side 414 is not exposed.

[0059] In some examples the moisture-resistant fabric 430 is coupled with the cementitious substrate 410 in a manner that extends beyond the cementitious substrate 410. For instance, the moisture-resistant fabric 430 is trimmed to fit the cementitious substrate 410. In other examples, the moisture-resistant fabric 430 matches the size of the cementitious substrate 410. For instance, a perimeter 416 (including surface area) of the cementitious substrate 410 matches (e.g., is coextensive, aligns, matches 90-95 percent or the like) with the moisture-resistant fabric perimeter 426 (including its surface area). The moisture-resistant fabric 430, for example, is in continuous contact (including near continuous, such as 80 or 90 percent or more) with the cementitious substrate 410. For instance, the moisture-resistant fabric 430 is joined with the cementitious substrate 410 and is free (including 80 or 90 percent free) of ripples, wrinkles, gaps, or other irregularities that permit moisture penetration. Further, the moisture-resistant fabric 430 is applied as a solid layer in contract to a fluid or sprayed-on coating to ensure coverage of the cementitious substrate 410 while conversely avoiding gaps in coverage.

[0060] FIG. 5 is a schematic cross section of an example sheathing panel 500. The sheathing panel 500 includes, in this example, a cementitious substrate layer 510, an adhesive layer 540 and a moisture-resistant fabric 530 (e.g., as discussed related to any of FIGS. 1, 2, 3, 4). The sheathing panel 500 includes, in examples, at least one of woven, non-woven, fibrous, polymer material or the like. In an example, the moisture-resistant fabric 530 has a first surface 534 and a second surface 532. The first surface 534 is, for example, an exterior facing surface of the moisture-resistant fabric 530 and the second surface 532 is, for example, an interior facing surface of the moisture-resistant fabric 530 (e.g., directed toward the building).

[0061] In an example, the second surface 532 of the moisture-resistant fabric is coupled with a first side 514 of the cementitious substrate layer 510. The adhesive layer 540 is an example of an adhesive material distributed across the first side 514 that couples (e.g., attaches, fastens, or joins) the moisture-resistant fabric 530 with the cementitious substrate layer 510. In some examples, the adhesive layer 540 includes one or more of acrylics, neoprene, epoxies, polyurethanes, silicones, or modified silane (MS) polymers. For instance, the adhesive layer 540 is applied, sprayed, painted, or the like as a fluid continuously (e.g., completely covering, applied from proximate one side to proximate a second side, covers more than approximately 90 percent or the like) from a first end 516 to an opposing second end 517 of the cementitious substrate layer 510.

[0062] Optionally, the adhesive layer 540 is applied to the first side 514 of the cementitious substrate layer 510. In an example, the adhesive layer 540 is continuously applied (e.g., from end to end, covering greater than 90 percent of the surface area of the first side 514 of the cementitious substrate layer 510 or the like) to the cementitious substrate layer 510. The adhesive layer 540 is, for instance, spread or deposited on the first side 514 of the cementitious substrate layer 510 reducing disengagement of the moisture-resistant fabric 530 from the cementitious substrate layer 510. In examples, the adhesive layer 540 is applied in one or more specified locations on the first side 514 of the cementitious substrate layer 510.

[0063] In another example, the adhesive layer 540 is applied to the second surface 532 of the moisture-resistant fabric 530. The adhesive layer 540 applied to the second surface 532 of the moisture-resistant fabric 530 includes one or more of acrylics, neoprene, epoxies, polyurethanes, silicones, or MS polymers. For example, the adhesive layer 540 is sprayed, painted, continuously applied (e.g., from end to end, covering greater than 90 percent of the surface area of the first side 514 of the cementitious substrate layer 510 or the like) or the like to the second surface 532. In other examples, the adhesive layer 540 is applied in specified locations of the second surface 532 of the moisture-resistant fabric 530. In some examples with the adhesive layer 540 applied to the moisture-resistant fabric 530, the moisture-resistant fabric 530 is a self-adhesive layer. The self-adhesive forms a bond when pressure is applied to marry the adhesive with the moisture-resistant fabric 530. For example, the moisture-resistant fabric 530 is coupled (e.g., bonds) with the cementitious substrate layer 510 when pressure is applied to at least one of the moisture-resistant fabric 530 or the cementitious substrate layer 510.

[0064] In examples, the adhesive layer 540 includes a contact adhesive with the adhesive applied to both the first side 514 of the cementitious substrate layer 510 and the second surface 532 of the moisture-resistant fabric 530. For example, a contact adhesive is applied to both surfaces that are joined, such as the second surface 532 of the moisture-resistant fabric 530 and the cementitious substrate layer 510. After application of the adhesive layer 540, the solvent in the adhesive (or water in water-based adhesives) evaporates, leaving behind a tacky film. Once both surfaces (e.g., the second surface 532 and the first side 514) are set and the adhesive is tacky, the two surfaces are pressed together and the bond forms with contact.

[0065] A contact adhesive, for example including a polymer solvent applied to the moisture-resistant fabric 530, is joined with the cementitious substrate layer 510. In examples using a contact adhesive, the cementitious substrate layer 510 is fixedly joined with the moisture-resistant fabric 530 (e.g., one or both of the cementitious substrate layer 510 and the moisture-resistant fabric 530 would be damaged if separated).

[0066] The moisture-resistant fabric 530 is, for example, coupled with the cementitious substrate layer 510 with the adhesive layer 540 positioned between the moisture-resistant fabric 530 and the cementitious substrate layer 510. For example, the second surface 532 of the moisture-resistant fabric 530 matches (e.g., is coextensive, aligns, matches 90-95 percent or the like) the size of the cementitious substrate layer 510. In an example, the moisture-resistant fabric 530 is positioned on the cementitious substrate layer 510 free (including free, such as 80 or 90 percent or more) of wrinkles, ripples, gaps, protrusions or the like.

[0067] The adhesive layer 540 is optionally applied to the cementitious substrate layer 510 in a controlled environment, such as during a manufacturing process of the sheathing panel 500. A controlled environment includes, for examples, areas with reduced moisture, wind, temperature fluctuations, or the like. In examples, application of the moisture-resistant fabric 530 to the cementitious substrate layer 510 (either with the adhesive layer 540 applied to the moisture-resistant fabric 530 or the cementitious substrate layer 510 or both) in a controlled environment promotes accurate placement and coupling of the moisture-resistant fabric 530 with the cementitious substrate layer 510 to form the sheathing panel 500 having moisture-resistant properties as a unitary panel ready for later installation. In some examples, the controlled environment of the manufacturing process reduces misapplication of the moisture-resistant fabric 530 relative to the cementitious substrate layer 510 (e.g., overhanging an edge, portions of the cementitious substrate layer 510 have gaps in coverage or the like) or deformation (such as wrinkles, folds, undulations or the like) during application of the moisture-resistant fabric 530 to the cementitious substrate layer 510, for instance during a field application of a spray or film to a panel. In other examples, the sheathing panel 500 including the moisture-resistant fabric 530 is assembled in the field, for instance by a technician, tradesperson, lamination machine or the like applying adhesive layer 540 and coupling the moisture-resistant fabric 530 and the cementitious substrate layer 510 together.

[0068] FIG. 6 is an example of a sheathing panel 600 including additional functional layers 620. Additional functional layers 620 includes, for example, an insulation layer 650 that includes an insulation material. In examples, the insulation layer 650 promotes thermal insulation characteristics of the sheathing panel 600. The insulation layer 650 includes one or more of, but is not limited to, fiberglass, mineral wool, foam, cellulose, including multiple layers or the like.

[0069] The additional functional layers 620 are positioned, for example, between a moisture-resistant fabric 630 and a substrate 610. In an example, the insulation layer 650 has a first side 652 and a second side 654. The first side 652 of the insulation layer 650 is coupled, for instance, along a first side 614 of the substrate 610. The second side 654 of the insulation layer 650 is coupled with the moisture-resistant fabric 630 with an adhesive layer 640 along a second surface 632 of the moisture-resistant fabric 630. In an example, the second surface 632 of the moisture-resistant fabric 630 (e.g., nonwoven or woven material, including films, sheets or the like) is joined with the insulation layer 650 with a contact adhesive (as an example of the adhesive layer 640), as previously discussed with regard to the sheathing panel 500 in FIG. 5.

[0070] In another example, the second surface 632 of the moisture-resistant fabric 630 is joined to the insulation layer 650 with the adhesive layer 640 applied to the insulation layer 650 (in contrast to the moisture-resistant fabric 630). In other options, the adhesive layer 640 is a contact adhesive applied to both the moisture-resistant fabric 630 and the insulation layer 650.

[0071] Optionally, the sheathing panel 600 includes at least one or more substrates 610. In an example including two substrates 610, a second instance of the substrate 610 is coupled along a second instance of the moisture-resistant fabric 630. For example, the second instance of the moisture-resistant fabric 630 is coupled along an opposed surface of the sheathing panel 600 (e.g., a first side 611 of the substrate 610) and the second instance of the substrate 610 is coupled along an interior face of the second instance of the moisture-resistant fabric 630.

[0072] In another example, the one or more substrates 610 are coupled with a second instance of the insulation layer 650 (shown in FIG. 6). For instance, the second instance of the insulation layer 650 is coupled along a first side 611 of the substrate 610. Optionally, the second instance of the insulation layer 650 is interposed between a second instance of the moisture-resistant fabric 630 (shown in FIG. 6) and the substrate 610. In another example, any one or more of the functional layers 620 (e.g., moisture-resistant fabric 630, adhesive layer 640, insulation layer 650, combinations of the same or the like) discussed herein or shown in one or more of FIGS. 1-6 are coupled with the substrate 610.

[0073] FIG. 7 illustrates one example of a method 700 of forming a moisture-resistant sheathing panel, such as the one or more sheathing panels 100, 200, 300, 400, 500 and 600 as discussed related to any of FIGS. 1-6. In describing the method 700, reference is made to one or more components, features, functions, steps, or the like previously described herein. Where convenient, reference is made to the components, features, functions, steps, or the like with reference numerals. Reference numerals provided are exemplary and are not exclusive. For instance, components, features, functions, steps, or the like described in the method 700 include, but are not limited to, corresponding numbered elements provided herein, other corresponding features described herein (both numbered and unnumbered) as well as their equivalents.

[0074] In the method 700 of forming a moisture-resistant sheathing panel, a cementitious substrate is formed, as indicated in 710. The cementitious substrate includes, for example, a first side and second side. As shown in the examples of FIGS. 1-6, the first side of the cementitious substrate faces an exterior of a building, and the second side faces the interior of a building. For example, the first side is closer in proximity to environmental conditions than the second side.

[0075] A moisture-resistant fabric is formed as indicated in 720. The moisture-resistant fabric is, for example, the moisture-resistant fabric shown at least in FIGS. 4 and 5. In examples, the moisture-resistant fabric includes nonwoven or woven fabrics, as discussed previously. The moisture-resistant fabric includes a weather resistant barrier that decreases infiltration of environmental elements into the cementitious substrate and interior of buildings. The moisture-resistant material includes, but is not limited to, a fabric or a fabric-like material, polymer-based materials (including continuous sheets, membranes, films, or layers) or the like. For instance, the moisture-resistant fabric includes a first surface and a second surface. In one example, the moisture-resistant fabric includes the first surface directed toward the exterior of a building and the second surface directed toward the interior of the building.

[0076] The method 700 includes applying an adhesive layer, as indicated in 730 to, for example, one or more of the second surface of the moisture-resistant fabric or the first side of the cementitious substrate. The application of the adhesive layer to the second surface of the moisture-resistant fabric, for example, forms a self-adhesive, moisture-resistant fabric. A self-adhesive material is an example of type of adhesive that forms a bond when pressure is applied to marry the adhesive with the surface to which the adhesive is applied. Optionally, the adhesive layer is applied to the first side of the cementitious substrate, and coupling occurs by applying pressure to the moisture-resistant fabric against the cementitious substrate layer.

[0077] The method 700 further includes coupling the second surface of the moisture-resistant fabric with the adhesive layer applied to the cementitious substrate layer, as indicated in 740. In some examples, the moisture-resistant fabric is coupled to the first side of the cementitious substrate layer. In another example, intermediate layers (e.g., insulation layer 650 shown in FIG. 6) are positioned between the first side of the cementitious substrate layer and the moisture-resistant fabric. Intermediate layers include, for example, functional layers, such as an insulation layer, supplemental moisture-resistant layers, or the like (as discussed related to FIG. 6).

[0078] Optionally, the method 700 includes coupling an insulation layer between the moisture-resistant fabric and the cementitious substrate, as indicated in 735. In other examples, the insulation layer is joined with the first side of cementitious substrate, such as an opposing side relative to the placement of the moisture-resistant fabric. In examples where the moisture-resistant fabric and the insulation layer are on the same side (e.g., second side) of the cementitious substrate, the insulation layer is interposed between the moisture-resistant fabric and the substrate.

[0079] In examples, are two or more layers of a moisture-resistant fabric are coupled with the cementitious substrate. In other examples, two or more insulation layers are coupled with the cementitious substrate.

Various Notes and Aspects

[0080] Aspect 1 can include subject matter such as a sheathing panel including: a cementitious substrate having a first side and a second side; wherein the first side faces an interior of a building; wherein the second side faces towards an exterior of the building; a moisture-resistant fabric having a first surface and a second surface opposing the first surface; wherein the first surface is joined with the second side of the cementitious substrate; wherein the second surface faces an exterior; and an adhesive layer disposed on the first surface of the moisture-resistant fabric.

[0081] Aspect 2 can include, or can optionally be combined with the subject matter of Aspect 1, to optionally include the cementitious substrate includes magnesium oxide.

[0082] Aspect 3 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 1 or 2 to optionally include the cementitious substrate is at least one of moisture-resistant or fire resistant.

[0083] Aspect 4 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 1-3 to optionally include the moisture-resistant fabric includes a nonwoven fabric.

[0084] Aspect 5 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 1-4 to optionally include the adhesive layer is configured to be applied to the cementitious substrate; wherein the moisture-resistant fabric including the adhesive layer is configured to form a self-adhesive moisture-resistant fabric.

[0085] Aspect 6 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 1-5 to optionally include an insulation material disposed between the cementitious substrate and the moisture-resistant fabric.

[0086] Aspect 7 can include subject matter such as a sheathing panel including: a cementitious substrate including magnesium oxide, the cementitious substrate having a first side and a second side; wherein the first side is configured to be coupled with a frame of a building; wherein the second side faces towards an exterior of a building; a moisture-resistant fabric having a first surface and a second surface opposing the first surface; wherein the first surface is joined with the second side of the cementitious substrate; wherein the second surface faces an exterior; and an adhesive applied to the first surface of the moisture-resistant fabric; wherein the moisture-resistant fabric with the adhesive substrate applied is configured form a self-adhesive moisture-resistant fabric.

[0087] Aspect 8 can include, or can optionally be combined with the subject matter of Aspect 7, to optionally include an insulation material positioned between the first surface of the moisture-resistant fabric and the second side of the cementitious substrate.

[0088] Aspect 9 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 7 or 8 to optionally include a sheathing panel, wherein the cementitious substrate is a first moisture-resistant substrate, the sheathing panel including: a second substrate; and an insulation material having a first side and a second side, the first side of the insulation material coupled with a first side of the second substrate and the second side of the insulation material coupled with the first moisture-resistant substrate.

[0089] Aspect 10 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 7-9 to optionally include the insulation material includes at least one of graphite polystyrene or polystyrene.

[0090] Aspect 11 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 7-10 to optionally include the adhesive includes an acrylic.

[0091] Aspect 12 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 7-11 to optionally include the cementitious substrate is at least one of moisture-resistant or fire-resistant.

[0092] Aspect 13 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 7-12 to optionally include the cementitious substrate is mold and mildew resistant.

[0093] Aspect 14 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 7-13 to optionally include the cementitious substrate includes polymer filaments.

[0094] Aspect 15 can include subject matter such as a method of forming a moisture-resistant sheathing panel including: forming a cementitious substrate; wherein the substrate has a first side and a second side; forming a moisture-resistant fabric; wherein the moisture-resistant fabric has a first surface and an opposing second surface; converting the moisture-resistant fabric to a self-adhesive moisture-resistant fabric, including: applying an adhesive to the first surface of the moisture-resistant fabric; and joining the first surface of the moisture-resistant fabric with one of the first side or the second side of the cementitious substrate.

[0095] Aspect 16 can include, or can optionally be combined with the subject matter of Aspect 15, to optionally include the cementitious substrate is moisture-resistant and includes magnesium oxide.

[0096] Aspect 17 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 15 or 16 to optionally include the moisture-resistant fabric is a nonwoven fabric.

[0097] Aspect 18 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 15-17 to optionally include coupling a layer of insulation between the self-adhesive moisture-resistant fabric and the moisture-resistant substrate.

[0098] Aspect 19 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 15-18 to optionally include the moisture-resistant fabric includes a polymer.

[0099] Aspect 20 can include, or can optionally be combined with the subject matter of one or any combination of Aspects 15-19 to optionally include the adhesive includes one or more of neoprene, epoxies, polyurethanes, acrylics, silicones, MS polymers.

[0100] Each of these non-limiting aspects can stand on its own, or can be combined in various permutations or combinations with one or more of the other aspects.

[0101] The above description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention can be practiced. These embodiments are also referred to herein as aspects or examples. Such aspects or example can include elements in addition to those shown or described. However, the present inventors also contemplate aspects or examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate aspects or examples using any combination or permutation of those elements shown or described (or one or more features thereof), either with respect to a particular aspects or examples (or one or more features thereof), or with respect to other Aspects (or one or more features thereof) shown or described herein.

[0102] In the event of inconsistent usages between this document and any documents so incorporated by reference, the usage in this document controls.

[0103] In this document, the terms a or an are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of at least one or one or more. In this document, the term or is used to refer to a nonexclusive or, such that A or B includes A but not B, B but not A, and A and B, unless otherwise indicated. In this document, the terms including and in which are used as the plain-English equivalents of the respective terms comprising and wherein. Also, in the following claims, the terms including and comprising are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms first, second, and third, etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

[0104] Geometric terms, such as parallel, perpendicular, round, or square, are not intended to require absolute mathematical precision, unless the context indicates otherwise. Instead, such geometric terms allow for variations due to manufacturing or equivalent functions. For example, if an element is described as round or generally round, a component that is not precisely circular (e.g., one that is slightly oblong or is a many-sided polygon) is still encompassed by this description.

[0105] The above description is intended to be illustrative, and not restrictive. For example, the above-described aspects or examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. 1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description as aspects, examples, or embodiments, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.