Apparatus and method for exposed insulated wallboard
View Patent ↗Insulated wallboards are exposed interior insulation panels, for walls and ceilings, in occupiable spaces, that can be taped, finished, textured, and painted, which eliminates the need for gypsum board, and reduces or eliminates the need for other insulation, such as wall cavity insulation and exterior insulation. Insulated wallboard panels are formed by applying various combinations of thermal reflection layers such as aluminum foil; moisture resistance layer; or reinforcement layers over an insulating core. An enhanced surface or enhanced surface layer is provided on the interior-facing surface of the panel, to accept joint compound, paint, plaster, texture, or other interior finish. The core may be phenolic or other material with appropriate insulating and fire-retardant properties. The insulated wallboards may be applied directly to wood or metal framing, masonry, CMU, tilt-up concrete walls; or over existing gypsum board or other interior surfaces to retrofit additional insulation without disrupting exterior walls or roof.
1. An insulated wallboard comprising a
phenolic insulating core comprising
a thickness of 0.5 inch or greater,
a first face,
a second face,
a first side edge, and
a second side edge;
the insulated core having an R value of at least R5 per inch; and
an aluminum foil layer applied to the first face of the insulating core, the foil layer comprising
an internal face bonded to the first face of the phenolic insulating core, and
an exposed mechanically-treated external face, such that the mechanically-treated external face alters the external face of the foil to create an enhanced surface configured to accept a paint, paint primer, drywall compound, plaster, wallpaper, or other finish.
2. The insulated wallboard of claim 1 further comprising
an exterior facer applied to the second face of the insulating core.
3. The insulated wallboard of claim 2 wherein
the exterior facer is an external thermal reflection layer.
4. The insulated wallboard of claim 3 wherein
the external thermal reflection layer is an aluminum foil sheet.
5. A construction method comprising
building an exterior wall or ceiling of an occupiable space with a structural element, the structural element having an exterior face and an interior face;
providing a plurality of insulated wallboards, each insulated wallboard comprising a
phenolic insulating core comprising
a thickness of 0.5 inch or greater,
a first face,
a second face,
a first side edge, and
a second side edge,
the insulated core having an R value of at least R5 per inch, and
an aluminum foil layer applied to the first face of the insulating core, the foil layer comprising
an internal face bonded to the first face of the phenolic insulating core, and
an exposed mechanically-treated external face, such that the mechanically-treated external face alters the external face of the foil to create an enhanced surface configured to accept a paint, paint primer, drywall compound, plaster, wallpaper, or other finish;
securing the plurality of insulated wallboards to the interior face of the structural element such that the enhanced surface of the aluminum foil layer is exposed to the occupiable space; and
applying a paint, paint primer, drywall compound, plaster, wallpaper, or other finish to the enhanced surface of the aluminum foil layer.
6. The construction method of claim 5 wherein
the structural element comprises wood studs, joists, or trusses.
7. The construction method of claim 5 wherein the
structural element comprises metal studs or beams.
8. The construction method of claim 5 wherein
the structural element comprises a concrete or masonry wall formed from poured concrete, a tilt wall, or a plurality of masonry or concrete masonry units.
9. The construction method of claim 5 further comprising
securing the plurality of multilayer wallboards to the interior face of the structural element with adhesive sealant, clips, fasteners, or crown washers.
10. The construction method of claim 5 further comprising
concealing abutting edges of the plurality of insulated wallboard joints by taping and floating the abutting edges.
11. The construction method of claim 5 wherein securing the plurality of insulated wallboards to the interior face of the structural element further comprises
securing a plurality of insulated wallboard panels to the interior face of the structural element in a manner that creates a plurality of joints between abutting insulated wallboard panels; and
concealing the plurality of joints by, for each joint,
providing a length of a first tape, having a tape thickness and tape width;
providing a tool having a roller, such as “J-roller” with a width greater than the tape width, and a handle;
applying the tape along a joint between abutting insulated wallboard panels;
creating a recessed trough, having the width of the roller, extending along the joint while depressing the tape into recessed trough by rolling the roller over the tape; and
applying a layer of joint or drywall compound over the recessed trough.
12. The construction method of claim 11 further comprising
applying a layer of fiberglass or fiberglass mesh tape over the length of the first tape prior to applying a layer of joint or drywall compound.
13. The construction method of claim 5 wherein finishing the interior faces of the plurality of insulated wallboards further comprises
applying texture to the plurality of insulated wallboards; and painting
the plurality of insulated wallboards.
14. The construction method of claim 5 wherein securing the plurality of insulated wallboards to the interior face of the structural element further comprises
securing the plurality of multilayer wallboards over the interior faces of existing drywall walls or ceiling.