INSULATION PANELS WITH INTEGRAL STRAPPING

CROSS-REFERENCE TO RELATED APPLICATION(S)

[0001]This Application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63/726,055, entitled “INSULATION PANELS WITH INTEGRAL STRAPPING,” filed Nov. 27, 2024, by Natalia H. THOMAS et al., which is assigned to the current assignee hereof and is incorporated herein by reference in its entirety.

TECHNICAL FIELD

[0002]The present disclosure relates generally to an insulation sheet for insulating a building. The present disclosure relates more particularly to an insulation sheet with integral strapping.

BACKGROUND

[0003]When installing siding over thick exterior insulation panel, there are additional steps that are generally required so that the siding can be properly installed to a wall of the building. For example, vinyl siding to be installed on a wall with exterior insulation panel having a thickness of 2 inch or greater, strapping (e.g., pieces of 1×2 or 1×3 dimensional lumber) is needed so that the vinyl siding can be pinned to it rather than nailing all the way through the exterior insulation panel to the exterior sheathing. However, since vinyl siding tends to telegraph (i.e., appear warped or wavy) if there is no support directly behind it, then gaps between the strapping may need to be filled, such as with foam board. This is time consuming and adds significant labor to the installation process. Therefore, improvements in insulation panels are continually needed.

SUMMARY

[0004]This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify indispensable features of the claimed subject matter, nor is it intended for use as an aid in limiting the scope of the claimed subject matter.

[0005]One general aspect includes an insulation panel having an insulation sheet with an exterior surface and an interior surface, and a plurality of strips that are installed in or on the exterior surface of the insulation sheet, where the plurality of strips are spaced apart from each other, and where the plurality of strips are angled relative to a bottom side of the insulation sheet.

[0006]One general aspect includes a method for producing an insulation panel that includes attaching a plurality of strips on an exterior surface of an insulation sheet, where the insulation sheet may include the exterior surface, an interior surface opposite the exterior surface, and a bottom side, where each of the plurality of strips are spaced apart from each other, and where each of the plurality of strips are angled relative to the bottom side of the insulation sheet.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007]Embodiments are illustrated by way of example and are not limited to the accompanying figures. These and other features, aspects, and advantages of present embodiments will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

[0008]FIG. 1 is a representative perspective view of a portion of a stud wall with exterior insulation panels and cladding panels installed on exterior sheathing, the exterior insulation panels having integral diagonal strapping, in accordance with certain embodiments;

[0009]FIG. 2A is a representative perspective view of an exterior insulation panel with cladding panels attached to strips of integral strapping in an insulation sheet, in accordance with certain embodiments;

[0010]FIG. 2B is a representative perspective view of an exterior insulation panel with integral strapping in an insulation sheet and markings to assist in fastener placement, in accordance with certain embodiments;

[0011]FIGS. 3A, 3B, and 3C are representative partial cross-sectional views along line 3A-3A, as indicated in FIG. 2A, of a portion of an exterior insulation panel with diagonal strips, in accordance with certain embodiments;

[0012]FIGS. 4A-4D are representative partial cross-sectional views along line 4A-4A, as indicated in FIG. 1, of an insulation sheet with diagonal strips, the panel being mounted to a wall with or without exterior sheathing, in accordance with certain embodiments;

[0013]FIG. 5 is a representative perspective view of a portion of a stud wall with exterior insulation panel and cladding installed on exterior sheathing, the exterior insulation panel having vertical strips, in accordance with certain embodiments;

[0014]FIGS. 6A-6B are representative partial cross-sectional views along line 6A-6A, as indicated in FIG. 5, of an insulation sheet with vertical integral strapping, the panel being mounted to a wall with or without exterior sheathing, in accordance with certain embodiments;

[0015]FIG. 7 is a representative front view of adjacent exterior insulation panels, each with integral strapping, in accordance with certain embodiments;

[0016]FIG. 8A is a representative perspective view of a strip with a T-shaped cross-section, where the strip can be used for the diagonal strapping for the exterior insulation panels, in accordance with certain embodiments; and

[0017]FIG. 8B is a representative partial cross-sectional view of a strip with a T-shaped cross-section mounted to an exterior insulation panel with a cladding panel attached to the strip, in accordance with certain embodiments.

[0018]FIG. 9A is a representative perspective view of a strip with a Z-shaped cross-section, where the strip can be used for the diagonal strapping for the exterior insulation panels, in accordance with certain embodiments; and

[0019]FIG. 9B is a representative partial cross-sectional view of a strip with a Z-shaped cross-section integrated into the exterior insulation panel with a cladding panel attached to the strip, in accordance with certain embodiments.

DETAILED DESCRIPTION

[0020]The following description in combination with the figures is provided to assist in understanding the teachings disclosed herein. The following discussion will focus on specific implementations and embodiments of the teachings. This focus is provided to assist in describing the teachings and should not be interpreted as a limitation on the scope or applicability of the teachings.

[0021]FIG. 1 is a representative perspective view of a portion of a stud wall 10 (or other building structure) with exterior construction elements 42 (e.g., exterior sheathing 28, insulation panels 60, or cladding panels 40), in accordance with certain embodiments. The exterior sheathing 28 can be drywall, plywood, oriented strand board (OSB), etc. The stud wall 10 (or building structure) can have an interior sheathing material 24 (e.g., drywall, plywood, OSB, etc.) attached to an interior side of the elongated supports 20 (e.g., studs) that faces the interior 14 of the building. Adjacent elongated supports 20 can form a cavity 22 therebetween, into which cavity insulation 26 (e.g., fiberglass, spray foam, loose material, prefabricated panels, etc.) can be installed.

[0022]Exterior sheathing 28 can be attached to an exterior side of the elongated supports 20 that face the exterior 16 of the building, thereby isolating the cavity insulation within the cavities 22. Additional insulation and cladding can be attached to the exterior sheathing 28 (or to the elongated supports 20 when exterior sheathing is not used). The additional insulation can be continuous insulation that includes prefabricated insulation panels 60, where the prefabricated insulation panel 60 can be made from any material that increases resistance to heat transfer through the stud wall 10 as compared to a stud wall 10 without the insulation panels 60.

[0023]The insulation panel 60 can include an insulation sheet 62 with integral strapping such as using a plurality of strips 64 that are attached to an exterior surface of the insulation sheet 62 or embedded in channels that are recessed in the exterior surface. The strips 64 can be attached to the insulation sheet 62 at equal spacing and angled relative to a bottom side 94 of the insulation sheet 62, such as angled at an angle A1 that is greater than 30 degrees and less than 150 degrees. It can be preferred that the strips 64 are substantially angled at 37 degrees (e.g., 37 degrees or 143 degrees) from the bottom side 94, such that the strips 64 intersect with an elongated support 20 regardless of the spacing of the elongated supports 20. This provides a time savings during construction processes in that registering the strips 64 with the elongated supports 20 can be trivial due to the diagonal strips 64. The insulation sheet 62 can include extruded polystyrene (XPS), expanded polystyrene (EPS), EPS containing graphite (GPS), polyisocyanurate foam, polyurethane foam, phenolic foam, melamine foam, and fibrous insulation such as wood fiberboard, stonewool fiberglass, or combinations thereof.

[0024]The strips 64 can be made from wood (e.g., dimensional lumber such as 1×2's, 1×3's, 1×4's, etc.), OSB, metal, composite material, and any suitable polymer including but not limited to, polyvinyl chloride (PVC), cellular PVC, chlorinated polyvinyl chloride (CPVC), acrylonitrile styrene acrylate (ASA), an acrylic material, acrylonitrile butadiene styrene (ABS), polyvinylidene fluoride (PVDF), polyester, polyethylene terephthalate (PET), a cross-linked polyethylene, polypropylene, polystyrene, a thermoplastic polyolefin (TPO), polyurethane, nylon, epoxy, any combination thereof. The strips 64 can be made from any recycled versions of these materials, or any recycled blends of these materials or combinations thereof. The strips 64 can be made from a combination of one of the above virgin (i.e., new/non-recycled) materials and one of the above recycled materials.

[0025]In a non-limiting embodiment, the composite material for the strips 64 can include recycled synthetic fibers of post industrial or post consumer waste. In a non-limiting embodiment, at least one of the strips 64 can be formed of a composite material comprising one or more layers that include fibrous components and a binder. In a non-limiting embodiment, composite material can incorporate a core layer and one or more surface layers, where the core provides strength and the surface layers enhance durability and appearance. The fibrous components can comprise any suitable synthetic or natural fibers that can be virgin (new/non-recycled) material or recycled (post industrial or post consumer) material. Suitable examples of synthetic fibers include, but are not limited to, polymeric fibers such as polypropylene, polyethylene, polyester, nylon, fiberglass, aramid fibers, and carbon fibers. Suitable examples of natural fibers include, but are not limited to, cellulose-based fibers such as wood pup or paper fiber, plant fibers such as jute, hemp, flax, sisal, bamboo, and cotton fibers such as from textiles and recycled fibers. Some sources of recycled fibers include, but are not limited to, carpet fibers, automotive, etc. Additionally, the composite material can include fillers or additives to improve performance characteristics such as fire resistance, moisture resistance, and dimensional stability. One or more outer layers can include treated or reinforced materials to provide improved stiffness, reduced thermal expansion, and enhanced resistance to environmental effects.

[0026]The strips 64 can be adhered to the insulation sheet 62 in recesses on the exterior surface 90 or adhered to the exterior surface (or side) 90 of the insulation sheet 62 using an adhesive. The recesses can be formed in the insulation sheet 62 by compressing the material of the insulation sheet 62 to form the recesses, removing material from the insulation sheet 62 to form the recesses, extruding the insulation sheet 62 with the recesses formed during extrusion, or extruding both the insulation sheet 62 and the strips 64 together with the process forming the strips 64 in respective recesses, or forming recess during molding (e.g., as shown in FIG. 4A), or expanding foam material around the strips 64 that are contained in a fixture of mold. The strips 64 and insulation sheet 62 can also be extruded together to form the insulation panel 60 with the strips 64 adhered to the exterior surface 90 of the insulation sheet 62 (e.g., as shown in FIG. 4B). The strips 64 can also be a strip with multiple picks extending from one side, where the picks are inserted into the insulation sheet 62 to secure the strips 64 to the sheet 62. The strips 64 can also be a strip with multiple picks extending from one side, where the picks are inserted into the insulation sheet 62 and inserted into receptors on another backer strip to form I-beam cross-section strips to secure the strips 64 to the sheet 62.

[0027]As the angle A1 (see FIG. 2A) of the strips 64 is decreased from 45 degrees, then the strips 64 may need to be spaced closer together to provide sufficient fastener positions between the strips 64 and the cladding panels 40. Fastener positions between the elongated supports 20 and the strips 64 are increased, possibly providing an abundance of fastener positions. As the angle A1 of the strips 64 is increased from 45 degrees, then the strips 64 may need to be spaced closer together to provide sufficient fastener positions between the strips 64 and the elongated supports 20. Fastener positions between the cladding panels 40 and the strips 64 are increased, possibly providing an abundance of fastener positions. For example, with substantially a 37 degree angle (or substantially 143 degrees), substantially a 16″ spacing can be achieved in one direction and substantially 12″ spacing in substantially perpendicular direction. For example, the insulation panel 60 using similar spacing for the strips 64 can be used for various types of siding that may require a shorter than 16″ spacing for fasteners (e.g., Board and Batten siding) to attach the siding to the insulation panel 60. In some installations, both horizontal and vertical siding may be used the same wall, such as for aesthetic purposes. However, with the angled strips 64 of the current insulation panel 60, a user can accommodate both types of siding with the same strapping of the insulation panel 60.

[0028]However, if the insulation panel 60 is installed on exterior sheathing 28, then the strips 64 may not be required to intersect the elongated supports 20 for attaching the insulation panel 60 to the wall 10. It should be understood that even with exterior sheathing 28 installed, it may still be desirable for the strips 64 to intersect the elongated supports 20 to receive fasteners thereby attaching the strips 64 to the elongated supports 20 through the sheathing 28.

[0029]FIG. 2A is a representative perspective view of an insulation panel 60 with one or more cladding panels 40 attached to strips 64 in an insulation sheet 62, in accordance with certain embodiments. The insulation panel 60 can include an insulation sheet 62 with diagonally oriented strips 64 (e.g., strips 64a, 64b, 64c). Since the strips 64 are angled (angle A1) relative to the bottom side 94, these strips can intersect one or more of the elongated supports at intersection points 50. These intersection points 50 can be preferred for attaching the insulation panel 60 to the elongated supports 20 by inserting fasteners through the corresponding strips 64 and into the corresponding elongated supports 20. If exterior sheathing is used, the fasteners can be installed into the exterior sheathing and into the elongated supports 20 at the intersection points 50. As can be seen, some of the possible intersection points 50 are indicated.

[0030]Once the insulation panel 60 is attached to the elongated supports 20, the cladding panels 40 can be attached to the insulation panel 60. Since the strips 64 are angled relative to the bottom side 94, these strips can intersect one or more attachment locations or fastener portions (e.g., fastener hems, desired region for fasteners, etc.) of the cladding panels 40 at intersection points 52. These intersection points 52 can be preferred for attaching the cladding panels 40 to the insulation panel 60 by inserting fasteners through the cladding panels 40 and into the corresponding strips 64. The insulation sheet 62 can include the exterior surface 90, an interior surface 92 (configured to engage the building structure), a bottom side 94, a top side 96, a left side 98, and a right side 99.

[0031]FIG. 2B is a representative perspective view of an exterior insulation panel 60 with integral strips 64 in an insulation sheet 62 and markings 51 (e.g., inked lines, scored lines, etc.) to assist in fastener placement, in accordance with certain embodiments. The markings 51 can be applied to the exterior surface 90 of the insulation panel 60 to indicate a standard spacing (e.g., 16 inch, 24 inch, combinations of spacings, etc.) of elongated supports 20. These markings 51 can assist the user in aligning fasteners with the elongated supports 20, which can be installed with standard spacing in the wall 10. Therefore, with the markings 51 generally aligned with respective ones of the elongated supports 20, the user can install the fasteners with increased confidence.

[0032]FIGS. 3A, 3B, and 3C are representative partial cross-sectional views along line 3A-3A, as indicated in FIG. 2A, of a portion of an insulation panel 60 with diagonal strips 64, in accordance with certain embodiments. FIG. 3A is a partial cross-sectional view of a portion of the insulation panel 60 including the strips 64a, 64b, 64c. The strips 64a, 64b, 64c are shown received in recesses 68a, 68b, 68c, respectively, in the exterior surface 90 of the insulation sheet 62. The dashed lines for strips 64a, 64b, 64c indicate a body portion of the corresponding strips 64a, 64b, 64c that extend at an angle from the portion viewed in the cross-section. This version of the insulation panel 60 can be used with some cladding panels 40 (e.g., vinyl siding) which can benefit from the structural support provided by insulation being substantially flush with the outside of the strips 64a, 64b, 64c. In this configuration, the cladding panels 40 can engage the exterior surface 90 of the insulation sheet 62, which can provide structural support for the portions of the cladding panels 40 that extend between the strips 64a, 64b, 64c.

[0033]FIG. 3B is a partial cross-sectional view of a portion of the insulation panel 60 including the strips 64a, 64b, 64c. The strips 64a, 64b, 64c are shown attached to an exterior surface 90 of the insulation sheet 62, with a space 66 formed between adjacent strips 64a, 64b, 64c. A body portion of each strip 64a, 64b, 64c can be seen to extend at an angle from the portion viewed in the cross-section. This version of the insulation panel 60 can be used with other cladding panels 40 (e.g., fiber cement siding) which can benefit from the space 66 formed between adjacent strips 64a, 64b, 64c. Fiber cement siding systems need a drainage plane to allow fluid between the cladding panels 40 and the insulation panel 60 to drain away from the siding. Therefore, the strips 64a, 64b, 64c can be mounted to the exterior surface 90 of the insulation sheet 62 to provide a space 66 that supports drainage of the fluid.

[0034]Additionally, insulation pieces can be cut to fill in the space 66. This version of the insulation panel 60 can be used with some cladding panels 40 (e.g., vinyl siding) which can benefit from the structural support provided by insulation being substantially flush with the outside of the strips 64a, 64b, 64c. In this configuration, the cladding panels 40 can engage the exterior surface of the insulation pieces, which can provide structural support for the portions of the cladding panels 40 that extend between the strips 64a, 64b, 64c.

[0035]FIG. 3C is a partial cross-sectional view of a portion of the insulation panel 60 including the strips 64a, 64b, 64c. The strips 64a, 64b, 64c are shown received in recesses 68a, 68b, 68c, respectively, in the exterior surface 90 of the insulation sheet 62 forming respective spaces 67 above the strips 64a, 64b, 64c. The dashed lines for strips 64a, 64b, 64c indicate a body portion of the corresponding strips 64a, 64b, 64c that extends at an angle from the portion viewed in the cross-section. This version of the insulation panel 60 can be used with some cladding panels 40 (e.g., vinyl siding) which can benefit from the structural support provided by insulation being substantially flush with the exterior surface 90 of the insulation sheet 62 and above the outside of the strips 64a, 64b, 64c. In this configuration, the cladding panels 40 can engage the exterior surface 90 of the insulation sheet 62, which can provide structural support for the portions of the cladding panels 40 that extend between the strips 64a, 64b, 64c.

[0036]FIGS. 4A-4D are representative partial cross-sectional views along line 4A-4A, as indicated in FIG. 1, of an insulation panel 60 with diagonal strips 64a, 64b that were installed prior to the panel being mounted to a wall 10 (or other building structure) with or without exterior sheathing 28, in accordance with certain embodiments.

[0037]FIGS. 4A and 4B show a portion of the wall 10 with an interior sheathing 24 attached to an interior side of an elongated support 20. An insulation panel 60 is attached to an exterior side of the elongated support 20 using fasteners 76 that penetrate a strip 64 (e.g., strip 64b) and the insulation sheet 62, to engage the elongated support 20 at an intersection point 50 of the strip 64 and the elongated support 20.

[0038]Fasteners 74 can be used to secure the cladding panel 40 to the strip 64 (e.g., strip 64b) by passing the fasteners 74 through the fastener portion of the cladding panel 40 (e.g., a fastener hem 44 in vinyl siding, a fastener portion in fiber cement siding, etc.) and into the strip 64 at the intersection point 52 of the strip and the fastener portion of the cladding panel 40. In FIGS. 4A and 4B, the intersection points 50, 52 overlap each other. However, it is not required for the intersection points 50, 52 to overlap each other as is shown in FIG. 2A.

[0039]FIG. 4A shows an insulation panel 60 with strips 64a, 64b embedded in a recess 68 in the insulation sheet 62. The thickness L1 of the insulation sheet 62 is substantially equal to the thickness L2 of the insulation panel 60 that includes the strips 64. As can be seen, the insulation sheet 62 provides structural support for the cladding panels 40 between adjacent strips 64.

[0040]FIG. 4B shows an insulation panel 60 with strips 64a, 64b attached to an exterior surface 90 of the insulation sheet 62. The thickness L1 of the insulation sheet 62 is not equal to the thickness L2 of the insulation panel 60, since the insulation panel 60 includes the strips 64 and the insulation sheet 62 does not. As can be seen, the strips 64 attached to the exterior surface 90 of the insulation sheet 62 can provide spaces 66 between adjacent strips 64, which can provide a drainage plane for fluids between the cladding panels 40 and the insulation sheet 62.

[0041]FIGS. 4C and 4D show a portion of the wall 10 with an interior sheathing 24 attached to an interior side of an elongated support 20. An exterior sheathing 28 can be attached to an exterior side of the elongated support 20 using fasteners 72. An insulation panel 60 can be attached to an exterior sheathing 28 using fasteners 76 that penetrate a strip 64 (e.g., strip 64b) and the insulation sheet 62 to engage the exterior sheathing 28. The insulation panel 60 can also be attached to the exterior sheathing 28 at an intersection point 50 of the elongated support 20 and the strip 64. However, the fastener 76 at the intersection point 50 is not shown since it is at a position spaced away from the cross-sectional view of FIGS. 4C and 4D.

[0042]Fasteners 74 can be used to secure the cladding panel 40 to the strip 64 (e.g., strip 64b) by installing the fasteners 74 through the fastener portion of the cladding panel 40 (e.g., a fastener hem 44 in vinyl siding, a fastener portion in fiber cement siding, etc.) and into the strip 64 at the intersection point 52 of the strip 64 and the fastener portion of the cladding panel 40. In FIGS. 4C and 4D, the intersection points 50, 52 do not overlap each other. However, as shown in FIG. 2A, the intersection points 50, 52 can overlap each other.

[0043]FIG. 4C shows an insulation panel 60 with strips 64a, 64b embedded in a recess 68 in the insulation sheet 62. The thickness L1 of the insulation sheet 62 is substantially equal to the thickness L2 of the insulation panel 60 that includes the strips 64. As can be seen, the insulation sheet 62 provides structural support for the cladding panels 40 between adjacent strips 64.

[0044]FIG. 4D shows an insulation panel 60 with strips 64a, 64b attached to an exterior surface 90 of the insulation sheet 62. The thickness L1 of the insulation sheet 62 is not equal to the thickness L2 of the insulation panel 60, since the insulation panel 60 includes the strips 64 and the insulation sheet 62 does not. As can be seen, the strips 64 attached to the exterior surface 90 of the insulation sheet 62 provide spaces 66 between adjacent strips 64, which can provide a drainage plane for fluids between the cladding panels 40 and the insulation sheet 62. It should be understood that the strips 64 can be partially recessed in the exterior surface 90 of the insulation sheet 62, such that a narrower space 66 is provided, but is not removed, as shown in FIGS. 4A and 4C.

[0045]FIG. 5 shows a wall construction similar to the wall construction shown in FIG. 1. However, FIG. 5 differs at least in that the strips 64 of the insulation panel 60 are oriented at an angle A1 of substantially 90 degrees from the bottom side 94 (or horizontal when the building structure is vertically oriented). This orientation of the strips 64 is a possible configuration of the insulation panel 60, however, some features of the other angled strips 64 may not be available when the strips 64 are oriented at 90 degrees. One of these benefits can be that some of the other angled orientations (e.g., angle A1 equals 30 degrees, 37 degrees, 45 degrees, 60 degrees, etc.) periodically intersection the elongated supports 20. However, at 90 degrees, to intersect the elongated supports 20, the strips 64 may need to be spaced apart to align with the elongated supports 20.

[0046]For example, if the strips 64 were spaced apart at 8 inch center spacing, then the strips 64 could align with elongated supports 20 that are spaced apart at 16 inch center spacing or 24 inch center spacing. This can add additional steps to the wall construction process, if alignment with the elongated supports 20 is desired. In a non-limiting embodiment, the insulation panel 60 can be manufactured to have a particular spacing of the strips 64, such as 16 inch or 24 inch center spacing, to match the center spacing of the elongated supports 20.

[0047]FIGS. 6A and 6B are representative partial cross-sectional views along line 6A-6A, as indicated in FIG. 5, of an insulation panel 60 with vertical strips 64, the panel being mounted to a wall 10 with (or without) exterior sheathing 28, in accordance with certain embodiments.

[0048]FIGS. 6A and 6B show a portion of the wall 10 with an interior sheathing 24 attached to an interior side of an elongated support 20. An exterior sheathing 28 can be attached to an exterior side of the elongated support 20 using fasteners 72. An insulation panel 60 can be attached to an exterior sheathing 28 using fasteners 76 that penetrate the strip 64 and the insulation sheet 62 to engage the exterior sheathing 28. FIGS. 6A and 6B show the strip 64 not aligned with the elongated support 20, but it should be understood that the insulation panel 60 can be positioned on the wall at a position that aligns the strips 64 with the elongated supports 20. In the aligned configuration, the fastener 76 can be used to secure the strip 64 directly to the elongated support 20.

[0049]Fasteners 74 can be used to secure the cladding panel 40 to the strip 64 by installing the fasteners 74 through the fastener portion of the cladding panel 40 (e.g., a fastener hem 44 in vinyl siding, a fastener portion in fiber cement siding, etc.) and into the strip 64 at the intersection point 52 of the strip 64 and the fastener portion of the cladding panel 40. The strips 64 intersect the elongated supports 20 when a vertical portion of the strips 64 overlap a vertical portion of the elongated supports 20.

[0050]FIG. 6A shows an insulation panel 60 with strips 64 embedded in recesses 68 in the insulation sheet 62. The thickness L1 of the insulation sheet 62 is substantially equal to the thickness L2 of the insulation panel 60 that includes the strips 64. As can be seen, the insulation sheet 62 provides structural support for the cladding panels 40 between adjacent strips 64.

[0051]FIG. 6B shows an insulation panel 60 with strips 64 attached to an exterior surface 90 of the insulation sheet 62. The thickness L1 of the insulation sheet 62 is not equal to the thickness L2 of the insulation panel 60, since the insulation panel 60 includes the strips 64 and the insulation sheet 62 does not. As can be seen, the strips 64 attached to the exterior surface 90 of the insulation sheet 62 provide spaces 66 between adjacent strips 64, which can provide a drainage plane for fluids between the cladding panels 40 and the insulation sheet 62.

[0052]FIG. 7 is a representative front view of adjacent exterior insulation panels 60a, 60b butted together (e.g., side 99a of panel 60a is butted up to side 98a of panel 60b), each panel having integral strapping (i.e., strips 64), in accordance with certain embodiments. Each insulation panel 60 can have strips 64 that end at an inner perimeter 86, which can define a perimeter region 84 between the outer perimeter 88 and the inner perimeter 86, for example to apply tape 80 across the intersection of the two panels 60a, 60b, install additional strips 82 along the perimeter region 84, etc. When strips 82 are installed along the perimeter region 84, these strips 82 can be used to secure panels 60a, 60b along the outer perimeter 88, such as around a wall penetration for a window or door, or along the top and bottom edges of the wall 10.

[0053]These strips 82 can extend the length of any of the sides 94a, 94b, 96a, 96b, 98a, 98b, 99a, 99b as a single piece or made up of multiple pieces. The panel 60b is shown with a strip 82 installed along the perimeter region 84 along the top side 96b and potential positions for additional strips 82 shown as dashed outlines. A strip 82 can be installed along the perimeter region 84 on the right side 99a of panel 60a and along the perimeter region 84 on the left side 98b of panel 60b as well as along other portions of the perimeter regions 84. The strips 82 can also be cut at an angle A1 at both ends and installed along the perimeter region 84 between adjacent strips 64 that (unlike as shown in FIG. 7) can extend through the perimeter region 84 to the outer perimeter 88 (e.g., as shown in FIGS. 2A and 2B). This configuration of strips 82 can provide a fastener strip along the perimeter region 84. The adjacent exterior insulation panels 60a, 60b can have mated edges that have complimentary shapes that mate together, such as tongue and groove, shiplap, etc. with a male mating feature on one of the adjacent exterior insulation panels 60a, 60b and a female mating feature on the other one of the adjacent exterior insulation panels 60a, 60b.

[0054]FIG. 8A is a representative perspective view of a strip 64 with a T-shaped cross-section, where the strip 64 can be used for the diagonal strapping of the exterior insulation panels 60 (e.g., see FIGS. 2A and 2B), in accordance with certain embodiments. The strip 64 has an elongated body with a center protrusion 102 and two sides 104, 106 that extend from one end of the protrusion 102 in opposite directions. The strip 64 can include one or more holes 112 for receiving a fastener (e.g., fasteners 120, 74, etc.) to secure a cladding panel 40 to the strip 64. A fastener (e.g., fastener 76, etc.) can be used to secure the strip 64 to the exterior sheathing 28 through the exterior insulation sheet 62.

[0055]FIG. 8B is a representative partial cross-sectional view of a strip 64 of FIG. 8A mounted to an exterior insulation sheet 62 and a cladding panel 40 attached to the strip 64, in accordance with certain embodiments. The insulation sheet 62 can have a thickness L1 and the insulation panel 60 (including the strip 64) can have a thickness L2. The sides 104, 106 can be formed to create a desired gap distance L3, which can provide a flow path for fluid that is trapped between the cladding panel 40 and the insulation sheet 62. Elongated slots 122 can be formed in the exterior surface 90 of the insulation sheet 62 to receive the protrusion 102 and secure the strip 64 to the insulation sheet 62. The protrusion 102 can be press-fit into the elongated slots 122, glued via an adhesive (not shown) in the slot 122, or otherwise retained in the slot 122.

[0056]A fastener 76 can attach and secure the strip 64 to the insulation sheet 62 as well as secure the insulation sheet 62 to an exterior sheathing 28 (not shown in this figure) on a wall 10 or an elongated support (not shown in this figure). The holes 112 can receive various types of fasteners 120 (e.g., Christmas tree fastener, double Christmas tree fastener, barbed fastener, umbrella fastener, wall anchor fastener, molly bolt fastener, split leg fastener, staple fastener, screw fastener, cam lock fastener, snap fastener, hook fasteners, etc.) that can be installed through the cladding panel 40 (e.g., through pre-drilled hole 114 or through a puncture formed by the fastener) and then into or through the strip 64 (e.g., through pre-drilled hole 112 or through a puncture formed by the fastener). In an embodiment, the insulation panel 60 comprises an adhesive/sealant layer disposed under the strip 64, where the adhesive/sealant layer is configured to provide a substantial seal around the fastener 120, which could provide benefits such as improved mechanical hold of the fastener 120 by the insulation panel 60. The strips 64 can also include various embedded (partially or fully embedded) inserts installed in holes in the strips 64, where the inserts can be press fit into the holes or screwed into the holes via threads. The inserts can receive barbed fasteners or threaded fasteners to secure the cladding panels to the strips 64.

[0057]FIG. 9A is a representative perspective view of a strip 64 with a Z-shaped cross-section, where the strip 64 can be used for the diagonal strapping for the exterior insulation panels 60 (e.g., similar to strips seen in FIGS. 2A and 2B), in accordance with certain embodiments. The strip 64 has an elongated body with a support leg 132 and two sides 134, 136, with one side 134 extending perpendicularly in one direction from one end of the support leg 132 and the other side extending perpendicularly in an opposite direction from the other end of the support leg 132. This forms a cross-section that is generally referred to as a Z-shaped cross-section (or Z-channel, or Z-bar).

[0058]FIG. 9B is a representative partial cross-sectional view of a strip 64 of FIG. 9A integrated into the exterior insulation panel 60 with a cladding panel 40 attached to the strip 64, in accordance with certain embodiments. The insulation sheet 62 can have a thickness L1 and the insulation panel 60 (including the strip 64) can have a thickness L2. The elongated strip 64 can be positioned between edges of two adjacent portions of the insulation sheet 62 and adhered to the edges on either surface of the support leg 132 via an adhesive 140. The adhesive 140 can also be applied between the side 136 and a portion of the exterior surface 90 that is overlapped by the side 136. The adhesive 140 can also be applied between the side 134 and a portion of the interior surface 92 that is overlapped by the side 134. However, the insulation sheet can be formed by placing the Z-shaped cross-section strips 64 in a fixture and then filling the fixture with expandable foam which will act as the adhesive 140 to attach the foam insulation to the strips 64. One or both of the sides 134, 136 can include pre-drilled holes (or elongated holes such as slots) to receive the siding fasteners 120, 74 as well as the insulation panel fasteners 76.

[0059]A fastener 76 can attach and secure the strip 64 to the insulation sheet 62 as well as secure the insulation sheet 62 to an exterior sheathing 28 (not shown in this figure) on a wall 10 or an elongated support (not shown in this figure). A fastener 74 can attach the cladding panel 40 to the strip 64. The strips 64 can be spaced in the insulation sheet 62 at desired spacing (e.g., 16 inch, 24 inch, etc.).

[0060]As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0061]The use of “a” or “an” is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include one or at least one and the singular also includes the plural, or vice versa, unless it is clear that it is meant otherwise.

[0062]The use of the word “about”, “approximately”, “generally”, or “substantially” is intended to mean that a value of a parameter is close to a stated value or position. However, minor differences may prevent the values or positions from being exactly as stated. Thus, differences of up to ten percent (10%) for the value are reasonable differences from the ideal goal of exactly as described. A significant difference can be when the difference is greater than ten percent (10%).

[0063]It should be noted that the X-Y-Z coordinate axes are indicated in FIG. 1, where the X-Y-Z coordinate axes are relative to wall 10 of a building. The wall 10 forms an X-Z plane with the Y axis being substantially perpendicular with the wall 10. As used herein, “horizontal,” “horizontal position,” or “horizontal orientation” refers to a position that is substantially parallel with the X-Y plane. As used herein, “vertical,” “vertical position,” or “vertical orientation” refers to a position that is substantially perpendicular relative to the X-Y plane or substantially parallel with the Z axis.

VARIOUS EMBODIMENTS

[0067]Embodiment 2. The insulation panel of embodiment 1, wherein each of the plurality of strips is embedded in respective recesses in the exterior surface of the insulation panel.

[0068]Embodiment 3. The insulation panel of embodiment 1, wherein exterior surfaces of each of the plurality of strips is flush with the exterior surface of the insulation sheet.

[0069]Embodiment 4. The insulation panel of embodiment 1, wherein each of the plurality of strips is attached to the exterior surface and extend from the exterior surface.

[0070]Embodiment 5. The insulation panel of embodiment 1, wherein exterior surfaces of each of the plurality of strips are positioned above the exterior surface of the insulation sheet.

[0071]Embodiment 6. The insulation panel of embodiment 1, wherein a space is formed between adjacent ones of the plurality of strips that are positioned above the exterior surface of the insulation sheet.

[0072]Embodiment 7. The insulation panel of embodiment 1, wherein ones of the plurality of strips are parallel to each other.

[0073]Embodiment 8. The insulation panel of embodiment 1, wherein each of the plurality of strips is configured to intersect one or more elongated supports at one or more first intersections and configured to receive fasteners at the one or more first intersections to attach the plurality of strips to the elongated supports at the one or more first intersections.

[0074]Embodiment 9. The insulation panel of embodiment 1, wherein each of the plurality of strips is configured to intersect one or more cladding panels at one or more second intersections and configured to receive fasteners at the one or more second intersections to attach the one or more cladding panels to the plurality of strips at the one or more second intersections.

[0075]Embodiment 10. The insulation panel of embodiment 9, wherein the exterior surface of the insulation sheet engages the one or more cladding panels between adjacent ones of the plurality of strips.

[0076]Embodiment 11. The insulation panel of embodiment 9, wherein the exterior surface of the insulation sheet is spaced away from the one or more cladding panels by a space.

[0077]Embodiment 12. The insulation panel of embodiment 11, wherein the space is a flow path for fluid that has collected between the one or more cladding panels and the insulation sheet.

[0078]Embodiment 13. The insulation panel of embodiment 1, wherein the insulation sheet is greater than or equal to 2 inches thick.

[0079]Embodiment 14. The insulation panel of embodiment 1, wherein the plurality of strips is configured to receive fasteners that attach the insulation sheet to an exterior sheathing.

[0085]Embodiment 17. The method of embodiment 15, wherein installing the plurality of strips further comprises installing each of the plurality of strips in respective recesses in an exterior surface of the insulation sheet.

[0086]Embodiment 18. The method of embodiment 17, further comprising adhering each of the plurality of strips in the respective recesses.

[0087]Embodiment 19. The method of embodiment 17, wherein the respective recesses are parallel to each other and spaced apart from each other.

[0088]Embodiment 20. The method of embodiment 19, wherein the respective recesses are angled relative to a bottom side of the insulation sheet.

[0089]Embodiment 21. The method of embodiment 15, wherein installing the plurality of strips further comprises installing each of the plurality of strips on an exterior surface of the insulation sheet.

[0090]Embodiment 22. The method of embodiment 21, wherein each of the plurality of strips are parallel to each other and spaced apart from each other.

[0091]Embodiment 23. The method of embodiment 22, wherein each of the plurality of strips are angled relative to a bottom side of the insulation sheet.

[0095]Embodiment 25. The method of embodiment 15, wherein each of the plurality of strips is installed on the insulation sheet at an angle A1 relative to a bottom side of the insulation sheet prior to installation of the insulation sheet on a structure of a building.

[0096]Embodiment 26. The method of embodiment 25, wherein the angle A1 is greater than 30 degrees and less than 150 degrees.

[0097]Embodiment 27. The method of embodiment 25, wherein the angle A1 is substantially equal to 37 degrees.

[0098]Embodiment 28. An insulation panel, system and method, substantially as described above and/or depicted in the drawings.

[0102]Embodiment 30. The insulation panel of embodiment 29, wherein ones of the plurality of strips are embedded in respective recesses in the exterior surface of the insulation panel, and wherein the ones of the plurality of strips are flush with or below the exterior surface of the insulation sheet.

[0103]Embodiment 31. The insulation panel of embodiment 29, wherein each of the plurality of strips has a T-shaped cross-section with a center protrusion that is elongated, a first side, and a second side, wherein the first side extends in a first direction from an end of the center protrusion and the second side extends in a second generally opposite direction from the end.

[0104]Embodiment 32. The insulation panel of embodiment 31, wherein the center protrusion of each of the plurality of strips are inserted into a respective slot formed in the exterior surface of the insulation sheet.

[0105]Embodiment 33. The insulation panel of embodiment 29, wherein each of the plurality of strips has a Z-shaped cross-section with a support leg extending through the insulation sheet, a first side extending along the exterior surface of the insulation sheet from the support leg, and a second side extending along the interior surface of the insulation sheet from the support leg.

[0106]Embodiment 34. The insulation panel of embodiment 29, wherein the plurality of strips are attached to the exterior surface and protrude outward from the exterior surface, and wherein a space is formed between adjacent ones of the plurality of strips.

[0107]Embodiment 35. The insulation panel of embodiment 34, wherein the space is at least partially filled with insulation that is formed to conform to the space.

[0108]Embodiment 36. The insulation panel of embodiment 29, wherein each of the plurality of strips extend from one of four sides of the insulation sheet to another one of the four sides of the insulation sheet.

[0109]Embodiment 37. The insulation panel of embodiment 29, wherein the insulation sheet comprises an outer perimeter that includes a left side, a right side, a top side, and the bottom side, wherein the insulation sheet further comprises an inner perimeter that is spaced inwardly away from the outer perimeter, wherein a space between the outer perimeter and the inner perimeter defines a perimeter region, and wherein each of the plurality of strips extend from one of four sides of the inner perimeter to another one of the four sides of the inner perimeter.

[0110]Embodiment 38. The insulation panel of embodiment 37, wherein one or more perimeter strips are attached to the insulation sheet and extend along at least a portion of the perimeter region.

[0111]Embodiment 39. The insulation panel of embodiment 29, wherein each of the plurality of strips are angled relative to the bottom side by an angle between 30 degrees and 150 degrees.

[0123]Embodiment 45. The method of embodiment 40, wherein the plurality of strips are substantially parallel to each other.

[0124]Embodiment 46. The method of embodiment 40, wherein each of the plurality of strips are angled relative to the bottom side by an angle between 30 degrees and 150 degrees.

[0125]Embodiment 47. The method of embodiment 40, wherein ones of the plurality of strips are configured to intersect vertically oriented supports in a wall at first intersection points when the insulation panel is being installed on the wall, and wherein the first intersection points are configured to receive fasteners to attach the insulation panel to the wall.

[0126]Embodiment 48. The method of embodiment 47, wherein the ones of the plurality of strips are configured to intersect fastener portions of cladding panels at second intersection points when the cladding panels are being installed on the insulation panel, and wherein the second intersection points are configured to receive fasteners to attach the cladding panels to the insulation panel.

[0127]Note that not all of the activities described above in the general description, or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Still further, the order in which activities are listed is not necessarily the order in which they are performed.

[0128]Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

[0129]The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any sub-combination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.