Building panels are often used to provide functional and/or aesthetic features to a building façade. One example of a panel-based façade cladding is an Exterior Insulation and Finish System (EIFS). As defined by the International Building Code and ASTM International, an EIFS is a non-load bearing, exterior wall cladding system that is formed from insulation boards or panels attached to an exterior substrate (e.g., building wall); an integrally reinforced base coat; and a textured protective finish coat. EIFS structures may be used to provide a weather resistant, seamless, insulated finish to a residence or commercial building.
In an exemplary embodiment of the present disclosure, an insulative panel includes a panel body having opposed front and rear surfaces extending between first and second lateral edges and between first and second longitudinal edges, with a plurality of recessed drainage channels formed in the rear surface and extending from the first longitudinal edge to the second longitudinal edge.
In another exemplary embodiment of the present disclosure, an insulative panel includes a panel body having opposed front and rear surfaces extending between first and second lateral edges and between first and second longitudinal edges, and a plurality of elongated rigid struts secured to the rear surface of the panel body, with end portions extending beyond the first and second longitudinal edges of the panel body for fastening to a building substrate.
In another exemplary embodiment of the present disclosure, an insulative panel includes a panel body having opposed front and rear surfaces extending between first and second lateral edges and between first and second longitudinal edges, and a reinforcing material secured to the front surface of the panel body. The front surface of the panel body comprises a textured surface defining raised portions and recessed portions. The reinforcement material is adhered to the raised portions of the textured surface, and a basecoat is disposed over the reinforcement material and between the reinforcement material and the recessed portions of the textured surface to at least partially encapsulate the reinforcement material in the basecoat.
In another exemplary embodiment of the present disclosure, a method of installing an exterior insulation and finish system is contemplated. In the exemplary method, an insulative panel is provided having a panel body having opposed front and rear surfaces extending between first and second lateral edges and between first and second longitudinal edges, with a plurality of recessed drainage channels formed in the rear surface and extending from the first longitudinal edge to the second longitudinal edge. The rear surface of the panel body is secured to an exterior surface of a building structure using one or more non-drying/curing attachment arrangements.
In another exemplary embodiment of the present disclosure, a method of installing an exterior insulation and finish system is contemplated. In the exemplary method, an insulative panel is provided having a panel body having opposed front and rear surfaces extending between first and second lateral edges and between first and second longitudinal edges, and a plurality of elongated rigid struts secured to the rear surface of the panel body, with end portions extending beyond the first and second longitudinal edges of the panel body. The end portions of the plurality of elongated rigid struts are fastened to a building substrate.
In another exemplary embodiment of the present disclosure, a method of fabricating an insulative panel is contemplated. In the exemplary method, a panel body is provided having opposed front and rear surfaces extending between first and second lateral edges and between first and second longitudinal edges, the front surface comprising a textured surface defining raised portions and recessed portions. A reinforcing material is adhered to the raised portions of the textured surface. A liquid basecoat is applied to the front surface of the panel body, such that the basecoat is disposed over the reinforcement material and between the reinforcement material and the recessed portions of the textured surface to at least partially encapsulate the reinforcement material in the basecoat.
Further features and advantages of the invention will become apparent from the following detailed description made with reference to the accompanying drawings, wherein:
This Detailed Description merely describes exemplary embodiments and is not intended to limit the scope of the claims in any way. Indeed, the invention as claimed is broader than and unlimited by the described embodiments, and the terms used have their full ordinary meaning. For example, while certain exemplary features presented in the present disclosure are described and/or shown as being used with building panels for an Exterior Insulation and Finish System (EIFS), any one or more of the features described herein may be utilized with or incorporated into other types of building façade cladding, including, for example, continuous insulation (CI) panels.
In conventional EIFS applications, as shown in
According to an exemplary aspect of the present disclosure, an EIFS arrangement may be adapted or configured to eliminate one or more conventional EIFS installation steps, for example, to reduce the time for installation and/or the amount of skilled labor required for installation.
In one such exemplary arrangement, an insulative panel for an EIFS arrangement may be provided with a panel body of insulation material (e.g., foam) having a rear surface having one or more recessed channels for providing drainage of moisture disposed between the panel and the air/weather barrier. Such an arrangement may replace the conventional notched adhesive defining drainage channels and may provide for consistent drainage space without reliance on proper application of a notched adhesive by the installer. These recessed channels may be formed in the insulative panel, for example, by sawing, molding, embossing, and/or hotwire cutting.
While the recessed channels may extend in a parallel, vertical direction to provide desired drainage, in some embodiments, the rear surface of the panel body may also be provided with crossing channels (e.g., horizontal or at an angle between vertical and horizontal), for example, to provide for cross-flow drainage (e.g., in the event that one of the vertical channels is blocked or impeded), or to allow for installation of the panel in a 90-degree rotated orientation (e.g., with “vertical” channels extending horizontally and cross-channels extending vertically).
Other types and shapes of drainage recesses may additionally or alternatively be provided in the rear surface of the panel body, including, for example, diagonally extending recesses, or spaced-apart raised features (e.g., diamonds, circles, rectangles, or any other suitable shape) defining surrounding channels. The drainage channels may be provided with a variety of depths, including, for example, at least 1 mm, at least 2 mm, or at least 10 mm channel depth, and may be provided with a variety of channel widths, including, for example at least 5 mm, at least 15 mm, or at least 25 mm, or any other depth and width dimensions as may be desired for drainage efficiency or required by jurisdictional compliance. The illustrated embodiments of
With drainage channels formed in the insulative panel, and not by notched adhesive applied between the panel and the air/weather barrier, other arrangements for fastening the panel to the air/weather barrier may be utilized, including, for example, fastening arrangement that do not require significant curing/drying time for a field applied adhesive. For example, the non-recessed portions of the rear surface 13, 13′ of the panel body 11, 11′ may be provided with a pre-applied pressure sensitive adhesive 18, 18′ (e.g., acrylic transfer adhesives, butyl rubber adhesives, or other pressure sensitive adhesive materials) for attachment of the insulative panel to the wall/structure. In some such embodiments, one or more disposable liners may be provided over the pressure sensitive adhesive. In other embodiments, a front surface of the air/weather barrier (e.g., an air barrier membrane) may be provided with a pre-applied pressure sensitive adhesive (e.g., acrylic transfer adhesives, butyl rubber adhesives, or other pressure sensitive adhesive materials) for attachment of the non-recessed portions of the panel rear surface to the wall/structure.
In still other embodiments, the insulative panel(s) may additionally or alternatively be secured to the wall/structure by one or more mechanical fasteners, including, for example, threaded fasteners (e.g., bolts, screws) installed through apertures in the panel bodies, and/or rigid struts (e.g., steel, aluminum, rigid plastic, such as polypropylene) secured to the panel bodies and attachable by mechanical fasteners (e.g., nails, screws, staples) to the wall/structure. In some such embodiments, the insulative panel may be initially (e.g., less securely) fastened to the wall/structure by a pressure sensitive adhesive, with the pressure sensitive adhesive facilitating positioning of the panel on the wall while more securely attaching the panel to the wall using mechanical fasteners. These attachment arrangements may be selected and configured to meet desired EIFS/ASTM performance standards, such as, for example, ASTM E2568, Standard Specification for PB Exterior Insulation and Finish Systems.
As shown in
In other embodiments, mounting struts may be provided with a snap fit (e.g., elastically biased or resilient) rib or projection configured to snap into a corresponding groove in the panel body. As shown in
While the struts are shown as extending vertically, in other embodiments, the panel may be provided with horizontally extending struts or struts extending at some other angle.
In other embodiments, a panel may utilize two or more fastening arrangements, including, for example, two or more of the fastening arrangements described herein (e.g., pressure sensitive adhesive, mounting struts, through-fasteners, wet adhesive) to securely attach the panels.
According to another exemplary aspect of the present disclosure, insulative panels for an EIFS arrangement may be provided with edge portions having one or more interlocking or alignment features for aligned engagement with adjacent insulative panels during installation. As one example, as shown in
According to another exemplary aspect of the present disclosure, insulative panels for an EIFS arrangement may be provided with edge portions having outward tapered front surfaces defining a recessed front surfaces at the adjoining edges of adjacent installed panels. These recessed adjoining edge portions may facilitate application of a reinforcing material (e.g., overlapping mesh) along the adjoining edges of the insulative panels, for example, for fire testing or impact resistance performance, while eliminating or minimizing protrusion of these reinforcement materials, making it easier to provide a planar front surface when an architectural coating (e.g., basecoat and/or finishing coatings) are applied.
According to another exemplary aspect of the present disclosure, a reinforcing material 14a, 24a, 34a (
According to another exemplary aspect of the present disclosure, as shown in
The insulative panels described herein may be formed from a variety of suitable materials, including, for example, expanded polystyrene (EPS) foam, extruded polystyrene (XPS) foam, polyurethane (PU) foam, and mineral wool. Insulative materials and panel thickness (e.g., between 1 and 12 inches) may be selected, for example, to provide a desired insulating R-value (e.g., an R-value of at least about R-4/inch nominal for a system between 1 and 12 inches thick), and/or based on other factors (e.g., cost, weight, inflammability, impact resistance). In some embodiments the panel material may include one or more additive materials, such as, for example, graphite, silicone, glass, or other such additive materials, for example, to provide enhanced properties, such as enhanced insulation (e.g., increased R-value), increased fire resistance, etc.
According to another exemplary aspect of the present disclosure, an insulative panel having one or more adapted front and/or rear features (e.g., one or more of the adapted features described herein) may be fabricated using a base panel element providing a desired material and thickness, and one or both of a rear facer element and a front facer element carrying the one or more adapted features. For example, as shown in
In an exemplary method of installing an insulative building wall cladding, a drainage channel defining rear surface of an insulative panel is secured to an exterior surface of a wall/structure (e.g., to an air/weather barrier applied to the wall/structure) using one or more non-drying/curing attachment arrangements (e.g., pressure sensitive adhesive and/or mechanical fasteners).
While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions—such as alternative materials, structures, configurations, methods, devices and components, alternatives as to form, fit and function, and so on—may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure, however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Parameters identified as “approximate” or “about” a specified value are intended to include both the specified value and values within 10% of the specified value, unless expressly stated otherwise. Further, it is to be understood that the drawings accompanying the present disclosure may, but need not, be to scale, and therefore may be understood as teaching various ratios and proportions evident in the drawings. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention, the inventions instead being set forth in the appended claims. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.
This application claims priority to and all benefit of U.S. Provisional Patent Application Ser. No. 63/440,491, filed on Jan. 23, 2023, for MULTIFUNCTIONAL EXTERIOR INSULATION AND FINISH SYSTEM STRUCTURES, the entire disclosure of which is incorporated herein by reference.
Number | Date | Country | |
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63440491 | Jan 2023 | US |