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Multilayered structural insulated panel

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Title: Multilayered structural insulated panel.
Abstract: A structural insulated panel includes an internal foam (EPS) core, oriented strand board (OSB) faces on the core, and a sheet of magnesium oxide (MagOx) on one or both of the faces for environmental purposes of either weather resistance and/or fire protection. The outer faces incorporate interior and exterior surfaces that need little more than a finish top coat paint. The combination of core, oriented strand board, and outer sheets provide a thermally efficient insulating structure that is a fully nationally code approved building structure. ...

USPTO Applicaton #: #20090313931 - Class: 523094 (USPTO) - 12/24/09 - Class 523 

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The Patent Description & Claims data below is from USPTO Patent Application 20090313931, Multilayered structural insulated panel.

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This application claims benefit under 35 U.S.C. §119(e) of provisional application Ser. No. 61/075,054, filed Jun. 24, 2008, entitled MULTILAYERED STRUCTURAL INSULATED PANEL, the entire contents of which are incorporated herein in its entirety.


The present invention relates to structural insulated panels useable in buildings.

The building industry continues to be challenged by increasing costs of construction, including material and labor. Large structural insulated panels (e.g., 8 foot×24 foot panels) can help by reducing the number of components and pieces that must be handled during construction, and further by reducing energy costs in the buildings once constructed. However, further improvements are desired to reduce on-site work and reduce components costs, and to reduce the risk of poor assembly/construction. For example, insulating systems are known for use with studded wall constructions (e.g., fiberglass batting, cellulose, and/or sprayed urethane products), however these systems are prone to have gaps that allow drafts and/or they can be squeezed thin such that they do not provide the insulative “R” value advertised.

In particular, it has been challenging to make structural insulated panels (SIPs) that meet cost, weight, code, environmental and structural requirements. Oriented strand board (OSB) by itself can potentially meet cost, structural and weight requirements, but it does not meet environmental needs for weather or code requirements for fire unless it is further covered or treated. Structural products made of foam are advantageous since they have low weight, but foam by itself potentially lacks strength. Further, when a fire occurs in a room lined with bare foam, the room heats up very quickly to a point where the foam may explode in flames. Because of this, residential building codes require that the plastic foam be separated from the inside of an enclosed area with the equivalent of ½ inch drywall. Notably, it is not acceptable to simply construct a structural insulated panel using a foam core covered with oriented strand board, since fire codes are not met. Further, substantial secondary finishing and/or covering layers must be added. However, available materials might include cementous materials or intermessent paints that, when they are machined in the factory or later cut in the paint, produce fine particles of silicon dust which are a health hazard (silicosis) or are destructive to cutting machines.



In one aspect of the present invention, a structural insulated panel includes an internal foam (EPS) core, oriented strand board (OSB) faces of the core, and at least one thin sheet of non-cementous, fire retardant material (such as magnesium oxide (MagOx)), on one of the faces.

In narrower aspects, magnesium oxide sheet is attached to one or both of the faces with an adhesive.

In another aspect of the present invention, a method comprises steps of providing a foam core with oriented strand board faces, and applying a thin layer of magnesium oxide sheet over the faces.

In another aspect of the present invention, a structural insulated panel includes a structural insulated panel (SIP), and at least one thin layer of fire retardant material such as magnesium oxide (MagOx) on at least one of the faces of the structural insulated panel.

An object of the present invention is to provide an improved structural insulated panel that is energy efficient and insulative (e.g., 50% more energy efficient over conventional “stick” wood-stud-built construction), goes up quickly, and incorporates interior and exterior surfaces that need little more than a finish top coat paint . . . and which are fully nationally code-approved structures.

An object of the present invention is to provide an improved structural insulated panel of large size (e.g. 8 feet×24 feet), and which can be custom cut (e.g., by using CNC-type equipment) to match a building plan.

An object of the present invention is to provide a large panel having a highly insulative value and hence excellent energy efficiency, but competitive price when compared to other products (including their required on-site construction work such as the cost and labor and secondary processes required when using studs).

An object and function of this invention is to provide a light, smooth, thin layer of material over the OSB that will meet the fire code requirements and interior surface finish requirements.

An object and function of the present invention is to provide layering of a smooth layer of fire resistant material over the OSB that allows the SIP panels to meet the common code requirements for a thermal barrier or over the foam core of the SIP.

These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.


FIG. 1 is a perspective view of a multilayered panel of the present construction.

FIG. 2 is an enlarged transverse cross section through FIG. 1.



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stats Patent Info
Application #
US 20090313931 A1
Publish Date
Document #
File Date
Other USPTO Classes
5230915, 527941, 523093
International Class

Fire Protection
Magnesium Oxide

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