WO2020231735A1 - Panneaux d'écran pare-pluie isolés et leurs procédés de fabrication et d'utilisation - Google Patents

Panneaux d'écran pare-pluie isolés et leurs procédés de fabrication et d'utilisation Download PDF

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Publication number
WO2020231735A1
WO2020231735A1 PCT/US2020/031845 US2020031845W WO2020231735A1 WO 2020231735 A1 WO2020231735 A1 WO 2020231735A1 US 2020031845 W US2020031845 W US 2020031845W WO 2020231735 A1 WO2020231735 A1 WO 2020231735A1
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WO
WIPO (PCT)
Prior art keywords
panel
corrugated
insulated
foam
rainscreen
Prior art date
Application number
PCT/US2020/031845
Other languages
English (en)
Inventor
Joel Bolin
Original Assignee
Crate Right Llc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Crate Right Llc filed Critical Crate Right Llc
Publication of WO2020231735A1 publication Critical patent/WO2020231735A1/fr

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Classifications

    • 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
    • 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
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/20—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics
    • E04C2/205—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products of plastics of foamed plastics, or of plastics and foamed plastics, optionally reinforced
    • 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
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/32—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material
    • E04C2/322—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material with parallel corrugations
    • 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
    • E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
    • E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
    • E04C2/526—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits with adaptations not otherwise provided for, for connecting, transport; for making impervious or hermetic, e.g. sealings
    • E04C2/528—Impervious or hermetic panels not otherwise provided for
    • 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
    • E04F13/0889—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 characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections
    • E04F13/0892—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 characterised by the joints between neighbouring elements, e.g. with joint fillings or with tongue and groove connections with means for aligning the outer surfaces of the covering elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F2201/00—Joining sheets or plates or panels
    • E04F2201/02—Non-undercut connections, e.g. tongue and groove connections
    • E04F2201/026—Non-undercut connections, e.g. tongue and groove connections with rabbets, e.g. being stepped

Definitions

  • Insulated rainscreen panels are disclosed herein, as well as methods of making and using the same.
  • a benefit to the insulated rainscreen panels can be providing an insulating panel with moisture control properties between a wall and a building material.
  • Embodiments herein are directed to insulated rainscreen panels and methods for the making and use thereof.
  • an insulated rainscreen panel includes a corrugated foam panel, wherein the corrugated foam panel has a panel length, a panel width, a panel thickness, a front panel surface, a back-panel surface, and at least two panel edges; wherein the front panel surface includes a front corrugated surface having front ridges and front trenches that extend the panel length of the corrugated foam panel; and wherein the back-panel surface includes a back corrugated surface having back ridges and back trenches that extend the panel length of the corrugated foam panel.
  • the corrugated foam panel is rectangular.
  • the panel thickness is from about 2.5 cm to about 30.5 cm.
  • the panel length is from about 1.2 meters to about 2.0 meters.
  • the panel front ridges have a height of from about 6 mm to about 13 mm, measured from a front ridge top to a front trench bottom.
  • the back ridges have a height of from about 6 mm to about 13 mm, measured from a back ridge top to a back trench bottom.
  • the front ridges or the back ridges have a period center distance between them of from about 5 cm to about 8 cm.
  • a ridge period center distance of the front panel surface differs by from 0 cm to about 8 cm from the ridge period center distance of the back-panel surface. In certain embodiments, a ridge period center distance of the front panel surface is aligned with a ridge period center distance of the back-panel surface by a percentage offset of from 0 percent to 99 percent.
  • about 80% to 100% weight of the corrugated foam panel is a polystyrene foam material, based on a total weight of the corrugated foam panel.
  • the polystyrene foam material has a weight per volume of about 1 pound per cubic foot (16 g/L), about 2 pounds per cubic foot (32 g/L), or about 3 pounds per cubic foot (48 g/L).
  • the corrugated foam panel includes expanded polystyrene foam material, extruded polystyrene foam material, or combinations thereof.
  • the two panel edges include a first panel edge having a first interlocking shape and a second panel edge having a second interlocking shape.
  • the first interlocking shape is complementary to the second interlocking shape.
  • the first interlocking shape and second interlocking shape are configured to allow for interlocking of a plurality of corrugated foam panels together.
  • the first interlocking shape protrudes from about 3 mm to about 13 mm from the first panel edge.
  • the second interlocking shape protrudes from about 3 mm to about 13 mm from the second panel edge.
  • At least a portion of the front ridges have flat or substantially flat front perches located on front tops of the front ridges.
  • at least a portion of the back ridges have flat or substantially flat back perches located on back tops of the back ridges.
  • the front trenches and the back trenches have a flat or substantially flat bottom.
  • the front panel surface is
  • the complementary front panel surface and back-panel surface portions have flat or curved surfaces.
  • the front corrugated surface has at least one row of guide lips on top of the front ridges that extend above the front perches.
  • the rows of guide lips are arranged in rows that are perpendicular or substantially perpendicular to the front ridges and front trenches.
  • a height of the guide lip is from about 3 mm to about 13 mm, as measured from a top of the guide lip to an adjacent perch.
  • the perches have a length of about 5 cm to about 10 cm between rows of guide lips.
  • a distance between rows of guide lips is equal or
  • the siding includes a brick, a wood panel, or an aluminum panel.
  • the brick includes standard brick, modular brick, norman brick, roman brick, jumbo brick, economy brick, engineer brick, king brick, queen brick, and utility brick.
  • the method includes a corrugated foam panel, wherein the corrugated foam panel has a panel length, a panel width, a panel thickness, a front panel surface, a back-panel surface, and at least two panel edges; wherein the front panel surface includes a front corrugated surface having front ridges and front trenches that extend the panel length of the corrugated foam panel; and wherein the back-panel surface includes a back corrugated surface having back ridges and back trenches that extend the panel length of the corrugated foam panel;
  • the corrugated foam panel is attached to the wall by a fastener or an adhesive.
  • the at least one building material includes a plaster or a siding material.
  • a method of making an insulated rainscreen panel includes extruding or molding a foam material to form a corrugated foam panel according to embodiments herein, or providing a block of foam material according to embodiments herein, and wire cutting the block of foam material to form the corrugated foam panel according to embodiments herein.
  • Figure 1 shows a schematic depiction of an embodiment of an insulated rainscreen panel.
  • Figure 2 shows a schematic depiction of the insulated rainscreen panel in Figure 1 as viewed down the length of the panel.
  • Figure 3 shows a schematic expanded view of the insulated rainscreen panel in Figure 2
  • Figure 4 shows a schematic view of an embodiment of an insulated rainscreen panel as well as an expanded view down the length of the panel.
  • Figure 5 shows an illustration of an embodiment of an insulated rainscreen panel used as a double-sided rain screen.
  • Figure 6 shows an illustration of an embodiment of an insulated rainscreen panel used as a single sided rain screen.
  • Figure 7 shows an illustration of an embodiment of an insulated rainscreen panel used as a single sided rain screen and jig for attaching a brick siding.
  • “at least one” means one or more than one of an object.
  • “at least one row of guide lips” means a single row of guide lips, two or more rows of guide lips, or any combination thereof.
  • the term“about” refers to ⁇ 10% of the non-percentage number that is described, rounded to the nearest whole integer. For example, about 10 cm, would include 9 cm to 11 cm. Unless otherwise noted, the term“about” refers to ⁇ 5% of a percentage number. For example, about 20% would include 15 to 25%. When the term “about” is discussed in terms of a range, then the term refers to the appropriate amount less than the lower limit and more than the upper limit. For example, from about 10 cm to about 100 cm would include from 9 cm to 110 cm.
  • the term“substantially” as used herein changes depending on context, as understood by those skilled in the art. When used to indicate a direction or alignment, such as “substantially perpendicular” or“substantially parallel,” then the term“substantially” would include up to plus or minus 10 degrees.
  • the phrase“substantially flat” refers to a planar surface while allowing for a degree of non-planarity, such as bowing of plus or minus 20% or a radius of curvature of from 1 to 10°, and also allowing for structural defects in the surface, such as pitting and unevenness of 2 mm or less.
  • measurable properties are understood to be averaged measurements.
  • An insulated rainscreen panel includes a corrugated foam panel 100.
  • the corrugated foam panel has a panel length 102, a panel width 104, a panel thickness 106, a front panel surface 108, a back-panel surface 110, and at least two panel edges 112.
  • An insulated rainscreen panel includes a corrugated foam panel 200.
  • the front panel surface includes a front corrugated surface 202 having front ridges 204 and front trenches 206 that extend the panel length of the corrugated foam panel.
  • the back-panel surface includes a back corrugated surface 208 having back ridges 210 and back trenches 212 that extend the panel length of the corrugated foam panel.
  • the corrugated foam panel has overall thickness 214 measured from a front ridge top to a back ridge top, and panel material thickness 216 measured from a front trench bottom to a back trench bottom.
  • the front ridges or the back ridges have a period center distance 218 between them.
  • the panel edges include a first panel edge 220 having a first interlocking shape 222 and a second panel edge 224 having a second interlocking shape 226.
  • the second interlocking shape has a protruding distance 228 from the second panel edge.
  • An insulated rainscreen panel as disclosed herein is shown in Figure 3.
  • An insulated rainscreen panel includes a corrugated foam panel 300.
  • the front ridges have a height 306 measured from a front ridge top 302 to a front trench bottom 304.
  • the front ridges have a period center distance 308 between them, and the back ridges have a period center distance 310 between them.
  • a ridge period center distance of the front panel surface has an alignment 312 with a ridge period center distance of the back-panel surface.
  • An embodiment of an insulated rainscreen panel as disclosed herein is shown in Figure 4.
  • An insulated rainscreen panel includes a corrugated foam panel 400.
  • the front panel surface has flat front perches 402 on front tops of the front ridges, and rows of guide lips 404 perpendicular to the front ridges and front trenches on the front corrugated surface.
  • An embodiment of an insulated rainscreen panel can function as a double-sided rain screen as illustrated in Figure 5.
  • a corrugated foam panel according to embodiments herein forms a double-sided rain screen 500 between wall 502 and preformed siding 506, such as wood paneling.
  • the panel front corrugated surface forms rain screen spaces 508 in the front trenches of the panel between the preformed siding and the wall.
  • the panel back corrugated surface forms rain screen spaces 510 in the back trenches of the panel between the panel and the wall.
  • An embodiment of an insulated rainscreen panel can function as a single-sided rain screen as illustrated in Figure 6.
  • a corrugated foam panel according to embodiments herein forms single sided rain screen 600 between a wall 602 and formed siding 606, such as plaster.
  • the panel back corrugated surface forms rain screen spaces 603 in the back trenches of the panel between the panel and the wall.
  • An embodiment of an insulated rainscreen panel can function as a single-sided rain screen and jig as illustrated in Figure 7.
  • FIG. 702 is attached to the wall 702, wherein the panel back corrugated surface forms rain screen spaces 703 in the back trenches of the panel between the panel and the wall.
  • An adhesive 706 and mortal 710 is shown bound or adhered to the front corrugated surface of the panel and a siding 708, such as brick.
  • a screw 712 can connect extend from the mortar 710, through the adhesive 706, through a washer 714, through the panel 704 into the wall 702.
  • Conventional rigid foam board insulation is often applied in layers to the outside of the walls of buildings, in order to lower the amount of heat loss through the walls.
  • the conventional foam layer can also act as a vapor barrier that can result in moisture being trapped inside walls, limiting the ability of the wall to dry out. Trapped moisture creates the potential for the growth of mold, such as black mold, and decay of the wall structure.
  • the conventional foam layer is thick enough, as may be required to provide sufficient insulation, it can act as a vapor barrier even if the foam is made of a moisture permeable material.
  • moisture moving outward through walls during the use of heaters can condense into liquid vapor/water on the inner surface of the foam board. Warm and humid climates also present challenges due to condensation of moisture inside walls.
  • Conventional exterior foam board insulation can also create critical issues for moisture control resulting from rain penetration into walls. Even with minor exterior rain penetration, a wall with conventional exterior foam may not ever dry out, and can remain sufficiently warm and humid to remain in the mold danger zone, even in the winter.
  • Conventional foam panels also may not include any indexing to indicate the placement of the units of building material, such as bricks, onto the panels. Conventional foam panels having flat surfaces and lips to guide the placement of building materials, such as bricks. Such conventional foam panels may not allow for sealant to be placed between the units of building material or between a unit of the building material and the form panel itself. This lack of sealant can result siding layers with weak attachments between siding units and week attachment to the panel.
  • Conventional foam panels may also not provide a way to use fasteners, such as screws and washers, to attach the panels directly to a wall surface, without significant risk of damaging of the foam panel. Even when a formed siding, such as plaster or cement, is also applied directly to the outer surface of foam board insulation, conventional foam panels may not allow for sufficient formed siding material to be placed between the foam panels and the structures used to reinforce plaster and cement, such as rebar.
  • conventional foam panels do not provide for the control or reduction of moisture within wall structures.
  • Conventional foam panels limit the amount of mortar that can be placed between units of siding and between the siding and the conventional foam panel, resulting in weakly attached siding.
  • Conventional panels do not guide the placement of fasteners and the panel can be damaged when trying to get screws to flush with the flat surface of the panel.
  • an insulated rainscreen provides a corrugated foam panel including a front corrugated surface and a back corrugated surface.
  • the corrugated surfaces can have ridges and trenches that can extend the panel length of the corrugated foam panel.
  • Such an insulated rainscreen can provide a benefit of forming rain screen spaces between the panel and surface on at least one side of the panel.
  • Such an embodiment can have a benefit of allowing moisture to flow away from or evaporate from the wall structure.
  • Such an embodiment of an insulated rainscreen can have a dual benefit of controlling or reducing moisture both between a wall surface and the insulated rainscreen, and between a building material and the insulated rainscreen while still providing adequate insulation for the material to satisfy modem building requirements.
  • Insulated rainscreens embodied herein can provide a benefit for the control of moisture within wall structures, while providing an improved surface for the attachment of building materials.
  • a back corrugated surface of the panel can be attached to a wall surface, where the trenches of the back corrugated surface can form rain screen spaces for the collection of and disposal of moisture.
  • a building material such as a siding can be adhered to a front corrugated surface of the panel.
  • a preformed siding, such as a brick or other material, can be adhered to the front corrugated surface using a sealant material.
  • Such an embodiment can provide for the placement of sealant into the front surface trenches, as well as around and on units of the siding material.
  • a benefit of such an embodiment can include allowing a sufficient amount of sealant to be placed both between and underneath units of the siding to allow a more robust seal to be formed between the units of the siding and between the siding and the front panel surface.
  • a formed siding material such as plaster or cement, can be adhered directly to the front corrugated surface of the panel.
  • a benefit of such an embodiment can included allowing a sufficient amount of formed siding material to be applied to the front corrugated surface to result in a stronger finished wall structure.
  • Another benefit of an embodiment of the insulated rainscreen panels embodied herein can include providing the recessed surface the front trenches that allow for fasteners, such as screws, washers, bolt, and nails, to be attached to the surface of the panel without damaging the panel or disputing the planarity of the siding material.
  • the fastener can also be surrounded by an adhesive, such as glue or mortar.
  • the screw holds the conventional foam panel to the wall and placed brick on to of the screws. This situation creates the problem that a heavy siding material, such as brick, is weakly adhered to the foam panel and the heavy siding material layer and foam layer are only held onto the wall by the cohesive strength of the foam material the fasteners are embedded in.
  • an embodiment of the insulated rainscreens embodied herein can allow for an adhesive, such as mortar, plaster, cement, to surround the head of a fastener.
  • an adhesive such as mortar, plaster, cement
  • This situation has the heavy siding layer, such as brick and mortar, connected by steel fasteners through the foam of the insulated rainscreens embodied and into the material of the wall. This creates the solution that the heavy siding layer is strongly bound to the wall and the insulated rainscreen panel.
  • the insulated rainscreen can include a front panel surface having a front corrugated surface, the front corrugated surface having front ridges and front trenches that extend from about 50% to 100% of the panel length of the corrugated foam panel, including about 80% to 100% of the panel length, including about 90% to 98% of the panel length based on a total length of the panel.
  • the ridges might be cut in a direction diagonal or perpendicular to the direction of the ridges to allow for water to pass from one rain screen space to another.
  • At least a portion of the front ridges can have flat or substantially flat front perches located on front tops of the front ridges, and at least one row of guide lips on top of the front ridges extending above the front perches, and where the rows of guide lips are arranged perpendicular or substantially perpendicular to the front ridges and front trenches.
  • a distance between rows of guide lips can be equal or substantially equal to a width of a siding.
  • a benefit of such an embodiment can include providing for indexed placement of units of siding onto the front corrugated surface.
  • Such an embodiment can additionally provide for the placement of sealant into the front trenches, as well as onto the front perches and onto the guide lips.
  • a benefit of such an embodiment can include allowing a sufficient amount of sealant to be placed both between units of the siding, such as bricks, and also underneath the units of siding, allowing an effective seal to be formed between the siding and the front panel surface.
  • the terms“front” and“back” are interchangeable.
  • the at least two panel edges having an interlocking shape both terminate with in a front ridge.
  • a benefit to having two panel edges having an interlocking shape terminate in a front ridge can be that panel are joined to from a rain screen space between them facing the wall. This feature reduces thermal loss and water retention at gaps between panels.
  • the “front” of the panel can be distinguished from the“back” by this presence of two panel edges having interlocking shapes terminate in front ridges. Where a panel having two panel edges having interlocking shapes terminate in one front ridge and one front trench, then the terms “front” and“back” as used herein may become arbitrary, as either side can be designate the “front” or“back.”
  • the insulated rainscreen includes a corrugated foam panel.
  • a corrugated foam panel can be formed from a rigid foam material, such as a Styrofoam material.
  • the corrugated foam panel can include a polystyrene foam or a polyisocyanurate foam.
  • the corrugated foam panel can include an expanded polystyrene (EPS) foam material, an extruded polystyrene (XPS) foam material, or combinations thereof.
  • EPS expanded polystyrene
  • XPS extruded polystyrene
  • from about 80% to 100% weight of a corrugated foam panel is a polystyrene foam material, based on a total weight of the corrugated foam panel.
  • a corrugated foam panel is a polystyrene foam material.
  • the polystyrene foam material has a weight per volume of about 1 pound per cubic foot, about 2 pounds per cubic foot, or about 3 pounds per cubic foot.
  • a corrugated foam panel is rectangular, and having a panel thickness from about 2.5 cm to about 30.5 cm. In an embodiment, the panel has a thickness from about 5.0 cm to about 25.0 cm. In an embodiment, the panel has a thickness from about 10.0 cm to about 15.0 cm. In an embodiment, the panel length is from about 1.2 meters to about 2.0 meters. In an
  • the panel length is from about 1.5 meters to about 1.7 meters.
  • the panel width is from about 1.2 meters to about 2.0 meters.
  • the panel length is from about 1.5 meters to about 1.7 meters.
  • front ridges of a corrugated foam panel have a height of from about 6 mm to about 13 mm, measured from a front ridge top to a front trench bottom. In an embodiment, the front ridges have a height of from about 8 mm to about 11mm, measured from a front ridge top to a front trench bottom. In an embodiment, the back ridges have a height of from about 6 mm to about 13 mm, measured from a back ridge top to a back trench bottom. In an embodiment, the back ridges have a height of from about 8 mm to about 11 mm, measured from a back ridge top to a back trench bottom.
  • the front ridges or the back ridges have a period center distance between them of from about 5 cm to about 8 cm. In an embodiment, the front ridges or the back ridges have a period center distance between them of from about 6 cm to about 7 cm. In an embodiment, a ridge period center distance of the front panel surface differs from 0 cm to about 8 cm from the ridge period center distance of the back-panel surface. In an embodiment, a ridge period center distance of the front panel surface differs from 0 cm to about 4 cm from the ridge period center distance of the back-panel surface.
  • a ridge period center distance of the front panel surface is aligned with a ridge period center distance of the back-panel surface by a percentage offset of from 0% to 99%. In an embodiment, a ridge period center distance of the front panel surface is aligned with a ridge period center distance of the back- panel surface by a percentage offset of from 40% to 60%.
  • an insulated rainscreen panel includes a first panel edge having a first interlocking shape, and a second panel edge having a second interlocking shape.
  • the first interlocking shape is complementary to the second interlocking shape.
  • the first interlocking shape and second interlocking shape are configured to allow for interlocking of a plurality of corrugated foam panels together.
  • a plurality of corrugated foam panels may be interlocked together to attach to an area of a wall surface.
  • the first interlocking shape protrudes from about 3 mm to about 13 mm from the second panel edge.
  • the first interlocking shape protrudes from about 6 mm to about 9 mm from the second panel edge.
  • the second interlocking shape protrudes from about 3 mm to about 13 mm from the second panel edge.
  • the second interlocking shape protrudes from about 6 mm to about 9 mm from the second panel edge.
  • an insulated rainscreen panel include that at least a portion of the front ridges of the corrugated front surface of the panel have flat or substantially flat front perches located on front tops of the front ridges. In an embodiment, at least a portion of the back ridges of the back corrugated surface have flat or substantially flat back perches located on back tops of the back ridges. In an embodiment, the front trenches and the back trenches have a flat or substantially flat bottom. In an embodiment, the front panel surface is complementary to the back-panel surface.
  • an insulated rainscreen panel include that the front corrugated surface of the panel has at least one row of guide lips on top of the front ridges that extend about the front perches, and wherein the at least one row of guide lips is arranged in rows that are perpendicular or substantially perpendicular to the front ridges and front trenches.
  • a height of the guide lip is from about 3 mm to about 13 mm, as measured from a top of the guide lip to an adjacent perch.
  • a height of the guide lip is from about 5 mm to about 12 mm, as measured from a top of the guide lip to an adjacent perch.
  • a height of the guide lip is from about 7 mm to about 10 mm, as measured from a top of the guide lip to an adjacent perch.
  • the perches have a length of about 5 cm to about 10 cm between rows of guide lips.
  • the perches have a length of about 6 cm to about 9 cm between rows of guide lips.
  • a distance between rows of guide lips is equal or substantially equal to a width of a siding.
  • the building material or siding includes a brick, a wood panel, or an aluminum panel.
  • the siding includes a plastic building material, or a tile material.
  • the brick includes standard brick, modular brick, norman brick, roman brick, jumbo brick, economy brick, engineer brick, king brick, queen brick, and utility brick.
  • Embodiments herein present methods of forming an insulated rain screen between a wall and a building material. Such methods may be practiced using the various embodiments of the insulated rainscreen panels disclosed herein.
  • a corrugated foam panel is provided, the corrugated foam panel including a panel length, a panel width, a panel thickness, a front panel surface, and back-panel surface, and at least two panel edges.
  • the front panel surface includes a front corrugated surface having front ridges and front trenches that extend the panel length of the corrugated foam panel
  • the back-panel surface includes a back corrugated surface having back ridges and back trenches that extend the panel length of the corrugated foam panel.
  • Such an embodiment can provide for attaching the corrugated foam panel to a wall with the back ridges and the back trenches of the back corrugated surface oriented perpendicular or substantially perpendicular to a floor.
  • Such an embodiment can include laying at least one building material against the front panel surface, and binding the at least one building material onto the front panel surface of the corrugated foam panel.
  • the building material can include a formed siding, including a plaster or a cement material.
  • the building material can include a preformed siding such as brick, a wood panel, or an aluminum panel.
  • the siding includes a plastic building material, or a tile material.
  • the brick includes standard brick, modular brick, norman brick, roman brick, jumbo brick, economy brick, engineer brick, king brick, queen brick, and utility brick.
  • a corrugated foam panel is attached to a wall surface.
  • the wall surface can include a concrete surface, a cinderblock surface, a wood surface, a plywood surface, an oriented strand board (OSB) surface, furring, studs, and combinations thereof.
  • OSB oriented strand board
  • the corrugated foam panel is attached to the wall by a fastener or an adhesive.
  • the fastener can include a cap nail, a screw, a screw and washer, and combinations thereof.
  • the adhesive can include a liquid adhesive, a tape adhesive, and combinations thereof. Such embodiments can provide a benefit of attaching a foam panel directly to a wall surface without breakage of the foam panel.
  • Embodiments herein present methods of making an insulated rainscreen panel.
  • One such embodiment provides extruding or molding a foam material to form a corrugated foam panel according to the various embodiments of insulated rainscreen panels herein.
  • Another such embodiment provides a block of foam material, and wire cutting the block of foam material to form a corrugated foam panel according to the various embodiments of insulated rainscreen panels herein.
  • the corrugated foam panel can be formed from a rigid foam material, such as a Styrofoam material.
  • the corrugated foam panel can include a polystyrene foam or a polyisocyanurate foam.
  • the corrugated foam panel can include an expanded polystyrene (EPS) foam material, an extruded polystyrene (XPS) foam material, or combinations thereof.
  • EPS expanded polystyrene
  • XPS extruded polystyrene
  • from about 80% to 100% weight of a corrugated foam panel is a polystyrene foam material, based on a total weight of the corrugated foam panel.
  • from about 90% to 100% weight of a corrugated foam panel is a polystyrene foam material.
  • the polystyrene foam material has a weight per volume of about 1 pound per cubic foot, about 2 pounds per cubic foot, or about 3 pounds per cubic foot.
  • a block of polystyrene foam was provided and wire cut into an insulated rainscreen panel having a front panel surface and a back-panel surface, both front and back panel surfaces including a corrugated surface.
  • the panel had an overall length of 96 inches (243.8 cm), a panel width of 48 inches (121.9 cm), and a panel thickness of 1 3 ⁇ 4 inches (4.5 cm).
  • the front corrugated surface was formed with front ridges and front trenches extending the panel length of the corrugated foam panel, the front ridges having a height of 3/8 inch (0.95 cm) measured from a front ridge top to a front trench bottom, and a period center distance between the front ridges of 2 inches (5.1 cm).
  • the panel had panel edges with an interlocking shape, the interlocking shape having a protrusion of 1 ⁇ 4 inch (0.64 cm) from the panel edge.
  • An insulated rainscreen panel was molded of polystyrene foam material into a corrugated panel having a front panel surface configured for the application of a modular brick, and a back-panel surface having a back corrugated surface with back ridges and back trenches extending the panel length of the corrugated foam panel.
  • the panel had an overall length of 47 3 ⁇ 4 (121.3 cm) inches, a panel width of 48 inches (121.9 cm), and a panel thickness of 1 1/8 inches (2.86 cm).
  • the front panel surface was formed with flat front perches and rows of guide lips, the front perches having a length of 2 5/8 inches (6.67 cm) between the rows of guide lips, and the guide lips having a height of 3/8 inch (0.95 cm), as measured from a top of a guide lip to an adjacent perch.
  • the panel had panel edges with an interlocking shape, the interlocking shape having a protrusion of 1 ⁇ 4 inch (0.64 cm) from the panel edge.
  • An insulated rainscreen panel was molded of polystyrene foam material into a corrugated panel having a front panel surface configured for the application of a king brick, and a back-panel surface having a back corrugated surface with back ridges and back trenches extending the panel length of the corrugated foam panel.
  • the panel had an overall length of 47 3 ⁇ 4 inches (121.3 cm), a panel width of 48 inches (121.9 cm), and a panel thickness of 1 3/8 inches (3.49 cm).
  • the front panel surface was formed with flat front perches and rows of guide lips, the front perches having a length of 3 3/16 inches (8.1 cm) between the rows of guide lips, and the guide lips having a height of 3/8 inch (0.95 cm), as measured from a top of a guide lip to an adjacent perch.
  • the panel had panel edges with an interlocking shape, the interlocking shape having a protrusion of 1 ⁇ 4 inch (0.64 cm) from the panel edge.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Finishing Walls (AREA)
  • Building Environments (AREA)

Abstract

L'invention concerne des panneaux d'écran pare-pluie isolés, ainsi que des procédés de fabrication et d'utilisation de ceux-ci. Un avantage des panneaux d'écran pare- pluie isolés peut être un écran pare-pluie isolant avec des propriétés de régulation de l'humidité entre une paroi et un matériau de construction.
PCT/US2020/031845 2019-05-10 2020-05-07 Panneaux d'écran pare-pluie isolés et leurs procédés de fabrication et d'utilisation WO2020231735A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201962846495P 2019-05-10 2019-05-10
US62/846,495 2019-05-10

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WO2020231735A1 true WO2020231735A1 (fr) 2020-11-19

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Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3563038A (en) * 1969-04-03 1971-02-16 Research Corp Subterranean drain
US3867800A (en) * 1973-01-22 1975-02-25 Gazelle Systems Ltd Precast rain-screen wall
US5765329A (en) * 1993-06-28 1998-06-16 Huang; Chihshu Roof construction of corrugated sheets
US6584740B2 (en) * 1999-07-23 2003-07-01 Leading Edge Earth Products, Inc. Frameless building system
US20050055983A1 (en) * 2003-09-11 2005-03-17 Clear Family Limited Partnership Of C/O Dale Lierman, Esq. Wall cavity drain panel
US7367165B2 (en) * 2004-04-01 2008-05-06 Michael Hatzinikolas Moisture control strip
US7698858B2 (en) * 2003-11-10 2010-04-20 Ewald Dörken Ag Membrane for the protection of buildings
US8555581B2 (en) * 2011-06-21 2013-10-15 Victor Amend Exterior wall finishing arrangement
US9010050B2 (en) * 2009-05-15 2015-04-21 Michael Hatzinikolas Pre-cast rain screen wall panel
US20180305921A1 (en) * 2017-04-24 2018-10-25 Ayo-Ap Corporation Water draining spandrel assembly and insulated panel window walls

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3563038A (en) * 1969-04-03 1971-02-16 Research Corp Subterranean drain
US3867800A (en) * 1973-01-22 1975-02-25 Gazelle Systems Ltd Precast rain-screen wall
US5765329A (en) * 1993-06-28 1998-06-16 Huang; Chihshu Roof construction of corrugated sheets
US6584740B2 (en) * 1999-07-23 2003-07-01 Leading Edge Earth Products, Inc. Frameless building system
US20050055983A1 (en) * 2003-09-11 2005-03-17 Clear Family Limited Partnership Of C/O Dale Lierman, Esq. Wall cavity drain panel
US7698858B2 (en) * 2003-11-10 2010-04-20 Ewald Dörken Ag Membrane for the protection of buildings
US7367165B2 (en) * 2004-04-01 2008-05-06 Michael Hatzinikolas Moisture control strip
US9010050B2 (en) * 2009-05-15 2015-04-21 Michael Hatzinikolas Pre-cast rain screen wall panel
US8555581B2 (en) * 2011-06-21 2013-10-15 Victor Amend Exterior wall finishing arrangement
US20180305921A1 (en) * 2017-04-24 2018-10-25 Ayo-Ap Corporation Water draining spandrel assembly and insulated panel window walls

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