Insulated reinforced foam sheathing, reinforced elastomeric vapor permeable air barrier foam panel and method of making and using same
The invention comprises a product. The product comprises a first foam panel having an edge, a first primary surface and an opposite second primary surface and a second foam panel having an edge, a first primary surface and an opposite second primary surface, wherein the first and second foam panels are disposed such that their edges are adjacent each other and define a joint therebetween. The product also comprises an elongate metal strip having a body portion and a projection extending outwardly from the body portion, the metal strip being disposed such that at least a portion of the projection is disposed in the joint between the foam panels and at least a portion of the body portion covers a portion of the second primary surface of the first foam panel and a portion of the second primary surface of the second foam panel. A method of making and using the composite panel is also disclosed.
1. A product comprising:
a first foam panel having an edge, a first primary surface and an opposite second primary surface;
a first layer of reinforcing material substantially covering and adhered to the first primary surface of the first foam panel;
a second foam panel having an edge, a first primary surface and an opposite second primary surface, wherein the first and second foam panels are disposed such that their edges are adjacent each other and define a joint therebetween;
a second layer of reinforcing material substantially covering and adhered to the first primary surface of the second foam panel;
a first elongate metal strip having a body member and a projection extending outwardly from the body portion, the metal strip being disposed such that at least a portion of the projection is disposed in the joint between the first and second foam panels and at least a portion of the body member covers a portion of the first layer of reinforcing material on the first foam panel and a portion of the second layer of reinforcing material on the second foam panel; and
wherein the first and second, layers of reinforcing material are attached to the first foam insulating panel with a vapor permeable air barrier material having a vapor transmission rate of at least 1 perm and an air permeance of less than 0.004 cfm/sq. ft. under a pressure differential of 0.3 inches of water.
2. The product of claim 1 further comprising:
a third layer of reinforcing material substantially covering and adhered to the second primary surface of the first foam panel; and
a fourth layer of reinforcing material substantially covering and adhered to the second primary surface of the second foam panel.
3. The product of claim 2 further comprising:
a second elongate metal strip having a body member and a projection extending outwardly from the body portion, the metal strip being disposed such that at least a portion of the projection is disposed in the joint between the first and second foam panels and at least a portion of the body member covers a portion of the third layer of reinforcing material on the first foam panel and a portion of the fourth layer of reinforcing material on the second foam panel.
4. The product of claim 3 , wherein the first elongate metal strip has a plurality of cleats extending outwardly from the body member and wherein at least some of the plurality of cleats extend through the first and second layers of reinforcing materials and into the first and second foam panels.
5. The product of claim 4 , wherein the second elongate metal strip has a plurality of cleats extending outwardly from the body member and wherein at least some of the plurality of cleats extend through the third and fourth layers of reinforcing materials and into the first and second foam panels.
6. The product of claim 3 further comprising a fastener penetrating the first elongate metal strip, the first layer of reinforcing material the first foam insulating panel, the third layer of reinforcing material and the second elongate metal strip.
7. The product of claim 6 further comprising a fastener penetrating the first elongate metal strip, the second layer of reinforcing material the second foam insulating panel, the fourth layer of reinforcing material and the second elongate metal strip.
8. The product of claim 7 , wherein the first, second, third and fourth layers of reinforcing material are each porous.
9. The product of claim 7 , wherein the first, second, third and fourth layers of reinforcing material are woven or nonwoven materials.
10. The product of claim 7 , wherein the first, second, third and fourth layers of reinforcing material are vapor permeable.
11. The product of claim 7 , wherein the first and second, layers of reinforcing material are attached to the first foam insulating panel with a polymeric material.