CA2321445A1 - Polymer-stone interlocking insulating exterior building panel - Google Patents
Polymer-stone interlocking insulating exterior building panel Download PDFInfo
- Publication number
- CA2321445A1 CA2321445A1 CA 2321445 CA2321445A CA2321445A1 CA 2321445 A1 CA2321445 A1 CA 2321445A1 CA 2321445 CA2321445 CA 2321445 CA 2321445 A CA2321445 A CA 2321445A CA 2321445 A1 CA2321445 A1 CA 2321445A1
- Authority
- CA
- Canada
- Prior art keywords
- panel
- stone
- polymer
- facing
- metal backing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
- B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
- B29C67/242—Moulding mineral aggregates bonded with resin, e.g. resin concrete
- B29C67/243—Moulding mineral aggregates bonded with resin, e.g. resin concrete for making articles of definite length
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/30—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being formed of particles, e.g. chips, granules, powder
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0875—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements having a basic insulating layer and at least one covering layer
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/14—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass
- E04F13/141—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements stone or stone-like materials, e.g. ceramics concrete; of glass or with an outer layer of stone or stone-like materials or glass with an outer layer of concrete
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Structural Engineering (AREA)
- Civil Engineering (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Finishing Walls (AREA)
Abstract
A polygonal configured building panel that consists of a expandable foam insulation, a front facing and a metal backing. The front facing consists of a mixture of polymer resin and stone or stone-like material which is reinforced with a fibre reinforcing mesh. The above components are used to define two adjacent projecting edges that are made to adapt to two adjacent complimentary cavities from an adjoining panel. A metal backing is used to provide the panel with strength. The backing also gives the panel the ability to be secure to an exterior building surface without the use for brackets or clips.
The expandable foam insulation adheres to both the polymer-stone facing and the metal backing. Additional polymer resin and stone granules are placed on the exterior facade of the panel in order to improve the appearance and provide a greater resistance to impact.
The expandable foam insulation adheres to both the polymer-stone facing and the metal backing. Additional polymer resin and stone granules are placed on the exterior facade of the panel in order to improve the appearance and provide a greater resistance to impact.
Description
Polymer-Stone Interlocking Insulating Exterior Building Panel Background of the Invention There are various types of Exterior Insulating Finishing Systems currently being used. These systems are reasonably priced and are able to insulate the building exterior as they cover. These systems do however require expert installation, under ideal conditions. There have been many stories of poor installation and subsequent failures have proven to be quite expensive.
Another difficulty that the systems have incurred is the fact that they are applied directly to the building exterior and therefore do not provide for air and moisture escape situations.
This invention does have many of the advantages of usual Exterior Insulating Finishing System however it is the purpose of the invention to provide for a much more improved concept and design.
As with many EIFS, it is an objective of the invention to be able to insulate the building exterior while at the same time cover the building facade.
The panel is prefabricated under ideal conditions and is brought to the building site for installation. Both the production and installation of the panels are relatively simple and therefore another objective of the invention would be that it does not require experts to both produce and install.
As previously mentioned, the panel is prefabricated under ideal conditions and therefore is able to be installed under various weather conditions, year round.
The panel also provides for several rainscreen advantages. During the installation process of the panel, Earrings are used to provide for an air cavity between the wall and the building panel. The cavity creates an equal air pressure between the inside and outside of the wall and therefore gives a lesser chance of moisture penetration and a greater chance of moisture escape.
Furrings also give the panel a place that a screw may be used to secure to building structure. The advantage that the screws possess is that it gives the wall the ability to shift according to the building structure and weather conditions without any cracking or loss of adherence.
Another rainscreen advantage is the ability to lock adjoining panels to each other with a dry joint. 'The dry joint permits air flow into the cavity while still impeding water penetration. The locking system also serves as a drainage for any water that may penetrate the outer facade.
The metal backing provides the panel and wall structure with additional strength and protection while eliminating the requirement of installing a sheathing to an exterior building surface. Another advantage that the backing presents is that it provides the panel with the ability to be secure to an exterior surface wall without the need for additional clips or tools.
The insulating material used provides a substantial amount of insulation protection. The thickness and strength density is able to be controlled to precise degrees and may therefore be customized according to requirements.
Another advantage to the panel is the exterior facing used. The polymer compound and stone composition provides for a very highly weather and impact resistant panel. The facing composition is also impervious to moisture and resists various types of vandalism.
The stone granules also provides for multiple types of styles and designs. There are unlimited amounts of stone and stone like materials able to be used for the production of the panel. Quartz granules, used in the production of shingles, are quite impressive and provide for a distinct appearance. They are available in all various colours and styles and are easily applied to the panel. The additional acrylic compound and granules also gives the panel a more improved resistance to impact.
Moulding the panel also gives additional benefits. All of the elements used is creating the building panel are able to be moulded into various different sizes and designs and is therefore limited only to the imagination of the building architect.
LIST OF SEVERAL VIEWS OF THE FIGURES
The objectives and advantages of the invention will be more easily understood when considered in relation to the preferred embodiments, as set forth in the specification and shown in the drawings.
FIGURE 1 Shows a perspective view of a single panel when taken into consideration with the present invention.
FIGURE 2 Shows a front view of a single panel with portions of the facing broken away to reveal its structural makeup.
FIGURE 3 Shows a cross sectional view of a single panel.
FIGURE 4 Shows a brick exterior building surface wall with building panels installed.
FIGURE 5 Shows a cross-sectional view of installed panels on a brick building surface.
The present invention understands that the panel 10, with all of its components must be created using a moulded surface. This mould may be designed to provide various different sizes and styles. In the diagrams, the panel 10 is styled to have bevelled edges 19. The body of the panel 10 may also be moulded to include various different types of designs 20, as ones commonly seen in vinyl siding.
Referring now to the drawings and more particularly to Figure 1. The drawing shows a single rectangular panel 10 that contains a front facing 11, a reinforcing backing 12, two adj acent proj ecting edges 13 which mate with the opposite two adjacent edges 14 which contain complimentary cavities that are adapted for the projecting edges 13 of an adjoining panel.
Figure 2 shows a building panel 10 from plan view with portions of the facing removed to reveal the structural makeup. The first portion of the panel 10 is created by mixing a polymer compound with a stone or stone-like material.
The polymer-stone composition is spread evenly throughout the mould, ranging in thickness from 1 /8 inch to 1/2 inch. A fibre reinforcing mesh 17 is placed on top of and secured into the composition The fiber mesh and polymer-stone composition 11 are spread out in such a manner that they will have defined both the two adjacent projecting edges 13 and the complimentary adj acent cavities 14.
In order to properly create the complimentary cavities 14, a fibreglass shaft is placed into the mould in the exact position the cavities would be located. The purpose of the shaft is to prevent the foam from expanding throughout the entire panel 10 and thus creating the complimentary cavity 14. In order to promote easy installation and proper air and moisture flow, the shaft should be slightly larger than the projecting edges 13.
Once the shafts have been placed into the mould, the metal backing 12 is placed on top. The metal backing 12 extends approximately 1 inch from both adjacent sides containing the complimentary cavity 14. This backing extension will be used to secure the panel to a building structure at the time of installation. To be able to be suited according to building requirements, the backing 12 may be of various different types of metals and thickness'.
'The panel 10 is then prepared to be injected with an expandable foam insulation 15. A lightweight foam material with excellent thermal heat transfer resistance is preferred. The most suitable forms of foam for such are Polyurethane and Polystyrene. These materials are preferred because of its low cost, high insulation rating and it's a relatively simple application process.
The entire mould is then placed into a unit that sustains constant pressure on panel and mould. It is then injected with the expandable foam insulation 15. The foam 15 expands throughout the mould and adheres to both the polymer-stone facing composition 11 and the metal backing 12.
After all components have cured, the panel 10 is removed from the mould with the polymer-stone facing 11, foam insulation 15 and metal backing 12 securely intact to one another. The foam insulation 15 and polymer-stone facing 11 should not adhere to the shafts and therefore they should be easily removed from the panel. The exterior facade of the panel 10 will have a hard and smooth surface that will contain any design 19 or style 20 that was contained in the mould.
At this point the panel may be created to have a more appealing facade. The polymer-stone facing 11 is coated with additional polymer resin and stone granules 18 are spread throughout and secured into the compound. The additional components provide the panel 10 with added strength. Once the compound has dried, any additional granules that have not adhered to the panel are removed.
The panel is now ready for installation.
Another difficulty that the systems have incurred is the fact that they are applied directly to the building exterior and therefore do not provide for air and moisture escape situations.
This invention does have many of the advantages of usual Exterior Insulating Finishing System however it is the purpose of the invention to provide for a much more improved concept and design.
As with many EIFS, it is an objective of the invention to be able to insulate the building exterior while at the same time cover the building facade.
The panel is prefabricated under ideal conditions and is brought to the building site for installation. Both the production and installation of the panels are relatively simple and therefore another objective of the invention would be that it does not require experts to both produce and install.
As previously mentioned, the panel is prefabricated under ideal conditions and therefore is able to be installed under various weather conditions, year round.
The panel also provides for several rainscreen advantages. During the installation process of the panel, Earrings are used to provide for an air cavity between the wall and the building panel. The cavity creates an equal air pressure between the inside and outside of the wall and therefore gives a lesser chance of moisture penetration and a greater chance of moisture escape.
Furrings also give the panel a place that a screw may be used to secure to building structure. The advantage that the screws possess is that it gives the wall the ability to shift according to the building structure and weather conditions without any cracking or loss of adherence.
Another rainscreen advantage is the ability to lock adjoining panels to each other with a dry joint. 'The dry joint permits air flow into the cavity while still impeding water penetration. The locking system also serves as a drainage for any water that may penetrate the outer facade.
The metal backing provides the panel and wall structure with additional strength and protection while eliminating the requirement of installing a sheathing to an exterior building surface. Another advantage that the backing presents is that it provides the panel with the ability to be secure to an exterior surface wall without the need for additional clips or tools.
The insulating material used provides a substantial amount of insulation protection. The thickness and strength density is able to be controlled to precise degrees and may therefore be customized according to requirements.
Another advantage to the panel is the exterior facing used. The polymer compound and stone composition provides for a very highly weather and impact resistant panel. The facing composition is also impervious to moisture and resists various types of vandalism.
The stone granules also provides for multiple types of styles and designs. There are unlimited amounts of stone and stone like materials able to be used for the production of the panel. Quartz granules, used in the production of shingles, are quite impressive and provide for a distinct appearance. They are available in all various colours and styles and are easily applied to the panel. The additional acrylic compound and granules also gives the panel a more improved resistance to impact.
Moulding the panel also gives additional benefits. All of the elements used is creating the building panel are able to be moulded into various different sizes and designs and is therefore limited only to the imagination of the building architect.
LIST OF SEVERAL VIEWS OF THE FIGURES
The objectives and advantages of the invention will be more easily understood when considered in relation to the preferred embodiments, as set forth in the specification and shown in the drawings.
FIGURE 1 Shows a perspective view of a single panel when taken into consideration with the present invention.
FIGURE 2 Shows a front view of a single panel with portions of the facing broken away to reveal its structural makeup.
FIGURE 3 Shows a cross sectional view of a single panel.
FIGURE 4 Shows a brick exterior building surface wall with building panels installed.
FIGURE 5 Shows a cross-sectional view of installed panels on a brick building surface.
The present invention understands that the panel 10, with all of its components must be created using a moulded surface. This mould may be designed to provide various different sizes and styles. In the diagrams, the panel 10 is styled to have bevelled edges 19. The body of the panel 10 may also be moulded to include various different types of designs 20, as ones commonly seen in vinyl siding.
Referring now to the drawings and more particularly to Figure 1. The drawing shows a single rectangular panel 10 that contains a front facing 11, a reinforcing backing 12, two adj acent proj ecting edges 13 which mate with the opposite two adjacent edges 14 which contain complimentary cavities that are adapted for the projecting edges 13 of an adjoining panel.
Figure 2 shows a building panel 10 from plan view with portions of the facing removed to reveal the structural makeup. The first portion of the panel 10 is created by mixing a polymer compound with a stone or stone-like material.
The polymer-stone composition is spread evenly throughout the mould, ranging in thickness from 1 /8 inch to 1/2 inch. A fibre reinforcing mesh 17 is placed on top of and secured into the composition The fiber mesh and polymer-stone composition 11 are spread out in such a manner that they will have defined both the two adjacent projecting edges 13 and the complimentary adj acent cavities 14.
In order to properly create the complimentary cavities 14, a fibreglass shaft is placed into the mould in the exact position the cavities would be located. The purpose of the shaft is to prevent the foam from expanding throughout the entire panel 10 and thus creating the complimentary cavity 14. In order to promote easy installation and proper air and moisture flow, the shaft should be slightly larger than the projecting edges 13.
Once the shafts have been placed into the mould, the metal backing 12 is placed on top. The metal backing 12 extends approximately 1 inch from both adjacent sides containing the complimentary cavity 14. This backing extension will be used to secure the panel to a building structure at the time of installation. To be able to be suited according to building requirements, the backing 12 may be of various different types of metals and thickness'.
'The panel 10 is then prepared to be injected with an expandable foam insulation 15. A lightweight foam material with excellent thermal heat transfer resistance is preferred. The most suitable forms of foam for such are Polyurethane and Polystyrene. These materials are preferred because of its low cost, high insulation rating and it's a relatively simple application process.
The entire mould is then placed into a unit that sustains constant pressure on panel and mould. It is then injected with the expandable foam insulation 15. The foam 15 expands throughout the mould and adheres to both the polymer-stone facing composition 11 and the metal backing 12.
After all components have cured, the panel 10 is removed from the mould with the polymer-stone facing 11, foam insulation 15 and metal backing 12 securely intact to one another. The foam insulation 15 and polymer-stone facing 11 should not adhere to the shafts and therefore they should be easily removed from the panel. The exterior facade of the panel 10 will have a hard and smooth surface that will contain any design 19 or style 20 that was contained in the mould.
At this point the panel may be created to have a more appealing facade. The polymer-stone facing 11 is coated with additional polymer resin and stone granules 18 are spread throughout and secured into the compound. The additional components provide the panel 10 with added strength. Once the compound has dried, any additional granules that have not adhered to the panel are removed.
The panel is now ready for installation.
Claims (10)
1. A method of constructing a prefabricated lightweight insulating and weather resistant exterior wall panel which is adapted for assembly with similar panels. The panel is fabricated using a moulded surface into which a facing composition of a polymer resin and stone granules is mixed and poured into, with said facing having a thickness in the range of 1/8 inch to 1/2 inch. A
fiber reinforcing mesh is placed on top of and secured into said polymer-stone composition facing. Metal backing is placed on top of the mould after which the mould is injected with an expandable foam insulating material. The panel is removed from the mould with the polymer-stone facing composition, insulating material and backing securely intact to one another. The exterior facade of the panel with have a smooth and glossy finish at which point it may be coated with additional polymer resin onto which stone granules are secured into.
fiber reinforcing mesh is placed on top of and secured into said polymer-stone composition facing. Metal backing is placed on top of the mould after which the mould is injected with an expandable foam insulating material. The panel is removed from the mould with the polymer-stone facing composition, insulating material and backing securely intact to one another. The exterior facade of the panel with have a smooth and glossy finish at which point it may be coated with additional polymer resin onto which stone granules are secured into.
2. A method according to claim 1, wherein said moulded surface shall have a polygonal configuration of a rectangular or square shape.
3. A method according to claim 1, wherein said moulded surface shall have at least one pair of adjacent sides defining projecting edges and the other two adjacent sides defining complimentary cavities for receiving said projecting edges of an adjacent panel.
4. A method according to claim 1, wherein said moulded surface shall have a pattern or design that shall become the exterior cladding of the building facade.
5. A method according to claim 1, wherein said polymer resin comprises any polymer type compound.
6. A method according to claim 1, wherein said stone granules comprises of any stone or stone like material.
7. A method according to claim 1, wherein said reinforcing mesh is a fibre reinforcing mesh.
8. A method according to claim 1, wherein said metal backing is extended approximately 1 inches on the horizontal and vertical axis of the two adjacent sides containing the complimentary cavities.
9. A method according to claim 7, wherein said metal backing will permanently adhere to said expandable foam insulating material.
10. A method according to claim 1, wherein said expandable foam insulating material is polyurethane or polystyrene.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2321445 CA2321445A1 (en) | 2000-10-27 | 2000-10-27 | Polymer-stone interlocking insulating exterior building panel |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2321445 CA2321445A1 (en) | 2000-10-27 | 2000-10-27 | Polymer-stone interlocking insulating exterior building panel |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2321445A1 true CA2321445A1 (en) | 2002-04-27 |
Family
ID=4167274
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2321445 Abandoned CA2321445A1 (en) | 2000-10-27 | 2000-10-27 | Polymer-stone interlocking insulating exterior building panel |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2321445A1 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20170225432A1 (en) * | 2014-08-04 | 2017-08-10 | Litestone Holdings Pty Limited | A Kit for Forming a Panel and a Method of Forming a Panel |
| CN109680866A (en) * | 2018-12-18 | 2019-04-26 | 北京榆构有限公司 | Heat preservation decoration integrative clear-water concrete precast facade hanging plate and its production mould |
| CN114800772A (en) * | 2022-04-14 | 2022-07-29 | 三一筑工科技股份有限公司 | Side formwork device and preparation method of external thermal insulation protection system of external wall |
-
2000
- 2000-10-27 CA CA 2321445 patent/CA2321445A1/en not_active Abandoned
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US20170225432A1 (en) * | 2014-08-04 | 2017-08-10 | Litestone Holdings Pty Limited | A Kit for Forming a Panel and a Method of Forming a Panel |
| US11014332B2 (en) * | 2014-08-04 | 2021-05-25 | Litestone Holdings Pty Limited | Kit for forming a panel and a method of forming a panel |
| CN109680866A (en) * | 2018-12-18 | 2019-04-26 | 北京榆构有限公司 | Heat preservation decoration integrative clear-water concrete precast facade hanging plate and its production mould |
| CN114800772A (en) * | 2022-04-14 | 2022-07-29 | 三一筑工科技股份有限公司 | Side formwork device and preparation method of external thermal insulation protection system of external wall |
| CN114800772B (en) * | 2022-04-14 | 2023-11-24 | 三一筑工科技股份有限公司 | Side mold device and preparation method of external wall external heat preservation and protection system |
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| Date | Code | Title | Description |
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| FZDE | Dead |