Patent ID: 8640421

Claim:
A wall system method for creating a liquid barrier from about 1 mm to about 3 mm thick with insulation over an area of building sheathing ( 10 ) having at least one joint ( 12 ), comprising: providing a supply of fluid caulking polymer mixture ( 14 ) containing a dispersion of spherical, rigid, non-reactive beads ( 16 ) of a substantially uniform diameter (T), the diameter of the beads ( 16 ) being selected to correspond to the thickness (T) of a liquid barrier to be applied to the area of building sheathing; wherein the fluid caulking polymer mixture contains, in percent by weight, 3-6 percent beads of diameter (T); wherein the diameter of the beads (T), and the corresponding thickness of the liquid barrier (T), is from about 1 mm to about 3 mm; affixing a mesh ( 18 ) across each joint ( 12 ) in the area of building sheathing ( 10 ); troweling the fluid caulking polymer mixture ( 14 ) onto the area of building sheathing ( 10 ) using a trowel ( 20 ) to apply a layer ( 14 ′) of the fluid mixture onto the area ( 10 ), spreading the fluid caulking polymer mixture ( 14 ) by applying pressure with the trowel ( 20 ) both towards the building sheathing ( 10 ) and substantially parallel to the building sheathing ( 20 ), the beads ( 16 ) limiting the movement of the trowel ( 20 ) towards the building sheathing ( 20 ), the trowel ( 20 ) rolling over the rigid beads ( 16 ) and leaving fluid mixture ( 14 ) between the beads ( 16 ) for creating the layer ( 14 ′) to have a substantially uniform thickness (T) on the building sheathing that is substantially equal to the diameter of the beads ( 16 ); before the layer of fluid mixture that has been applied to the area of building sheathing has dried, pressing peak portions ( 32 ) of an inner surface of an expanded foam insulation board ( 30 ) into the layer ( 14 ′) sufficiently to push a plurality of the beads away from a location between the peak portions and the sheathing, so that the peak portions are closer to the sheathing then the diameter of the beads, for adhering the board ( 30 ) to the area of building sheathing ( 10 ), the inner surface of the expanded foam insulation board ( 30 ) having valleys ( 34 ) between the peaks ( 32 ) with a distance (D) between the peaks ( 32 ) and valleys ( 34 ) being greater then twice the diameter of the beads (T) to leave channels for liquid flow between the barrier and the sheathing; and allowing the layer of fluid mixture to set to create the liquid barrier ( 14 ′) and for fixing the board ( 30 ) to the area of building sheathing ( 30 ) with spaces (S) being left between the liquid barrier and the valleys ( 34 ) for water runoff across the area of building sheathing ( 10 ).