throbber
1,2)UK Patent Application (19)GB 11,)2 364 338 (13)A
`
`(21) Application No 0110114.6
`
`(22) Date of Filing 25.04.2001
`
`(30) Priority Data
`(31) 0010187
`
`(32) 26.04.2000
`
`(33) GB
`
`(71) Applicant(s)
`Douglas Cownie Forbes
`Drums of Argaith Farm, Errol, PERTH, PA2 7RG,
`United Kingdom
`
`Douglas Stewart Forbes
`Drumlin, Glencarse, PERTH, PH2 7LX,
`United Kingdom
`
`Derek William Cumming
`21 Coldstream Avenue, Leven, FIFE, KYS 5TN,
`United Kingdom
`
`(43) Date of A Publication 23.01.2002
`
`(51)
`
`INT CL7
`E04C2/24
`
`(52) UK CL (Edition T J
`E1D DCF 01072 0193 0401 0404 D421
`
`(56) Documents Cited
`GB2319793A
`JP 630286331 A
`
`GB2103997 A
`US4630421 A
`
`(58) Field of Search
`UK CL (Edition S J E1D DCF DF193 DLCQW
`INT CL7 E04C 2/24 2/34
`
`(72)
`
`lnventor(sl
`Douglas Cownie Forbes
`Douglas Stewart Forbes
`Derek William Cumming
`John Finlayson Danskin
`
`John Finlayson Danskin
`12 Kirkland Road, STRATHAVEN, Glasgow, ML 10 6AR,
`United Kingdom
`
`(74) Agent and/or Address for Service
`Cruikshank & Fairweather
`19 Royal Exchange Square, GLASGOW, G1 3AE,
`United Kingdom
`
`(54) Abstract Title
`Insulated, vapour-permeable, liquid-impermeable panel
`
`(57) A structural insulated panel 50 is vapour permeable but liquid impermeable. The panel comprises a first
`layer of rigid insulation material 52 and a second layer of rigid, vapour permeable but liquid impermeable
`material 54. The panel 50 is fixable to a second similar panel by interlocking means on adjacent edges of the
`panels. A number of panels 50 may be arranged to form a building structure. The panels 50 may be wall, floor
`or roof panels.
`
`60
`
`50 "'
`
`54
`
`Fig.3
`
`At least one drawing originally filed was informal and the print reproduced here is taken from a later filed formal copy.
`
`G)
`CJ
`I\.)
`w
`~
`w
`w co
`)>
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 1
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`

`

`1/3
`
`10~
`
`22
`
`20
`
`---
`
`30~
`
`I
`I
`I
`I
`
`32
`
`42
`
`14
`
`16
`
`18
`
`12
`
`co
`
`36
`
`34
`
`38
`
`Fig.1
`Prior Art
`
`Fig.2
`Prior Art
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 2
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`

`

`2/3
`
`60
`
`56
`
`58
`
`50
`
`"'I I
`
`54
`
`Fig.3
`
`59
`
`60
`
`50
`
`/
`
`56
`
`52
`
`58
`
`Fig.4
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 3
`
`

`

`. 50a
`
`50b
`
`/
`
`54a
`
`52a
`
`64a
`
`62b
`
`54b
`
`52b
`
`Fig.5
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 4
`
`

`

`"
`
`2364338
`
`1
`
`IMPROVEMENTS RELATING TO CONSTRUCTION
`
`The present invention relates to construction of
`
`buildings, and in particular, though not exclusively, to
`
`vapour-permeable structural insulated panels
`
`( SIPs) eg.
`
`SIPs having a vapour-permeable outer layer.
`
`5
`
`Increasingly in the United Kingdom and elsewhere,
`
`walls (shells) of houses and other building structures are
`
`typically constructed using timber-frame technology.
`
`This
`
`normally involves providing a timber frame comprising
`
`horizontal sole plates and head binders and vertically
`
`10
`
`placed structural timber studs faced with oriented strand
`
`board (OSB) or plywood.
`
`Between the studs and the boards
`
`is typically placed mineral wool insulation.
`
`However,
`
`structural timber frames must be assembled on site and are,
`
`therefore, labour intensive and expensive as a result of
`
`15
`
`the on-site time required to build the frame.
`
`In recent years structural panels manufactured from
`
`rigid insulation board
`
`(typically expanded polystyrene
`
`(EPS) sandwiched between two sheets of OSB or plywood),
`
`have been employed for constructing walls of building
`
`20
`
`structures primarily in the United States of America. Such
`
`structural panels
`
`often referred to as
`
`fl
`
`Structural
`
`fl
`Insulated Panels
`
`(
`
`SIPs) - provide certain advantages over
`
`conventional timber-frame technology.
`
`However, building shells or frames constructed from
`
`25
`
`both conventional timber-frames or from structural panels
`
`require to be protected from the elements, such as rain
`
`Pll482GB
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 5
`
`

`

`2
`
`water, during construction.
`
`This is usually sought to be
`
`accomplished by wrapping the frame or shell in a breathable
`
`flexible sheet form material or membrane which allows water
`
`vapour from inside the building shell to evaporate out
`
`through the breathable material but acts to prevent any
`
`5
`
`ingress of 1 iquid.
`
`However, the membrane
`
`being a
`
`flexible sheet form member - can often tear during use, and
`
`flap in the wind.
`
`Furthermore, to fix together known structural panels,
`
`it is required for a section of the insulating material to
`
`10
`
`be removed and replaced with splines to secure the panels
`
`together.
`
`Such a fixing process is labour intensive, time
`
`consuming, and open to error.
`
`Panels s imilar to available SIPs have been known and
`
`used in the United States of America for over forty years.
`
`15
`
`Yet further escalating heating costs have led owners,
`
`occupants and t enants to demand greater thermal efficiency
`
`and improved energy performance in their buildings and
`
`homes.
`
`Governments are now working towards improving
`
`energy efficiency and t aking steps to ensure that this will
`
`20
`
`happen. At the same time, the building and construction
`
`market has become more competitive with accelerated
`
`construction schedules and shrinking profit margins and
`
`this is forcing builders, contractors and designers to look
`
`for more efficient and reliable construction methods that
`
`25
`
`reduce labour and alleviate quality variables that plague
`
`conventional methods.
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 6
`
`

`

`3
`
`It is an object of at least one aspect of the present
`
`invention to obviate or at least mitigate one or more of
`
`the aforementioned disadvantages associated with the prior
`
`art and,
`
`particularly
`
`(though not exclusively) with
`
`existing structural insulated panels.
`
`5
`
`It is a further object of at least one embodiment of
`
`the present invention to provide a structural insulated
`
`panel which requires no internal frame within the panel,
`
`and wherein, in use, the panel itself acts as at least part
`
`of a building frame or shell.
`These objects are sought to be addressed by a general
`
`lO
`
`solution of providing a structural insulated panel having
`
`means which act as a structural element of the panel and
`
`means which are substantially vapour permeable at least
`
`from one side but substantially liquid impermeable a t least
`
`15
`
`from another side.
`
`According to a first aspect of the present invention
`
`there is provided a vapour-permeable structural insulated
`
`panel comprising a first layer of substantially rigid
`
`insulation material and a second layer of substantially
`
`20
`
`vapour permeable but substantially liquid impermeable
`
`material, the second layer being disposed on or adjacent to
`
`a first surface of the first layer, and wherein, in use, at
`
`least one of the first or second layer is adapted to act as
`
`a structural element of the panel.
`
`25
`
`Preferably, the second layer is adapted to act as a
`
`structural element of the panel.
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 7
`
`

`

`4
`
`The panel may be adapted for use as a wall panel.
`
`However the panel may also be adapted for use as a f loor
`
`panel, a roof panel, or the like.
`
`The panel may comprise a third layer disposed on or
`
`adjacent to a second surface of the first layer.
`
`5
`
`This arrangement is particularly advantageous in
`
`providing a panel of a three-layer "sandwich" form which,
`
`in use,
`
`acts in an analogous way to an "I" beam.
`
`Preferably, therefore, the first, second and third layer
`
`act together as a structural element of the panel.
`
`10
`
`The second layer may be fixed in intimate contact with
`
`the first surface of the first layer.
`
`The third layer may be fixed in intimate contact with
`
`the second surface of the first layer.
`
`The
`
`second
`
`layer
`
`may
`
`comprise
`
`any
`
`suitable
`
`15
`
`substantially rigid material, eg. fibreboard.
`
`Suitable
`
`materials available include:
`
`(highly) compressed stonewool,
`ltTr-\
`l't"fM
`eg. available from Rockwool Rockpanel• such as Rockclad GT;
`
`a wood chip based material, eg. available from Fillcrete as
`R1fW\
`Panelvent•; and preferably, Diffusible Humid-resistant
`
`20
`
`Fibreboard (DHF)/medium density fibreboard, eg. available
`tTr'\
`from E. Egger as Formline DHF.
`
`The first layer
`
`(or core layer) may be made from
`
`expanded polystyrene (EPS) or similar insulation material,
`
`eg. loose insulation such as glass wool, or rigid foam
`
`25
`
`insulation such as polyurethane, extruded polystyrene, or
`
`phenolic foam.
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 8
`
`

`

`5
`
`The third layer comprise any suitable substantially
`
`rigid material, and may be made, for example, from oriented
`
`strand board (OSB), or alternatively from plywood, or from
`
`other rigid board materials such as listed above for the
`
`second layer.
`
`5
`
`Preferably, said first layer is fixed to said second
`
`and/or third layers using a suitable adhesive(s), eg. a PVA
`
`or polyurethane based adhesive such as, for example, Dorus
`
`MD074 available from Henkel.
`
`A vapour-permeable structural insulated panel may be
`
`10
`
`fixed to a second similar panel by butt-jointing and/or by
`
`use of one or more splines. Alternatively, adjacent panels
`
`may be fixed to one another by interlocking tongue-and­
`
`groove means carried on adjacent edges of the panels.
`
`According to a second aspect of the present invention
`
`15
`
`there is provided a building structure including at least
`
`one vapour permeable structural insulated panel, the panel
`
`comprising a first layer of substantially rigid insulation
`
`material and a second layer of substantially vapour
`
`permeable but substantially liquid impermeable material,
`
`20
`
`the second layer being disposed on or adjacent to a first
`
`surface of the first layer, and wherein, in use, at least
`
`one o f the first layer or second layer is adapted to act as
`
`a structural element of the building structure.
`
`Preferably, the second layer is adapted to act as a
`
`25
`
`structural element of the panel.
`
`In one embodiment the building structure may comprise
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 9
`
`

`

`6
`
`a domestic dwelling house or a II light II commercial premises.
`
`According to a third aspect of the present invention
`
`there is provided a method of forming a vapour-permeable
`
`structural insulated panel comprising the steps of:
`
`providing a first layer of substantially rigid
`
`5
`
`insulation material;
`
`providing a second layer of substantially vapour
`
`permeable but substantially liquid impermeable material;
`
`disposing the second layer on or adjacent to a first
`
`surface of the first layer so as to form the panel wherein,
`
`10
`
`in use, at least one of the first layer or second layer act
`
`as a structural element of the panel.
`
`According to a fourth aspect of the present invention
`
`there is provided a method of constructing a building
`
`structure comprising the steps of:
`
`15
`
`providing a plurality
`
`of substantially vapour-
`
`permeable structural insulated panels; and
`
`arranging the panels so as to form at least part of a
`
`structural frame of the building.
`
`According to a fifth aspect of the p resent invention
`
`20
`
`there is provided a building structure including a t least
`
`two structural insulated panels adjacent edges of adjacent
`
`panels being formed with interlocking means so as to
`
`position and retain adjacent panels in relation to one
`
`another.
`
`25
`
`The
`
`interlocking
`
`means may comprise releasably
`
`engageable interlocking means.
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 10
`
`

`

`7
`
`The interlocking means may comprise at least one
`
`tongue carried on an edge of a panel and at least one
`
`groove carried on an adjacent edge of an adjacent panel.
`
`The panels may preferably comprise wall panels; though
`
`the panels may alternatively or additionally comprise floor
`
`5
`
`and/or roof panels.
`
`According to a sixth aspect of the present invention
`
`there is provided a structural insulated panel for use in
`
`a building structure according to the fifth aspect of the
`
`present invention.
`
`10
`
`In a preferred embodiment an edge of the panel carries
`
`a tongue at or near a first surface of the panel and
`
`provides a groove at or near a second surface of the panel.
`
`The panel may be substantially vapour permeable but
`
`substantially liquid/moisture impermeable.
`
`15
`
`According to a seventh aspect of the present invention
`
`there is provided a method of constructing a building
`
`structure comprising the steps of:
`
`providing at least two structural insulating panels;
`
`placing the panels adjacent one another so that
`
`20
`
`interlocking means formed on adjacent edges of the panel
`
`act to position and retain the adjacent panels relative to
`
`one another.
`
`These and other aspects of the present invention will
`
`become apparent from the following description when taken
`
`25
`
`in combination with the accompanying drawings, in which:
`
`Figure 1 illustrates a prior art timber-frame wall
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 11
`
`

`

`construction;
`
`8
`
`Figure 2 illustrates a prior art structural insulated
`
`panel (SIP) ;
`
`Figure 3 illustrates a vapour-permeable structural
`
`insulated panel, in accordance with an embodiment of
`
`5
`
`the invention;
`
`Figure 4 is a side view of the vapour-permeable
`
`structural insulated panel illustrated in Figure 3;
`
`and
`
`Figure 5 is a sectional side view of two modified
`
`10
`
`vapour-permeable
`
`structural
`
`insulated
`
`panels
`
`illustrated in Figure 3 incorporating tough-and-groove
`
`interlocking means.
`
`Reference is f irst made to Figure 1 of the drawings
`
`which illustrates a typical
`
`(inner) wall of a house
`
`15
`
`generally denoted
`
`10 constructed
`
`using timber-frame
`
`technology according to the prior art.
`
`Wall 10 comprises
`
`a horizontal sole plate 12 and a head binder 14 and
`
`vertically placed structural timber studs 16. Timber studs
`
`16 are faced with oriented strand board or the like 18, the
`
`20
`
`surface of which is typically finished with building paper
`
`20.
`
`Between the studs 16 and boards 18 is typically placed
`
`mineral wool insulation 22.
`
`Figure 2 illustrates a prior art structural panel
`
`generally denoted 30.
`
`Structural panel 30 comprises a
`
`25
`
`first layer of substantially rigid insulation material 32
`
`and on a first surface thereof, a second layer 34 of
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 12
`
`

`

`9
`
`32.
`
`substantially rigid oriented strand board. A third layer
`36 comprising oriented strand board is provided against a
`second surface of substantially rigid insulation material
`Panel 3 0 is fixed in position using horizontal sole
`plate 38 and head binder 40.
`A surface of the panel 30
`intended to be internal the building structure is typically
`finished with building paper 42.
`Figures 3 and 4 illustrates a structural insulated
`panel, generally designated 50, in accordance with an
`embodiment of the present invention.
`Structural insulated
`panel 50 comprises a first layer of substantially rigid
`insulation material 52, typically expanded polystyrene
`(EPS) or other suitable insulation material, and a second
`layer 54 of substantially ri.gid and at least partially
`vapour permeable but substantially liquid impermeable
`This second layer 54 is disposed on a first
`material.
`surface of the first layer 52 and affixed using a suitable
`fixing means such as an adhesive, eg. a PVA or a
`polyurethane based adhesive.
`Materials suitable for use as the at least partially
`substantially
`but
`vapour-permeable
`liquid-impermeable
`second layer 54 are Diffusible Humid-resistant Fibreboard
`tl1M
`(DHF) , eg. Formline DHF, or alternatively a compressed
`{UI'\
`stonewool material, eg. available from Rockwool Rockpanel♦,
`ffl\
`Forml ine �
`or a wood chip based material, eg. Panelvent•.
`DHF is a medium density diffusible humid-resistant
`fibreboard suitable for structural purposes.
`It can be
`
`5
`
`10
`
`15
`
`20
`
`25
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 13
`
`

`

`10
`
`used as sarking for roofs and wall sheathing.
`
`It is
`
`vapour-permeable, water draining and air tight providing
`
`heat insulation. The panel is available from E. Egger.
`�T\"'\.
`t:1'l"\
`Rockclad GT from Rockwood Rockpanel• is manufactured
`
`from highly compressed stonewool.
`
`The panel is vapour
`
`5
`
`permeable and weather resistant/water repellant.
`
`In
`
`addition, Rockpanel•materials are fire safe, dimensionally
`
`stable, easy to cut and fit, flexible, environmentally
`
`friendly and recyclable.
`
`Panelvent4 is manufactured from wood chips selected
`
`10
`
`from wood waste and forest thinnings.
`
`This material is
`
`processed using a propriety system to produce long strand
`
`fibres.
`
`The water vapour transmission resistance is
`
`1.47MNs/g, in contrast to plywood which has a mean of
`
`4.78MNs/g.
`
`The panel has good vapour permeability, high
`
`1 5
`
`racking strength (1.73 kn/m�), weather resistant, satisfies
`
`requirements of a 60 minute fire (satisfies BS 476
`
`: Part
`
`21
`
`: 1987 60 minute loadbearing wall fire test), breather
`
`paper is not normally required, thermal conductivity is low
`
`(0.08W/mK), easy to cut, has a bending strength o f 22-
`
`20
`
`30MPa, a tensile strength of 10-16MPa and air permeability
`
`of 0.02-0.03 m'/m-). The panel is produced to ISO 9001 and
`
`BS 1142.
`
`It is in compliance with BS 5268, conforms to BS
`
`5250, and is available from Fillcrete.
`
`Expanded polystyrene (EPS) comprises expandable beads
`
`25
`
`of polystyrene pre-formed and fused together in a steam-
`
`heated mould under pressure .
`
`This produces a block of
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 14
`
`

`

`11
`
`material which is then cut to size and/ or shaped.
`
`A
`
`variety of grades of material are available as defined in
`
`BS3 83 7: part 1.
`
`These include standard duty, high duty
`
`extra high and ultra high duty.
`
`In addition, each grade is
`
`available as either normal
`
`(type N) or flame r etardant
`
`5
`
`(type A) which includes a flame-retardant additive.
`
`EPS
`
`has a high strength to weight ratio.
`
`Tensile strength
`
`ranges from 100 to 400 kPa, compressive strength ranges
`
`from 50 to 500 kPa, cross-breaking strength ranges from 50
`
`to 500 kPa and design load ranges from 20 to 160 kPa for 1%
`
`10
`
`nominal strain, with the exact properties all dependent on
`
`the particular grade and product.
`
`A suitable adhesive is PVA Dispersion Glue for
`
`Assembly which is available from Henkel under the name of
`
`DOMS MD 074. This adhesive is waterproof, fast-setting and
`
`15
`
`provides tough elastic joints.
`
`Panel 50 may advantageously comprise a third layer 56
`
`disposed on a second surface of the first layer 52.
`
`This
`
`third
`
`layer
`
`56
`
`generally
`
`comprises
`
`any
`
`suitable
`
`substantially rigid material such as oriented strand board
`
`20
`
`or fibre board but may in a preferred embodiment be made
`
`from a same material as the second layer 54.
`
`Oriented strand board is available under the trademark
`
`of Sterling OSB from CSC Forest Products Limited and from
`
`other manufacturers such as Louissenna Pacific, Egger, etc.
`
`25
`
`A range of thicknesses from 6 millimetre to 25 millimetre
`
`are available in either square-edged or tongue-in-grooved
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 15
`
`

`

`12
`
`formats.
`
`The boards are manufactured from strands
`
`processed from trees averaging 78 millimetre long and 25
`
`millimetre wide.
`
`The strands are dried, blending with
`
`resin binder and wax, and laid in a precisely oriented
`
`fashion to form large continuous mats.
`
`5
`
`During construction of a building shell, a panel 50 is
`
`placed upon horizontal sole plate 58 with the vapour­
`
`permeable but liquid impermeable material to an intended
`
`outside of the building shell.
`
`The panel 50 is held in
`
`place with head binder 60.
`
`Overlapping of sole plate 58
`
`10
`
`and head binder 60 b y second layer 54 and third layer 56
`
`secures the panel 50 to prevent movement in a substantially
`
`vertical direction perpendicular to sole plate 58 and head
`
`b inder 60.
`
`Securing of panel 50 to prevent movement in a
`
`direction parallel to sole plate 58 and head binder 60 may
`
`15
`
`usually accomplished using nails or the like driven through
`
`the sections of second layer 54 and third layer 56 which
`
`overlaps with sole plate 58 and head binder 60.
`
`Illustrated in Figure 4 is a cavity wall including a
`
`panel 50, and a cavity 59 between the vapour-permeable
`
`20
`
`second layer 54 and a conventional outer brickwork layer
`
`61.
`
`Panels 50 may be adjoined to one another by butt­
`
`joining, wherein a section of the insulation board is
`
`removed and splines approximately 100 millimetres wide are
`
`25
`
`affixed to the oriented strand board layers 34 and 36 using
`
`screws.
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 16
`
`

`

`13
`
`Alternatively, as can be seen in Figure 5, vapour
`
`permeable structural insulated panel s 50a and 50b can be
`
`secured to one another by interlocking tongue-and-groove
`
`edges 62a, 64b and 62b, 64a carried on adjacent ends of the
`
`panels 50a and 50b.
`
`5
`
`Openings for doors and windows may be excised from the
`
`panels 50 either during manufacture or construction.
`
`It will be appreciated that in addition to wall
`
`structures, the panels 50 can also be used for roofing.
`
`The panels 50 typically have a load bearing capacity
`
`10
`
`suitable at least for domestic and light commercial use.
`
`The panels 5 O may be used to support flooring joists, other
`
`panels 50, panelled roofs or roofing trusses or other
`
`elements of a building structure.
`
`Typically, a panel 50
`
`may take a vertical load of the order of 12kn per meter run
`
`15
`
`for a 2.7m high panel 50.
`
`Panels 50 can also be expected
`
`to be used for up to around 4m clear span in roof load
`
`situations depending upon a number of factors.
`
`It will b e appreciated that a principal advantage of
`
`the present invention is an ability to decrease the time
`
`20
`
`for constructing building shells. Large sections of a wall
`
`are manufactu red at a central location and construction
`
`only requires the erection of the pre-formed panels.
`
`The
`
`panels do not require any supporting frame
`
`- whether
`
`external to, or internal of, the panel - and are able to
`
`25
`
`withstand the necessary loads.
`
`Furthermore, the use of
`
`vapour-permeable layer eliminates the need for securing a
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 17
`
`

`

`14
`
`protective membrane to the outer surface of the housing
`
`shell prior to the construction of the outer wall.
`
`Moreover, the use of the inter-locking tongue-and-groove
`
`joints between adjacent structural insulated panels allows
`
`panels to be secured together in less time and with less
`
`5
`
`effort than would normally be required.
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 18
`
`

`

`15
`
`CLAIMS
`
`1. A panel comprising a first layer of substantially rigid
`
`insulation material and a second layer of substantially
`
`vapour permeable but substantially liquid imp e rmeable
`
`material, the second layer being disposed on or adjacent to
`
`5
`
`a first surface of the first layer, and wherein, in use, at
`
`least one of the first or second layer is adapted to act as
`
`a structural element of the panel.
`
`2. A panel as claimed in claim 1, wherein the s econd layer
`
`10
`
`is adapted to act as a structural element of the panel.
`
`3. A panel as claimed in claim 1 or 2 wherein the panel is
`
`adapted for use as a wall panel, floor panel, or roof
`
`panel.
`
`15
`
`4. A panel as claimed in any of the preceding claims,
`
`wherein the panel comprises a third layer disposed on or
`
`adjacent to a second surface of the first layer, the first,
`
`second and third layer" acting together as a structural
`
`20
`
`element of the panel.
`
`5. A panel as claimed in any of the preceding claims,
`
`wherein the second layer is fixed in intimate contact with
`
`the first surface of the first layer.
`
`25
`
`6. A panel as claimed in claim 4 or 5, wherein the third
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 19
`
`

`

`16
`
`layer is fixed in intimate contact with the second surface
`
`of the first layer.
`
`7. A panel as claimed in any of the preceding claims,
`
`wherein the second layer comprises a suitable substantially
`
`5
`
`rigid material, selected from fibreboard,
`
`compressed
`
`stonewool, wood chip based material, or Diffusible Humid­
`
`resistant Fibreboard
`
`(DHF)/medium density fibreboard.
`
`8. A panel as claimed in any of the preceding claims,
`
`10
`
`wherein the first layer is made from an i nsulation
`
`material, chosen from expanded polystyrene
`
`( EPS) , loose
`
`insulation such as glass wool, rigid foam insulation such
`
`as polyurethane, extruded polystyrene, or phenolic foam.
`
`15
`
`9. A panel as claimed in any of claims 4 to 8, wherein the
`
`third layer comprise a
`
`suitable substantially rigid
`
`material,
`
`chosen
`
`from oriented
`
`strand
`
`board
`
`(OSB) ,
`
`plywood, fibreboard, compressed stonewool, wood chip based
`
`material,
`
`or Diffusible
`
`Humid-resistant
`
`Fibreboard
`
`20
`
`(DHF)/medium density fibreboard.
`
`10. A panel as claimed in any of the preceding claims,
`
`wherein the first layer is fixed to the second and/or third
`
`layers using an adhesive.
`
`25
`
`11. A vapour-permeable structural insulated panel which is
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 20
`
`

`

`17
`
`fixable to a second similar panel by butt-jointing and/or
`
`by use of one or more splines.
`
`12. A vapour-permeable structural insulated panel which is
`
`fixable to another vapour-permeable panel by interlocking
`
`5
`
`tongue-and-groove means carried on adjacent edges of the
`
`panels.
`
`13. A building structure including at least one vapour
`
`permeable structural insulated panel, the panel comprising
`
`10
`
`a first layer of substantially rigid insulation material
`
`and a second layer of substantially vapour permeable but
`
`substantially liquid impermeable material, the second layer
`
`being disposed on o r a djacent to a first surface of the
`
`first layer, and wherein, in use, at least one of the first
`
`15
`
`layer or second layer is adapted to act as a structural
`
`element of the building structure.
`
`14. A building structure as claimed in claim 13, wherein
`
`the second layer is adapted to act as a structural element
`
`20
`
`of the panel.
`
`15. A method of forming a vapour-permeable structural
`
`insulated panel comprising the steps of:
`
`providing a first layer of substantially rigid
`
`25
`
`insulation material;
`
`providing a second layer of substantially vapour
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 21
`
`

`

`18
`
`permeable but substantially liquid impermeable material;
`
`disposing the second layer on or adjacent to a first
`
`surface of the first layer so as to form the panel wherein,
`
`in use, at least one of the first layer or second layer act
`
`as a structural element of the panel.
`
`5
`
`16.
`
`A method of constructing a building structure
`
`comprising the steps of:
`
`providing a
`
`plurality of substantially vapour­
`
`permeable structural insulated panels; and
`
`10
`
`arranging the panels so as to form at least part of a
`
`s tructural frame of the building.
`
`17. A building structure including at least two structural
`
`insulated panels adjacent edges of adjacent panels being
`
`15
`
`f ormed with interlocking means so as to position and retain
`
`adjacent panels in relation to one another.
`
`18. A building structure as claimed in claim 17, wherein
`
`the interlocking means comprises releasably engageable
`
`20
`
`interlocking means.
`
`19. A building structure as claimed in claim 17, wherein
`
`t he interlocking means comprises at least one tongue
`
`carried on an edge of a panel and at least one groove
`
`25
`
`carried on an adjacent edge of an adjacent panel.
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 22
`
`

`

`19
`
`20. A building structure as claimed in any of claims l7 to
`
`19, wherein the panels comprise of wall panels, floor
`
`panels, or roof panels.
`
`21. A structural insulated panel for use in a building
`
`5
`
`structure.
`
`22. A panel as claimed in claim 21, wherein an edge of the
`
`panel carries a tongue at or near a first surface of the
`
`panel and provides a groove at or near a second surface of
`
`10
`
`the panel.
`
`23. A panel as claimed in claim 21 or 22, wherein the panel
`
`is substantially vapour permeable
`
`but substantially
`
`liquid/moisture impermeable.
`
`15
`
`24.
`
`A
`
`method
`
`of constructing a building structure
`
`comprising the steps of:
`
`providing at least two structural insulating panels;
`
`placing the panels adjacent one another so that
`
`20
`
`interlocking means formed on adjacent edges of the panel
`
`act to position and retain the adjacent panels relative to
`
`one another.
`
`25. A vapour-permeable structural insulated panel as
`
`25
`
`hereinbefore described with reference to Figures 3 and 4,
`
`or Figure 5.
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 23
`
`

`

`20
`
`26. A building structure including a vapour-permeable
`
`structural insulated panel as hereinbefore described with
`
`reference to Figures 3 and 4, or Figure 5.
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 24
`
`

`

`Application No:
`Claims searched:
`
`GB 0110114.6
`1-10, 13-14, 15,23,25,26
`
`Examiner:
`Date of search:
`
`Eleanor Wade
`30 October 2001
`
`INVESTOR IN PEOPLE
`
`Patents Act 1977
`Search Report under Section 17
`
`Databases searched:
`
`UK Patent Office collections, including GB, EP, WO & US patent specifications, in:
`
`UK Cl (Ed.S): ElD DF193, DCF, DLCQW
`
`Int Cl (Ed.7): E04C
`
`Other: Online: EPODOC, JAPIO, WPI
`
`Documents considered to be relevant:
`
`Category Identity of document and relevant passage
`
`X
`
`X
`
`X
`
`X
`
`GB2319793
`
`The Lets Group Ltd
`
`GB 2103997
`
`Coolag Ltd.
`
`JP63286331
`
`Asahi Chem Ind Co Ltd
`
`see abstract
`
`us 4630421
`
`Diehl et al.
`
`Relevant
`to claims
`
`1,3-6,
`13,15,23
`
`1,4,5,6,23
`
`1,3,4,5,6,
`10,23
`
`1,3,5,23
`
`11 ____ _
`~ - - - -1
`
`A Document indicating technological backgroun d and/or state of the art.
`P Document published on or after the declared priority date but before the
`filing date of this invention.
`E Patent document published on or after, but with priority date earlier
`than, the filing date of this application.
`
`X Document indicating lack ofnovelty or inventive step
`Y Document indicating lack of inventive step if combined
`with one or more other documents of same category.
`
`& Member of the same patent family
`
`An ExecutiveAgency of the Department ofTrade and Industry
`
`Louisiana-Pacific Corporation, Exhibit 1038
`IPR of U.S. Pat. No. 8,474,197
`Page 25
`
`

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