NP-EIFS Non-Permissive Exterior Insulation and Finish Systems concept technology and details

{
  "publication_number": "US2011258944A1",
  "country": "US",
  "kind": "A1",
  "title": "NP-EIFS Non-Permissive Exterior Insulation and Finish Systems concept technology and details",
  "abstract": "A new concept wall system is provided, wherein the Exterior Insulation and Finish System cladding is created using components with no water absorption, a very low vapor permeability and sealing properties, accommodated with an installation technology which extend the materials properties to the assembly, together with bonding and sealing the intersections and terminations, creating a Non-Permissive to water and vapor diffusion, Exterior Insulation and Finish System (NP-EIFS). The present invention relates to an EIFS cladding having two air and vapor barriers, one applied to the substrate, a continuous liquid membrane with sheathing joints sealed to be moisture barrier for inside vapors, and an exterior weather and vapor barrier which is created using closed cell extruded polystyrene insulation boards, special assembled with joints sealed, to create a non-permissive insulation envelope of the enclosure. Another object of the invention is to provide waterproof and air/vapor-proof details, a new concept of flashing and sealant application around windows/doors and other constructive elements to avoid thermal bridges and air leakage inside thermal envelope and wall assembly. Methods of installation are included.",
  "claims": [
    "1. A non permissive to water vapors, exterior insulation and finishing system for application onto an associated sheathing of a building, the insulation cladding comprising: a substrate member attached to the exterior surface of said frame, having opposite facing inner and outer surfaces; an air-vapor barrier, applied to the said outer surface of sheathing, comprising a substantially uniform coat, trowel applied, with said polymer based liquid membrane, having the said sheathing joints sealed with grid-tape reinforced coating; a starter track horizontally disposed to the foundation termination of the wall, and sealed to the said outer surface of said substrate member; an outer non-permissive insulating assembly, consisting of said closed cell extruded polystyrene foam boards, interconnected assembled in a system with said specially designed joints, interiorly sealed with said stick polyurethane foam and exteriorly sealed with said sealant material; an adhesive application system using said stick polyurethane foam, to adhesively apply insulation boards; a joint system for corners and intermediary not shiplap extruded polystyrene foam boards, wherein said extruded polystyrene foam board edges are closely installed to create a gap, which is filled with said closed cell expanded polyurethane foam which expands, bonds and seals, wherein the outer facing of said expanded polyurethane foam is cut, rasp and leveled to the outer surface of said non-permissive insulating assembly and over-seal with said non-vapor-permissive sealant material; a system of said constructive elements which penetrates the wall and insulation system redesigned to have a said caulking element, which creates, together with the exterior surface of said mesh reinforced basecoat layer, a caulking joint around constructive elements; a flashing above said constructive elements, having a said caulking element disposed opposite and parallel with exterior surface of insulation edge forming a caulking joint and the said flashing being installed completely separate and insulated from said wall substrate sheathing; a sealant ensemble system which completely separates and insulates the said constructive elements in contact with the exterior environment from said wall assembly and encapsulates the insulation board's edge, back side and vertical flange of flashing and through the wall portion of the constructive element, by using said closed cell expandable polyurethane foam, flatten and rasp and treat the exterior surfaces with a special compatible non-permissive sealant material; a designed control and aesthetical joints performed in the continuity of said outer surface of non-permissive insulating assembly, before sealing the extruded polystyrene boards joints and the said outer surface of expandable polyurethane foam rasped to the outer surface level, by substantially uniformly coating with said non-vapor-permissive sealant material; sealing of all extruded polystyrene boards exterior joints, corners and other dovetails which use said closed cell expanding polyurethane foam, terminations with accessories that use closed cell expanding polyurethane foam and other system terminations, using the non-vapor-permissive sealant material; a caulking application in said specially created caulking joints, to seal said constructive elements with the mesh reinforced basecoat layer of the exterior weather resistant layer; a reinforcing layer embedded in water and vapor retardant sealant material, applied to completely encapsulate insulation board edges by using said mesh-reinforced sealant material at system terminations and behind over-applied moldings and other design effects; application of expanded or extruded polystyrene three-dimensional building designs to the outer surface of said non-permissive insulating assembly; a reinforcing layer embedded in a basecoat of cement and polymer; and a finish layer on said basecoat. 2. The non-permissive exterior insulation and finishing system of claim 1, wherein the substrate is selected from the group consisting of plywood, gypsum board, cement board, concrete block and others. 3. The system according to claim 2, wherein said adhesive used to install insulation boards is a polymer based adhesive or polymer modified cement. 4. A non-permissive exterior insulation and finishing system in accordance with claim 2 wherein the air-vapor impermeable membrane comprises a single adhesive and sealing layer, applied to the outer surface of said sheathing and to said sheathing joints and is an impermeable membrane, and also is an adhesive for said non-permissive insulation member. 5. The system of claim 2, wherein said non-permissive insulation layer is formed from polyisocyanurate or polyurethane foam panels. 6. The system of claim 2, wherein said non-permissive insulation layer is the two components, sprayed, closed cell polyurethane foam layer. 7. An exterior insulation and finish system wherein the non-permissive exterior insulation layer assembled in accordance with claim 1 is used in conjunction and in association with other exterior insulation and finish systems such as drainage systems or Flexible Class PM (Polymer Modified) systems to improve weatherability and to reduce water intrusion and vapor diffusion through the system. 8. An exterior insulation and finish system in accordance with claim 7 wherein said outer non-permissive insulating assembly is formed from polyisocyanurate or polyurethane foam panels. 9. A non-permissive exterior insulation and finishing system in accordance with claim 1 comprising the following layers and stages in the order provided: a substrate member said building sheathing attached to the exterior surface of said frame, having opposite facing inner and outer surfaces; an air-vapor impermeable membrane, applied to the said outer surface of sheathing, comprising a substantial uniform coat, trowel applied, with a said polymer based liquid membrane, having the said sheathing joints seal with grid-tape reinforced coating; a starter track horizontally disposed to the foundation termination of the wall, and sealed to the said outer surface of said substrate member; an additional inner insulation layer of said expanded polystyrene foam boards, adhesively applied to the outer surface of said air-vapor impermeable membrane, for use as an equalization component to create inherent flatness as support and substrate for said non-permissive layer by sanding, rasping and leveling; an outer non-permissive insulating assembly, consisting of said closed cell extruded polystyrene foam boards, adhesively applied to the said outer leveled surface of said expanded polystyrene layer, wherein said extruded polystyrene foam boards are interconnected assembled in a system with said specially designed joints, interiorly sealed with said stick polyurethane foam and exteriorly sealed with said non-vapor-permissive sealant material; an adhesive application system using said stick polyurethane foam, to adhesively apply insulation boards; a joint system for corners and intermediary not shiplap extruded polystyrene foam boards, wherein said extruded polystyrene foam board edges are closely installed to create a gap, which is filled with said closed cell expanded polyurethane foam, which expands, bonds and seals, wherein the outer facing of said expanded polyurethane foam is cut, rasped and leveled to the outer surface of said non-permissive insulating assembly and over-sealed with said non-vapor-permissive sealant material; a system of said constructive elements which penetrates the wall and insulation system redesigned to have a said caulking element, which creates, together with the exterior surface of said mesh reinforced basecoat layer, a caulking joint around constructive elements; a flashing above said constructive elements, having a said caulking element disposed opposite and parallel with exterior surface of insulation edge, forming a caulking joint and the said flashing being installed completely separate and insulated from said wall substrate sheathing; a sealant ensemble system which completely separates and insulates the said constructive elements in contact with the exterior environment from said wall assembly and encapsulates the insulation board edges, back side and vertical flange of flashing and through the wall portion of the constructive element, by using said closed cell expandable polyurethane foam, flatten and rasp and treat the exterior surfaces with a special compatible non-permissive sealant material; a designed control and aesthetical joints performed in the continuity of said outer surface of non-permissive insulating assembly, before sealing the extruded polystyrene board joints and the said outer surface of expandable polyurethane foam rasped to the outer surface level, by substantially uniformly coating with said non-vapor-permissive sealant material; sealing of all extruded polystyrene board exterior joints, corners and other dovetails, which use said closed cell expanding polyurethane foam, terminations with accessories which use closed cell expanding polyurethane foam and other system terminations, using the non-vapor-permissive sealant material; a caulking application on said specially created caulking joints, to seal said constructive elements with the mesh reinforced basecoat layer of the exterior weather resistant layer; a reinforcing layer embedded in water and vapor retardant sealant material, applied to completely encapsulate insulation board edges by using said mesh-reinforced sealant material at system terminations and behind over-applied moldings and other design effects; application of expanded or extruded polystyrene three-dimensional building designs to the outer surface of said non-permissive insulating assembly; a reinforcing layer embedded in a basecoat of cement and polymer; and a finish layer on said basecoat. 10. The non-permissive exterior insulation and finishing system of claim 9, wherein the substrate is selected from the group consisting of plywood, gypsum board, cement board, concrete block and others. 11. The system according to claim 10 wherein said adhesive used to install insulation boards is a polymer based adhesive or polymer modified cement. 12. A non-permissive exterior insulation and finishing system in accordance with claim 10 wherein the air-vapor impermeable membrane comprises a single adhesive and sealing layer, applied to the outer surface of said sheathing and to said sheathing joints and is an impermeable membrane, and also is an adhesive for said expanded or extruded polystyrene insulation member. 13. A non-permissive exterior insulation and finishing system in accordance with claim 10 wherein said equalization layer of said expanded polystyrene thermal insulation is fastened through said membrane to said sheathing. 14. The system of claim 10 wherein said non-permissive insulation layer is formed from polyisocyanurate or polyurethane foam panels. 15. An exterior insulation and finish system wherein the non-permissive exterior insulation layer assembled in accordance with claim 9 is used in conjunction and in association with other exterior insulation and finish systems such as drainage systems or Flexible Class PM (Polymer Modified) systems to improve weatherability and to reduce water intrusion and vapor diffusion through the system. 16. An exterior insulation and finish system in accordance with claim 15 wherein said outer non-permissive insulating assembly is formed from polyisocyanurate or polyurethane foam panels. 17. A closed cell, extruded polystyrene thermal insulation board, with L-type shiplap joint edges, wherein the two edge plans perpendicular situated to the said board flat front and rear surfaces form a retracted angle from a normally perpendicular angle, symmetrical opposite front and rear faces, with a retraction from exterior surface flatness around the edges, so as to, when assembled, to form a deep V-joint and a retracted surface symmetrical in both sides around the edges, for sealing with said non-vapor-permissive sealant material on the exterior and with said stick polyurethane foam on the interior. 18. A closed cell extruded polystyrene thermal insulation board according to claim 17 wherein a deep V-joint is formed adjoining two said extruded polystyrene boards having any different angle from said normal perpendicular edge angle to the said exterior surfaces of said extruded polystyrene board. 19. A closed cell extruded polystyrene thermal insulation board according to claim 18 wherein the said retraction from front and rear surface flatness around the edges has different dimensions in breadth and depth, to create a joint sealing area. 20. A closed cell extruded polyurethane thermal insulation board according to claim 19 wherein the said joint sealing area has roughness. 21. A closed cell extruded polystyrene thermal insulation board according to claim 20 wherein the said insulation board has opposite symmetrical flat front and rear face roughness, being imprinted. 22. A non-permissive thermal insulation board for use in non-permissive assemblies according to claim 21 wherein insulation board is polyisocyanurate or polyurethane foam. 23. A system for said construction elements, which penetrates the wall and insulation system comprising: a through-the-wall construction element frame; a flashing element, situated above the said construction element, constructively attached to the said construction element frame, further comprising a vertical flange perpendicular to the said frame and a second flange perpendicular to the said vertical flange which becomes the caulking joint delimitation element; a flange extending from lateral sides, constructively attached to the said constructive element frame, situated above and parallel to the outer surface of said insulation cladding, which forms the caulking joint for perimeter seal; a flange extending below said construction element, constructively attached to the said frame and continuous with the vertical sides flange, which form the said caulking joint and also become the draining board; a construction of said construction elements to adapt the said element with the thickness of wall frame and also to the thickness of insulation cladding; a method to install said constructive elements so as to create a continuous gap between said construction elements and said wall opening and insulation board edges to completely seal and insulate the said element to the wall frame, when said expanding polyurethane foam sealant is installed, and also to form a continuous caulking joint around said construction element perimeter, between said extending perimeter flanges and said outer surface of said impermeable insulation layer, after the mesh reinforced basecoat is applied. 24. A construction element as in claim 23 wherein the said construction element is a window. 25. A construction element as in claim 23 wherein the said construction element is a door. 26. A construction element as in claim 23 wherein the said construction element is a thru wall unit Heating, Venting and Air Conditioning. 27. A construction flashing accessory comprising: a first flange with drip edge for installation above said construction elements; a second flange extending perpendicular to the said first flange which have front and rear faces, the rear face of the flashing being installed with a distance from said sheathing wall substrate; a third flange extending perpendicular to the said second flange on front face, situated above and parallel to the first flange, which become the caulking delimitation element of the said caulking joint; an optional perforation system on the second flange, above situated to the third flange and above caulking area, which is the flashing installation area. 28. A construction flashing accessory according to claim 27 wherein the said accessory flashing is typically made of sheet metal. 29. A construction flashing accessory according to claim 27 wherein the said accessory flashing is typically made from a plastic (polyvinylchloride PVC, etc.). 30. A construction flashing accessory comprising: a first flange with drip edge for installation above said construction elements; a second flange extending perpendicular to the said first flange which have front and rear faces, the rear face of the flashing being installed with a distance from said sheathing wall substrate; a continuation of first flange extending on the back of second flange which is seated to the said constructive element frame and becomes the installation area; a third flange extending perpendicular to the said second flange on front face, situated above and parallel to the first flange, which becomes the caulking delimitation element of the said caulking joint. 31. A construction flashing accessory according to claim 30 wherein the said accessory flashing is typically made of sheet metal. 32. A construction flashing accessory according to claim 30 wherein the said accessory flashing is typically made from a plastic (polyvinylchloride PVC, etc.). 33. A sealant ensemble system, which completely separates and insulates the said constructive elements in contact with the exterior environment from said wall assembly and seals the perimeter of said constructive elements with the said impervious insulation layer comprising: a method of installing the said constructive elements with a distance from said wall opening, rear face of flashing and insulation board edges; filling the gap created with expanded closed cell polyurethane foam sealant; embed the rear face of flashing and top front face of flashing in expanded closed cell polyurethane foam sealant; create a caulking joint between caulking element of flashing and non-permissive insulation edge; create a caulking joint between extending caulking element of said constructive element and exterior surface of non-permissive insulation layer; over-seal all closed cell polyurethane foam outer surfaces with said non-vapor-permissive sealant material; a reinforced cementitious basecoat layer which covers the entire outer insulation surface and extends behind the said caulking elements; a suitable silicone sealant applied in the said caulking joint created, to seal the dovetail, before applying the said finish coat. 34. A sealant ensemble system according to claim 33 wherein the expanded closed cell sealant is selected from a group consisting of one component polyurethane foam, two component polyurethane foam, expanding foam kits, two parts liquid expanding urethane foam and others. 35. An exterior insulation and finish system wherein the said sealant ensemble system according to claim 33 is used in conjunction and in association with said other exterior insulation and finish systems to reduce or eliminate intruding water around said constructive elements. 36. An outdoor electrical box, one-piece construction accessory for using in conjunction with non-permissive exterior insulation and finish systems comprising: an electrical box body having depths in accordance with the thickness of insulation plus the thickness of said lamina plus the thickness of the caulking which surround and seal the said electrical box to the said mesh reinforced polymer modified cement layer of the said lamina; a first back flange member, which surrounds and extends to the back of said electrical box and serves as fastening and cementation and sealing area to the said impermeable membrane of said substrate sheathing; a second outer flange, parallel to the said back flange and surrounding the said electrical box body, which creates the said caulking joint member; a top and cover gasket which closes the outlet box and also masks the caulking joint. 37. An outdoor electrical box according to claim 36 wherein the said electrical box construction accessory is typically made of metal. 38. An outdoor electrical box according to claim 36 wherein the said electrical box construction accessory is typically made of plastic such PVC, Phenolic Resin, Fiberglass etc. 39. An outdoor electrical box according to claim 36 wherein the construct of said electrical box is round, square, rectangular or octagonal. 40. An outdoor electrical box according to claim 36 wherein the said cover is an outdoor application by neoprene gasket seal. 41. An outdoor electrical box according to claim 36 wherein the said cover is designed to completely cover and mask the said caulking joint. 42. An outdoor electrical box according to claim 36 wherein the said outlet mounting is effective a switch box, adapted for switch cover. 43. An outdoor electrical box according to claim 36 wherein the said outlet mounting is effective a plug box, adapted for plug cover. 44. An outdoor electrical box according to claim 36 wherein the said electrical box is effective a wall or ceiling pan electrical box used for installation of wall or ceiling mounted light fixtures. 45. An outdoors electrical box according to claim 36 wherein the said electrical box is effective a plastic or metal enclosure. 46. A flange construction accessory, which completely penetrates the wall and the non-permissive exterior insulation finish system comprising: a plastic flange constructive adapted to the thickness of insulation cladding and wall construction; a surrounding outlet member perpendicular to the said flange body, which creates the said caulking joint, for silicone sealant application; a surrounding installation and cementation back flange member extending perpendicular to the said flange body and parallel to the outlet caulking member, intermediary placed so as the distance between the said back flange and caulking flange to be adapted to the thickness of insulation, reinforcing member of said lamina plus a distance for silicone sealant application; an inside termination element of said flange which is slid or threaded to exterior of said flange to complete the penetration flange assembly when the inside gypsum board is installed. 47. A flange construction accessory according to claim 46 wherein the said flange construction accessory is typically made of metal. 48. A flange construction accessory according to claim 46 wherein the said flange is typically made of plastic material. 49. A flange construction accessory according to claim 46 wherein the said flange is round, square or rectangular. 50. An flange construction accessory according to claim 46 wherein the said flange is used as through-the-wall passage for various dimensions of pipes, power cables, vents diffusers, electrical panels, through-the-wall HVAC units and so on. 51. An expansion joint construction accessory comprising: an assembly of two casing beads, situated parallel and in opposition, coupled through a flexible area comprising; two flanges which are the back flanges of the two casing beads; a flexible flange which forms the flexible area, extending adjacent and between the said two back flanges, dictating the breadth of expansion joint, being the said coupling area; two flanges extending parallel and perpendicular to the edges of said coupling area and to the edges of said two coupled back flanges, wherein the coupling area with the two parallel flanges forms a channel for caulking application; two flanges extending oblique relative to the said two perpendicular flanges creating a V-joint look of the said expansion joint; two flanges extending from the said inclined flanges, being parallel with the said back flanges and forming the outer level, wherein the distance between the said back flange and the said outer leveling flange is the applied thickness of insulation. 52. A construction accessory according to claim 51 wherein the said expansion joint accessory is typically made of plastic material. 53. A construction accessory according to claim 51 wherein the said expansion joint accessory have various dimensions, in accordance with the said applied thickness of said insulation. 54. A construction accessory according to claim 51 wherein the said expansion joint accessory have various breadth dimensions of the said caulking joint created between the said two adjoining casing beads, being a breadth in accordance with the expansion joints code requirements. 55. A construction accessory according to claim 51 wherein the said oblique extending flanges have various forms and dimensions to create different looks of the said expansion joint, including angular or round forms. 56. A construction accessory according to claim 51 wherein the said expansion joint accessory is used in conjunction and in association with said other exterior insulation and finish systems and even in conjunction with other cladding systems. 57. A method of assembling a non-permissive exterior insulation and finish system on an associated building having outer substrate sheathing, the method comprising: applying a continuously vapor impermeable liquid membrane to the said substrate sheathing, together with sealing the said sheathing joints and adjacent constructive accessories sealed in the said cementation area; applying an intermediary insulation layer, the said equalization and leveling layer; providing an adhesive and sealing material which is preferably the said stick polyurethane foam; providing water-air-vapor impermeable extruded polystyrene boards having shiplap edges designed to form symmetrical inner and outer sealant joints when said insulation boards are assembled; applying an outer water-air-vapor impermeable layer consisting in extruded polystyrene boards or other vapor impermeable insulation materials, having said shiplap edges; providing specially designed constructive elements such as window/door frames, through-the-wall constructive flanges and construction accessories for terminations and expansion joints and electrical boxes, adapted to create caulking joints with the outer surface of said mesh reinforced cementitious layer of said lamina; providing specially designed flashings above constructive elements, which are completely separated and insulated from the wall assembly and are designed to facilitate the creation of said caulking joint; applying expanding polyurethane foam or similar expanding bond and seal and insulation materials to fill and seal gaps and joints between wall frame and constructive elements frame, flashings and insulation board edges and between every not shiplap impermeable board joints, and in every intersection of insulation with construction accessory elements; performing aesthetical and control joints; applying non-vapor-permissive sealant material to all impermeable insulation boards joints, intermediary joints, corner and termination joints sealed with expanding polyurethane foam and other terminations; applying expanded or extruded forms of aesthetical effects; applying reinforcing fiberglass mesh embedded on said polymer modified cement over entire outer insulation surfaces created, including the edges; applying suitable silicone sealant in the said caulking joints to seal the intersection of the said impervious insulation layer with the said constructive elements; applying a finish coat. 58. The method according to claim 57 wherein the said substrate sheathing is selected from the group consisting of plywood, OSB, gypsum board, cement board, CMU, brick masonry, poured or pre-cast concrete and others. 59. The method according to claim 57 wherein the said system is applied without the said liquid air-vapor impermeable membrane for situations wherein the inside environment doesn't involve heating and air conditioning, or where the said cladding system is applied priority decorative rather than as a thermal insulator."
  ],
  "cpc": [
    "E04B 2/58",
    "E04B 1/665",
    "E04B 1/6803",
    "E04B 1/70",
    "E04B 1/7625",
    "E04B 1/7641",
    "E04B 1/80",
    "E04B 2/88",
    "E04C 2/205",
    "E04C 2/243",
    "E04C 2/44",
    "E04F 13/04",
    "H02G 3/36"
  ],
  "assignees": [
    "RADOANE MARIUS"
  ],
  "filing_date": "2010-04-26",
  "publication_date": "2011-10-27",
  "priority_date": "2010-04-26",
  "application_number": "US-76695010-A",
  "family_id": "44814586",
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}