US20140170365A1 - Decorative insulative products for construction - Google Patents

Decorative insulative products for construction Download PDF

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Publication number
US20140170365A1
US20140170365A1 US14/235,851 US201114235851A US2014170365A1 US 20140170365 A1 US20140170365 A1 US 20140170365A1 US 201114235851 A US201114235851 A US 201114235851A US 2014170365 A1 US2014170365 A1 US 2014170365A1
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US
United States
Prior art keywords
product
base layer
layers
insulative
inches
Prior art date
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Abandoned
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US14/235,851
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English (en)
Inventor
Mihai Gavris
Tiberius Ioan Oltean
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VALHALL LLC
Original Assignee
Owens Corning Intellectual Capital LLC
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Filing date
Publication date
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Assigned to OWENS CORNING INTELLECTUAL CAPITAL, LLC reassignment OWENS CORNING INTELLECTUAL CAPITAL, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: GAVRIS, Mihai, OLTEAN, TIBERIUS IOAN
Publication of US20140170365A1 publication Critical patent/US20140170365A1/en
Assigned to VALHALL LLC reassignment VALHALL LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: OWENS CORNING INTELLECTUAL CAPITAL LLC
Abandoned legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
    • E04B1/88—Insulating elements for both heat and sound
    • 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
    • E04F13/0875—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
    • E04F13/0876—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 the covering layer comprising mutual alignment or interlocking means
    • 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
    • E04F13/18—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 of organic plastics with or without reinforcements or filling materials or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles
    • E04F13/185—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 of organic plastics with or without reinforcements or filling materials or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles with an outer layer imitating natural stone, brick work, tiled surface or the like
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23—Sheet including cover or casing
    • Y10T428/233—Foamed or expanded material encased
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249987—With nonvoid component of specified composition
    • Y10T428/249991—Synthetic resin or natural rubbers
    • Y10T428/249992—Linear or thermoplastic

Definitions

  • the exterior and interior surfaces of a building can be covered by many materials including natural materials, manufactured materials and materials simulating natural or manufactured materials.
  • natural materials include wood and stone.
  • manufactured materials include siding, stucco and masonry.
  • materials simulating natural and manufactured materials include simulated stone, simulated wood, simulated siding, simulated stucco and simulated brick.
  • the exterior coverings of a building are configured to repel weather elements and protect the interior of the building or structure from the effects of weather. Additionally, the exterior and interior coverings of a building can present a desired aesthetic appearance to the building or structure.
  • Simulated materials can take many forms including the non-limiting examples of individual pieces or panels formed to represent the combination of individual pieces. Simulated materials can be applied to various types of building structures. Some examples of building structures configured to support simulated materials include wood or metal framing members (studs) or framing members covered by layers of sheet material (sheathing) and subsequently covered by one or more layers of insulation.
  • a decorative, insulative product configured for application to the interior or exterior surfaces of a building structure.
  • the product includes one or more layers configured to form a rigid, puncture resistant outer protective surface for the product and a base layer configured to support the one or more layers.
  • the one or more layers forming the outer surface of the product are configured to provide a desired aesthetic appearance to the building or structure and the base layer is configured to provide a thermal insulative value and an acoustic insulative value to the product.
  • a method of manufacturing a decorative, insulative product configured for application to the interior or exterior surfaces of a building structure.
  • the method includes the steps of forming one or more layers within a mold, the one or more layers configured to form a rigid, puncture resistant outer protective surface for the product and applying a base layer over the one or more layers configured to support the one or more layers.
  • the one or more layers forming the outer surface of the product are configured to provide a desired aesthetic appearance to the building or structure and the base layer is configured to provide a thermal insulative value and an acoustic insulative value to the product.
  • the building wall includes a plurality of framing members forming an exterior or interior surface and a plurality of decorative, insulative product covering the exterior or interior surface formed by the framing members.
  • the decorative, insulative product includes one or more layers configured to form a rigid, puncture resistant outer protective surface for the product and a base layer configured to support the one or more layers forming the outer protective surface.
  • the one or more layers forming the outer surface of the product are configured to provide a desired aesthetic appearance to the exterior or interior surface of the building wall and the base layer is configured to provide a thermal insulative value and an acoustic insulative value to the product.
  • FIG. 1 is a perspective view of a decorative, insulative product.
  • FIG. 2 is a front view, in elevation, of a plurality of decorative, insulative products of FIG. 1 combined such as to cover a building wall.
  • FIG. 3 is a perspective view of a plurality of decorative, insulative products of FIG. 1 combined such as to cover building corner.
  • FIG. 4 is a side view, in elevation, of a mold for forming the decorative, insulative product of FIG. 1 .
  • the description and figures disclose decorative, insulative products configured for forming portions of interior or external walls for a building and methods for the production of the decorative, insulative products.
  • the decorative, insulative products can be in the form of panels, corner pieces, or architectural trim pieces.
  • the decorative, insulative products are manufactured using a mold filled with various layers of materials.
  • a decorative, insulative product is shown generally at 10 .
  • the decorative, insulative product 10 (hereafter product 10 ) is configured to provide both a decorative siding material and an insulative siding material for application to external and internal surfaces of a building.
  • the product 10 includes layers of resin-based material applied over a base of foam-based insulative material.
  • the term “decorative”, as used herein, is defined to mean providing an ornamental appearance.
  • insulative material as used herein, is defined to mean any material configured to provide a thermal insulative value (R) or an acoustic insulative value.
  • product as used herein, is defined to mean any desired form including panels, corner pieces and trim pieces.
  • the term “layer”, as used herein, is defined to mean a quantity or thickness of material.
  • the term “resin-based”, as used herein, is defined to mean a material having a polymeric base.
  • the product 10 has a front face 12 , a rear face 14 , a top edge 16 , a bottom edge 18 , a first side edge 20 and a second side edge 22 .
  • the product 10 formed from a mold filled with various layers of material.
  • the front face 12 has a textured surface that simulates a plurality of natural stones.
  • the term “textured surface”, as used herein, is defined to mean an imitation of the tactile quality of a represented object.
  • the front face 12 can have textured surfaces that simulate other materials, such as the non-limiting example of brick, natural wood, stucco or siding.
  • the front face 12 can have a non-textured or smooth surface.
  • the term “smooth” surface is defined to mean a substantially continuous even surface.
  • the top edge 16 , bottom edge 18 and opposing first and second side edges 20 and 22 have a smooth surface.
  • the top edge 16 , bottom edge 18 and opposing first and second side edges 20 and 22 can have textured surfaces that simulate other materials as discussed above for the front face 12 .
  • the back face 14 of the product 10 has a non-textured surface.
  • the back face 14 can have any other texture, such as a scratch coat, conducive for application to a structural surface.
  • the product 10 has a length LP and a height HP.
  • the length LP of the product 10 is in a range of from about 12.0 inches (30.5 cm) to about 48.0 inches (121.9 cm) and the height HP of the product 10 is in a range of from about 4.0 inches (10.2 cm) to about 16.0 inches (40.6 cm).
  • the length LP of the product 10 can be less than about 12.0 inches (30.5 cm) or more than about 48.0 inches (121.9 cm) and the height HP of the product 10 can be less than about 4.0 inches (10.2 cm) or more than about 16.0 inches (40.6 cm).
  • the product 10 illustrated in FIG. 1 is shown as having a generally rectangular shape, it should be appreciated that in other embodiments, the product 10 can have other desired shapes, including the non-limiting example of an irregular shape.
  • the product 10 includes an outer layer 30 , an optional intermediate layer 32 and a base layer 34 .
  • the outer layer 30 is configured to provide a protective surface and decorative surface to the product 10 .
  • the product 10 can be applied to the exterior surfaces of a building.
  • the outer layer 30 of the product 10 can be in contact with environmental conditions such as rain, sleet, hail and snow. Accordingly, the outer layer 30 is configured to substantially protect the product from damage from the environmental conditions.
  • the outer layer 30 is configured to provide a decorative surface to the product 10 . Accordingly, the surface of the outer layer 30 can have various coloring agents and patterns.
  • the material forming the outer layer 30 is formed from an unsaturated polymeric-based material, such as the non-limiting example of polyester resin or epoxy resin. However, other desired materials can also be used, sufficient to provide a protective surface and decorative surface to the product 10 . As will be discussed in more detail below, in the illustrated embodiment, the outer layer 30 is formed by spraying the unsaturated polymeric-based material into a mold. However, in other embodiments, the outer layer 30 can be formed by other desired methods, including the use of castable unsaturated polymeric-based materials.
  • the outer layer 30 can include reinforcing materials (not shown).
  • the reinforcing materials are configured to provide the outer layer 30 with desired levels of hardness and puncture resistance.
  • the reinforcing materials can be fibrous materials such as the non-limiting examples of fiberglass or carbon fibers.
  • the reinforcing materials can be other materials, such as for example sand, quartz, ground up rubber tire and sawdust. In still other embodiments, other suitable reinforcing materials can be used.
  • the outer layer 30 can include various additives or coatings configured to impart desired characteristics to the product 10 .
  • the outer layer 30 can include a fire retardant material.
  • fire retardant material include aluminum hydroxide and boron.
  • Other additives or protective coatings can be added to tailor the outer layer 30 to specialized conditions, such as extreme exposures of ultraviolet light, solar radiation, and/or temperature.
  • the protective coating can also contain other additives such as algaecides or fungicides.
  • the outer layer 30 has a thickness T 1 .
  • the thickness T 1 of the outer layer 30 is configured to provide the outer layer 30 with desired levels of strength and puncture resistance.
  • the thickness T 1 is in a range of from about 0.02 inches (0.5 mm) to about 0.12 inches (3.0 mm). In other embodiments, the thickness T 1 of the outer layer can be less than about 0.02 inches (0.5 mm) or more than about 0.12 inches (3.0 mm).
  • the product 10 includes the optional intermediate layer 32 .
  • the optional intermediate layer 32 is configured to provide support to the outer layer 30 , such as to improve the rigidity and puncture resistance of the outer layer 30 .
  • the size and shape of the product 10 coupled with the configuration of the outer layer 30 , may provide the product 10 with sufficient rigidity and puncture resistance so as to eliminate the need for the intermediate layer 32 .
  • the material forming the intermediate layer 32 is an unsaturated polymeric-based material, such as the non-limiting example of polyester resin, epoxy resin or high density polyurethane foam.
  • unsaturated polymeric-based material such as the non-limiting example of polyester resin, epoxy resin or high density polyurethane foam.
  • other desired materials can also be used, sufficient to provide a support to the outer layer 30 .
  • the intermediate layer 32 is formed by spraying the unsaturated polymeric-based material into the mold and over the inner surface formed by the outer layer 30 .
  • the intermediate layer 32 can be formed by other desired methods, including the use of castable unsaturated polymeric-based materials.
  • the intermediate layer 32 can include reinforcing materials (not shown).
  • the reinforcing materials are configured to provide the intermediate layer 32 with desired levels of strength and puncture resistance.
  • the reinforcing materials can be the same reinforcing materials used for the outer layer 30 , such as fiberglass or carbon fibers. In other embodiments, the reinforcing materials can be other desired materials.
  • the intermediate layer 32 has a thickness T 2 .
  • the thickness T 2 of the intermediate layer 32 is configured to combine with the thickness T 1 of the outer layer 30 to provide the product 10 with layers of resin-based material having a total desired thickness.
  • the thickness T 2 is in a range of from about 0.12 inches (3.0 mm) to about 0.32 inches (8.0 mm).
  • the thickness T 2 of the intermediate layer 32 can be less than about 0.12 inches (3.0 mm) or more than about 0.32 inches (8.0 mm).
  • the thickness of the intermediate layer 32 can be varied as desired such as to improve the rigidity and puncture resistance of the outer layer 30 and to provide an overall thickness of the layers of resin-based material.
  • the combination of the thicknesses T 1 and T 2 of the outer layer 30 and the intermediate layer 32 is in a range of from about 0.14 inches (3.6 mm) to about 0.44 inches (11.2 mm). In other embodiments, the combination of the thicknesses T 1 and T 2 of the outer layer 30 and the intermediate layer 32 can be less than about 0.14 inches (3.6 mm) or more than about 0.44 inches (11.2 mm).
  • the base layer 34 is configured to provide a thermal insulative value (R) to the product 10 as well as an acoustic insulative value to the product 10 .
  • the term “insulative value”, as used herein, is defined to mean the ability of a material to substantially retard the flow of thermal energy. Factors contributing to the thermal and acoustic insulative value of the product 10 include the thicknesses of the base layer 34 and the materials used to form the base layer 32 .
  • the base layer 34 has a nominal or average thickness T 3 .
  • the thickness T 3 is in a range of from about 0.59 inches (15.0 mm) to about 11.8 inches (300.0 mm). In other embodiments, the thickness T 3 of the base layer 34 can be less than about 0.59 inches (15.0 mm) or more than about 11.8 inches (300.0 mm).
  • the material forming the base layer 34 is a polymeric-based foam material such as for example polyurethane foam.
  • the material forming the base layer 34 can be other materials or combinations of materials including the non-limiting example of polyurethane foam combined with expanded or extruded polystyrene foam. Accordingly, as one non-limiting example, a base layer 34 having a thickness T 3 of 0.79 inches (20 mm) and formed from a polymeric-based foam material yields a thermal insulative value (R) of about 20. Other combinations of the thickness of the base layer 34 and materials forming the base layer 34 can provide other desired insulative values (R).
  • a base layer 34 having a thickness T 3 of 0.79 inches (20 mm) and formed from a polymeric-based foam material yields a noise reduction coefficient (NRC) in a range of from about 0.2 to about 0.7.
  • the NRC is a single-number index determined in a lab test and used for rating how noise absorptive a particular material is. This industry standard ranges from zero (perfectly reflective) to 1 (perfectly absorptive). The NRC simply averages the mid-frequency sound absorption coefficients (250, 500, 1000 and 2000 Hertz) rounded to the nearest 5%.
  • Other combinations of the thickness of the base layer 34 and materials forming the base layer 34 can provide other desired acoustic insulative values.
  • the base layer 34 can include reinforcing materials (not shown).
  • the reinforcing materials are configured to provide the base layer 34 with desired levels of rigidity and puncture resistance.
  • the reinforcing materials can be fibrous materials such as the non-limiting examples of fiberglass or carbon fibers.
  • the reinforcing materials can be other materials, such as for example sand, quartz, ground up rubber tire and sawdust. In still other embodiments, other suitable reinforcing materials can be used.
  • the base layer 34 can include various additives or coatings configured to impart desired characteristics to the product 10 .
  • the base layer 34 can include a fire retardant material as discussed above.
  • a plurality of products 10 A- 10 G can be combined to form a wall 50 .
  • the products 10 A- 10 G can optionally be shaped in a jig-saw fashion such as to allow adjoining products 10 A- 10 G to mesh together in a more natural appearance and avoid the appearance of rectangularly-shaped panels simply stacked together.
  • the products 10 A- 10 G can have other shapes, such as the non-limiting examples of rectangular, square or irregular shape, sufficient to allow adjoining products 10 A- 10 G to mesh together in a natural appearance.
  • the adjoining side edges of the products 10 A- 10 G have substantially straight and smooth surfaces, thereby allowing a tight fit between the adjoining products 10 A- 10 G.
  • the adjoining side edges of the products 10 A- 10 G can have other surfaces sufficient to allow a tight fit between the adjoining products 10 A- 10 G.
  • an optional sealant 52 is positioned between the adjoining side edges of the products 10 A- 10 G.
  • the sealant 52 is configured to seal gaps formed between the adjoining side edges of the products 10 A- 10 G, thereby substantially preventing the flow of acoustic energy, thermal energy and moisture through the wall 50 .
  • the sealant 52 is a polymeric material, such as for example polyurethane.
  • the sealant 52 can be other desired materials.
  • wall 50 illustrated in FIG. 2 is shown to have a quantity of seven products 10 A- 10 G and have a generally rectangular shape, it should be appreciated that in other embodiments, a wall can have any desired number of products 10 and can have any desired shape, including an irregular shape.
  • a plurality of products 110 A- 110 E can be combined to form a corner 150 .
  • the products 110 A- 110 E can optionally be shaped in a jig-saw fashion such as to allow adjoining products 110 A- 110 E to mesh together in a more natural appearance and avoid the appearance of rectangularly-shaped panels simply stacked together.
  • the products 110 A- 110 E can have other shapes, such as the non-limiting examples of rectangular, square or irregular shape, sufficient to allow adjoining products 110 A- 110 E to mesh together in a natural appearance.
  • the adjoining side edges of the products 110 A- 110 E have substantially straight and smooth surfaces, thereby allowing a tight fit between the adjoining products 110 A- 110 E.
  • the adjoining side edges of the products 110 A- 110 E can have other surfaces sufficient to allow a tight fit between the adjoining products 110 A- 110 E.
  • an optional sealant 152 is positioned between the adjoining side edges of the products 110 A- 110 E.
  • the sealant 152 is the same as, or similar to, the sealant 52 illustrated in FIG. 2 and discussed above. In other embodiments, the sealant 152 can be different from the sealant 52 illustrated in FIG. 2 and discussed above.
  • corner 150 illustrated in FIG. 3 is shown to have a quantity of five products 110 A- 110 E, it should be appreciated that in other embodiments, the corner 150 can have any desired number of products. Also, while the corner 150 illustrated in FIG. 3 is shown such that the sides of the corner have a generally right-angle orientation to each other, it should be appreciated that in other embodiments, the sides of the corner can have any desired orientation to each other.
  • the production mold 60 is configured to manufacture the products 10 .
  • the production mold 60 includes a mold frame 62 and structural material 64 .
  • the production mold 60 forms a mold cavity 70 within the structural material 64 .
  • the mold cavity 70 is oriented such that the outer layer 30 of the product 10 is arranged in a substantially horizontal orientation.
  • the mold cavity 70 can be oriented such that the outer layer 30 of the product 10 is arranged in a substantially vertical orientation.
  • production mold 60 illustrated in FIG. 4 shows a lone mold cavity 70
  • the production mold 60 can include any desired quantity of mold cavities 70 .
  • the mold frame 62 is configured to support the structural material 64 .
  • the mold frame 62 is made of a rigid material, such as for example metal.
  • the mold frame 62 can be made of other rigid materials, such as reinforced plastic, sufficient to hold the structural material 64 .
  • the structural material 64 is positioned within the mold frame 62 and is configured to form the mold cavity 70 .
  • the structural material 64 is configured to support the load formed during the forming of the product 10 .
  • the structural material 64 is a flexible material and in other embodiments, the structural material 64 can be a rigid material.
  • Non-limiting examples of a flexible material forming the structural material 64 include silicone rubber and polyurethane.
  • Non-limiting examples of rigid materials forming the structural material 64 include epoxy-based resins, Teflon®, polypropylene and polyurethane-based resins.
  • other desired materials can be used to form the structural material 64 , sufficient to be a load supporting material capable of providing substantially rigid structural support during the formation of the product 10 .
  • the production mold 60 can be made from a solid block of material.
  • the production mold 60 material can be any material suitable to form a mold 60 containing mold cavities 70 .
  • suitable material include latex rubber, elastomers such as polyurethane, and thermoplastics such as polyvinyl chloride.
  • the production mold 60 is positioned on a mold support (not shown).
  • the mold support is configured to retain the production mold 60 is a rigid and fixed position during the mold process.
  • the mold support can have any desired structure.
  • the mold support can be supported by mold isolation mechanisms (not shown).
  • the mold isolation mechanisms are configured to isolate the production mold 60 as the production mold 60 is vibrated by an optional mold vibrator (not shown).
  • the mold isolation mechanisms can be any desired structure, mechanism or device, or combination thereof, such as for example elastomeric isolators or air bags, sufficient to isolate the production mold 60 as the production mold 60 is vibrated by the mold vibrator.
  • the mold support can be configured for vertical movement as may be required for positioning the production mold 60 relative to dosing apparatus (not shown).
  • the mold support can be connected to a hydraulic lift cylinder (not shown), configured to facilitate the vertical movement of the production mold 60 .
  • the mold support can be connected to other structure or mechanisms, such as for example pneumatic or electric cylinders, or rack and pinion mechanisms, sufficient to vertically raise and lower the mold support.
  • a mold vibrator (not shown) can be connected to the mold support.
  • the mold vibrator is configured to vibrate the production mold 60 . Vibration of the production mold 60 can promote a flow of the materials forming the layers 30 , 32 and 34 of the product 10 into all portions of the mold cavity 70 .
  • the mold vibrator can be a pneumatic, high-amplitude piston-type vibrator providing a liner force.
  • a pneumatic, piston-type vibrator is model VTS 50/10, marketed by Powtek Corporation, headquartered in Bensalem, Pa.
  • the mold vibrator can be other suitable vibrators, such as for example electric or rotary vibrators, sufficient to promote a flow of materials into all portions of the mold cavity 70 .
  • the production mold 60 is secured to the mold support.
  • the mold cavity 70 can be colored or painted with one or more layers of suitable stone-colored paints.
  • the paint can be applied with any desired manual or automatic mechanism or device.
  • the mold support including the production mold 60 is positioned relative to one or more dosing apparatus (not shown).
  • dosing is defined to mean the use of defined quantities of material to manufacture the products 10 .
  • the dosing apparatus is configured to allow a flow of material to the mold cavity 70 .
  • the dosing apparatus can have any desired structure, mechanism or device or combinations thereof.
  • a lone dosing apparatus can be configured to sequentially apply the material for the outer layer 30 and the intermediate layer 32 .
  • separate dosing apparatus can be used for application of the outer layer 30 and the intermediate layer 32 .
  • the dosing apparatus can be connected to supply hoppers (not shown).
  • the supply hoppers are configured to supply material for the layers 30 and 32 to the dosing apparatus.
  • the supply hoppers can be any desired structure, mechanism or device or combination thereof.
  • a desired quantity of material forming the outer layer 30 flows through the supply hopper and into the dosing apparatus.
  • the material forming the outer layer 30 can be sprayable, such as to be sprayed into the mold cavity 70 .
  • the material forming the outer layer 30 can be deposited or cast into the mold cavity 70 .
  • the quantity of material is sufficient when the formed outer layer 30 has a thickness T 1 in the range as discussed above.
  • the material can be urged to flow into all portions of the mold cavity 70 by activation of the mold vibrator. Activation of the mold vibrator can change the rheological properties of the material and allow the material to flow more easily into all portions of the mold cavity 70 .
  • the dosing apparatus and the mold vibrator are deactivated and the material within the mold cavity 70 is allowed to harden.
  • any desired apparatus and any desired methods can be used to facilitate the hardening of the material forming the outer layer 30 .
  • a desired quantity of material forming the intermediate layer 32 flows through a supply hopper and into a dosing apparatus.
  • the material forming the intermediate layer 32 can be sprayable, such as to be sprayed over the outer layer 30 in the mold cavity 70 .
  • the material forming the intermediate layer 32 can be deposited or cast over the outer layer 30 in the mold cavity 70 .
  • the quantity of material is sufficient when the formed intermediate layer 32 has a thickness T 2 in the range as discussed above.
  • the material can be urged to flow into all portions of the mold cavity 70 by activation of the mold vibrator, as discussed above.
  • the dosing apparatus and the mold vibrator are deactivated and the material within the mold cavity 70 is allowed to harden.
  • any desired apparatus and any desired methods can be used to facilitate the hardening of the material forming the intermediate layer 32 , such as the non-limiting example of a curing chamber.
  • the thicknesses T 1 and T 2 are determined using any desired method. If the thicknesses T 1 and T 2 are not sufficient to provide the thickness of the resin-based layers as discussed above, then additional material is added to the intermediate layer 32 using the apparatus and methods described above.
  • the dosing apparatus and the mold vibrator are deactivated and the material within the mold cavity 70 is allowed to set to a gel condition.
  • any desired apparatus and any desired methods can be used to facilitate the setting of the material forming the intermediate layer 32 .
  • the material forming the base layer 34 is deposited within the mold cavity 70 by a foam dosing apparatus (not shown).
  • a desired quantity of foam material forming the base layer 34 flows through the dosing apparatus.
  • the quantity of foam material is sufficient when the base layer 34 is formed having a thickness T 3 in the range as discussed above.
  • the deposited material forming the base layer 34 contacts and bonds with the intermediate layer 32 .
  • the foam material can be urged to flow into all portions of the mold cavity 70 by activation of the mold vibrator, as discussed above.
  • the top of the mold cavity 70 cavity can be enclosed by a cap (not shown).
  • the cap can be configured such as to control the vertical expansion of the foam material forming the base layer 34 .
  • the optional cap can be any desired structure, mechanism or device sufficient to control the vertical expansion of the foam material forming the base layer 34 .
  • the cap is optional, and that the decorative, insulative product 10 can be practiced without the cap.
  • the material in the mold cavity 70 becomes the product 10 .
  • the product 10 is removed from the mold cavity 70 in a suitable manner, including passing the production mold 60 over rollers (not shown).
  • any other method of removing the product 10 from the production mold 60 such as introducing a pressurized fluid such as air between the outer layer 30 and the structural material 64 , or vacuum absorption can be used.
  • a removal or release agent can be applied to the mold cavity 70 prior to the deposition of the materials.
  • the removal or release agent is configured to facilitate removal of the product 10 from the mold cavity 70 .
  • the removal or release agent can be any desired material or combination of materials.
  • the product 10 can be further thermally cured using any desired curing apparatus or method, such as for example a curing oven (not shown).
  • the optional curing can also be used to substantially reduce or eliminate any residual odors.
  • the base layer 34 can be formed by introducing foam material forming the base layer 34 into a mold (not shown) having a mold cavity.
  • the mold cavity can have a textured surface that simulates a plurality of natural stones.
  • the mold cavity can have textured surfaces that simulate other materials, such as the non-limiting example of brick, natural wood, stucco or siding.
  • the mold cavity can have a non-textured or smooth surface.
  • smooth surface is defined to mean a substantially continuous even surface.
  • the foam material can be the same as the foam material discussed above, however other foam materials can be used.
  • the foam material can be urged to flow into all portions of the mold cavity by activation of the mold vibrator, as discussed above, or by other desired methods including pressure formed by apparatus in the form of a press.
  • the foam material forming the base layer having the optional textured surface is removed from the mold cavity.
  • An outer layer and optionally an intermediate layer can be applied to the base layer.
  • the outer layer and optional intermediate layer can be applied to the base layer in any desired manner, including spraying, casting or depositing, using any desired structures, mechanisms or devices.
  • the outer layer and optional intermediate layer assume the optional textured surface of the base layer.
  • the outer layer can be aesthetically finished as desired.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Electromagnetism (AREA)
  • Laminated Bodies (AREA)
  • Finishing Walls (AREA)
  • Building Environments (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
US14/235,851 2011-08-10 2011-08-10 Decorative insulative products for construction Abandoned US20140170365A1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2011/047219 WO2013022445A1 (fr) 2011-08-10 2011-08-10 Produits isolants décoratifs pour la construction

Publications (1)

Publication Number Publication Date
US20140170365A1 true US20140170365A1 (en) 2014-06-19

Family

ID=47668741

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US14/235,851 Abandoned US20140170365A1 (en) 2011-08-10 2011-08-10 Decorative insulative products for construction

Country Status (7)

Country Link
US (1) US20140170365A1 (fr)
EP (1) EP2742194A4 (fr)
CN (1) CN104040088A (fr)
CA (1) CA2844657A1 (fr)
IL (1) IL230740A0 (fr)
RU (1) RU2014108210A (fr)
WO (1) WO2013022445A1 (fr)

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JP2018009324A (ja) * 2016-07-12 2018-01-18 旭トステム外装株式会社 壁パネル
US20180056559A1 (en) * 2013-03-15 2018-03-01 Certainteed Corporation Variegated building product and method
FR3069561A1 (fr) * 2017-07-26 2019-02-01 Orsol Production Jeu de modeles en pierre pour parement decoratif
US20190301178A1 (en) * 2018-03-30 2019-10-03 Certainteed Corporation Individual polymer masonry panels, and methods of manufacture and installation
US10557272B1 (en) * 2018-12-21 2020-02-11 Associated Materials, Llc Siding panel assembly
US10753101B1 (en) * 2016-12-09 2020-08-25 Baton, LLC Artificial lightweight stone
US11007690B2 (en) 2013-03-15 2021-05-18 Certainteed Corporation System, method and article for siding corner

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Also Published As

Publication number Publication date
RU2014108210A (ru) 2015-09-20
WO2013022445A8 (fr) 2014-07-10
CA2844657A1 (fr) 2013-02-14
IL230740A0 (en) 2014-03-31
WO2013022445A1 (fr) 2013-02-14
EP2742194A4 (fr) 2015-06-03
EP2742194A1 (fr) 2014-06-18
CN104040088A (zh) 2014-09-10

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