BUILDING PANEL

PANNEAU DE CONSTRUCTION

English Abstract

A building panel is provided for affixing to above-grade exterior building surfaces, the building panel comprising: opposed front and back sides generally parallel to each other; opposed top and bottom edges generally parallel to each other; a generally horizontal groove in the top edge spaced from the front and back sides; and at least one generally vertical channel extending downwardly from the generally horizontal groove through the building panel to the bottom edge at a point on the bottom edge spaced from the front and back sides. The building panel is preferably for thermal insulation and for collection and drainage of moisture from water vapour, and is preferably used in conjunction with exterior insulated finish systems.

French Abstract

Description d'un panneau de construction conçu pour être fixé sur des surfaces d'immeuble extérieures au-dessus du sol. Il comporte des côtés avant et arrière opposés généralement parallèles l'un à l'autre, des bords supérieur et inférieur généralement parallèles l'un à l'autre, une rainure généralement horizontale dans le bord supérieur séparée des côtés avant et arrière, et au moins un canal généralement vertical s'étendant vers le bas à partir de la rainure généralement horizontale dans le panneau de construction jusqu'au bord inférieur à un emplacement sur le bord inférieur séparé des côtés avant et arrière. Le panneau de construction est préférablement conçu pour l'isolation thermique et pour l'absorption et l'évacuation de l'humidité de la vapeur d'eau et est employé de préférence avec des systèmes de finition et d'isolation extérieurs.

Claims

10
CLAIMS:
1. An insulated building panel far affixing to exterior building
surfaces in rows of the panels side by side and top to bottom to form an array
of the
panels, the building panel comprising:
a panel body formed of a single layer of an insulating foam material,
the panel body having:
opposed front and back surfaces of the foam material generally
parallel to each other;
opposed top and bottom horizontal sides of the foam material
arranged for butting engagement with other similar panel bodies;
opposed left and right vertical sides of the foam material
arranged for butting engagement with other similar panel bodies;
the panel body having therein a plurality of conduits for transmission of
water vapour through the array of panel bodies including at least one
generally
horizontal conduit spaced from the front and back surfaces of the foam
material;
and a series of transversely spaced generally vertical conduits, forming
a plurality greater than two, spaced from the front and back surfaces of the
foam
material, at least one of which is spaced from the left and right vertical
sides of the
foam material so as to extend through the panel body of the foam material;
wherein the at least one horizontal conduit is deferred by a groove
located at one of the horizontal sides.
2. An insulated building panel for affixing to exterior building

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surfaces in rows of the panels side by side and top to bottom to form an array
of the
panels, the building panel comprising:
a panel body formed of a single layer of an insulating foam material,
the panel body having:
opposed front and bade surfaces of the foam material generally
parallel to each other;
opposed top and bottom horizontal sides of the foam material
arranged for butting engagement with other similar panel bodies;
opposed left and right vertical sides of the foam material
arranged for butting engagement with other similar panel bodies;
the panel body having therein a plurality of conduits for transmission of
water vapour through the array of panel bodies including at least one
generally
horizontal conduit spaced from the front and back surfaces of the foam
material;
and a series of transversely spaced generally vertical conduits, forming
a plurality greater than two, spaced from the front and back surfaces of the
foam
material, at least one of which is spaced from the left and right vertical
sides of the
foam material so as to extend through the panel body of the foam material;
wherein the at least one horizontal conduit is defined by a groove
located at one of the horizontal sides and which has an open mouth at the side
and
converges inwardly toward an apex as it extends into the panel body.
3. The building panel of Claim 9 or 2 wherein the groove is V-
shaped in cross section.
4. The building panel of any one of Claims 1 to 3 wherein the

12
vertical channels are rectangular in cross section.
5. The building panel of any one of Claims 1 to 4 wherein the
vertical channels are formed by molding such that they are free from a wire
cut
connection to an external surface of the panel body.
6. An insulated cladding system affixed to an exterior building
surface comprising:
a plurality of insulated building panels affixed in rows of the panels side
by side and top to bottom to form an array of the panels defining an exterior
surface;
one or more exterior coating layers applied over the exterior surfaces
of the panels to form an exterior finish of the building;
each building panel comprising a panel body formed of a single layer
of an insulating foam material, the panel body having:
opposed front and back surfaces of the foam material generally
parallel to each other;
opposed top and bottom horizontal sides of the foam material
arranged for butting engagement with other similar panel bodies;
opposed left and right vertical sides of the foam material
arranged for butting engagement with other similar panel bodies;
the panel body having therein a plurality of conduits for transmission of
water vapour through the array of panel bodies including at least one
generally
horizontal conduit spaced from the front and back surfaces of the foam
material;
and a series of transversely spaced generally vertical conduits, forming

13
a plurality greater than two, spaced from the front and back surfaces of the
foam
material, at least one of which is spaced from the left and right vertical
sides of the
foam material so as to extend through the panel body of the foam material;
wherein the at least one horizontal conduit is defined by a groove
located at one of the horizontal sides.
7, An insulated cladding system affixed to an exterior building
surface comprising:
a plurality of insulated building panels affixed in rows of the panels side
by side and tap to bottom to form art array of the panels defining an exterior
surface;
one or more exterior coating layers applied aver the exterior surfaces
of the panels to form an exterior finish of the building;
each building panel comprising a panel body formed of a single layer
of an insulating foam material, the panel body having:
opposed front and back surfaces of the foam material generally
parallel to each other;
opposed tap and bottom horizontal sides of the foam material
arranged far butting engagement with other similar panel bodies;
opposed left and right vertical sides of the foam material
arranged for butting engagement with other similar panel bodies;
the panel body having therein a plurality of conduits for transmission of
water vapour through the array of panel bodies including at least one
generally
horizontal conduit spaced from the front and back surfaces of the foam
material;

14
and a series of transversely spaced generally vertical conduits, forming
a plurality greater than two, spaced from the front and back surfaces of the
foam
material, at least one of which is spaced from the left and right vertical
sides of the
foam material so as to extend through the panel body of the foam material;
wherein the at least one horizontal conduit is defined by a groove
located at one of the horizontal sides and which has an apes mouth at the side
and
converges inwardly toward an apex as it extends into the panel body.
8. The system of Claim 6 or 7 wherein the groove is V-shaped in
cross section.
9. The system of any one of Claims 6 to 8 wherein the vertical
channels are rectangular in cross section.
10. The system of any one of Claims 6 to 9 wherein the vertical
channels are formed by molding such that they are free from a wire cut
connection
to an external surface of the panel body.

Description

CA 02455438 2004-11-25
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BUILDING PANEL
FIELD OF THE INVENTION
The present invention relates to building panels, and more particularly
to building panels including a conduit system for transmission of water vapor.
BACKGROUND OF THE INVENTION
In the context of exterior building panels, the presence of moisture can
lead to undesirable results. Moisture that becomes trapped within and between
panels can generate rot in the substrate to which the panel is affixed, it can
bleed
through the panel finishing coat and discolour it, and it can even cause the
panel to
detach from the substrate.
Prior attempts to address this problem include Canadian Patent
1,220,041 to Larsson, which teaches a panel having drainage channels for use
with
subterranean wall surfaces. The channels communicate directly with the
subterranean wall surface, as the channels are intended to direct water
accumulation on the concrete surface away from that concrete surface. United
States Patent 6,318,041 to Stanley discloses a panel system that also employs
drainage channels or conduits.
While various attempts have been made to address the problem of
moisture in a variety of building panel contexts, a need has been felt for an
improved
means of addressing the problem in the specific context of Exterior Insulated
Finish
System (EIFS) technology. The EIFS system, developed in Europe in the 1950s,
uses multi-layered exterior wall systems for both commercial and residential
buildings, and it typically consists of an interior insulation board secured
to the

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exterior wall surface, a reinforced base coat applied to the insulation board,
and a
finish coat that is both visually attractive and resistant to environmental
impact. The
superior energy efficiency and design flexibility of the EIFS system have
resulted in
growing popularity, but the presence of moisture remains a vexing problem.
SUMMARY OF THE INVENTION
According to one aspect of the present invention there is provided an
insulated building panel for affixing to exterior building surfaces in rows of
the panels
side by side and top to bottom to form an array of the panels, the building
panel
comprising:
a panel body formed of an insulating foam material, the panel body
having:
opposed front and back surfaces generally parallel to each other;
opposed top and bottom horizontal sides arranged for butting
engagement with other similar panel bodies;
opposed left and right vertical sides arranged for butting engagement
with other similar panel bodies;
the panel body having therein a plurality of conduits for transmission of
water vapour through the array of panel bodies including at least one
generally
horizontal conduit spaced from the front and back surfaces; and a series of
transversely spaced generally vertical conduits, forming a plurality greater
than two,
spaced from the front and back surfaces;
wherein the at least one horizontal conduit is defined by a groove

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located at one of the horizontal sides.
According to a fourth aspect of the invention there is provided an
insulated building panel for affixing to exterior building surfaces in rows of
the panels
side by side and top to bottom to form an array of the panels, the building
panel
comprising:
a panel body formed of an insulating foam material, the panel body
having:
opposed front and back surfaces generally parallel to each other;
opposed top and bottom horizontal sides arranged for butting
engagement with other similar panel bodies;
opposed left and right vertical sides arranged for butting engagement
with other similar panel bodies;
the panel body having therein a plurality of conduits for transmission of
water vapour through the array of panel bodies including at least one
generally
horizontal conduit spaced from the front and back surfaces; and a series of
transversely spaced generally vertical conduits, forming a plurality greater
than two,
spaced from the front and back surfaces;
wherein the at least one horizontal conduit is defined by a groove
located at one of the horizontal sides and which has an open mouth at the side
and
converges inwardly toward an apex as it extends into the panel body.
According to a third aspect of the invention there is provided an
insulated cladding system affixed to an exterior building surtace comprising:

CA 02455438 2004-11-25
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a plurality of insulated building panels affixed in rows of the panels side
by side and top to bottom to form an array of the panels defining an exterior
surface;
one or more exterior coating layers applied over the exterior surfaces
of the panels to form an exterior finish of the building;
each building panel comprising a panel body formed of an insulating
foam material, the panel body having:
opposed front and back surfaces generally parallel to each other;
opposed top and bottom horizontal sides arranged for butting
engagement with other similar panel bodies;
opposed left and right vertical sides arranged for butting engagement
with other similar panel bodies;
the panel body having therein a plurality of conduits for transmission of
water vapour through the array of panel bodies including at least one
generally
horizontal conduit spaced from the front and back surfaces; and a series of
transversely spaced generally vertical conduits, forming a plurality greater
than two,
spaced from the front and back surfaces;
wherein the at least one horizontal conduit is defined by a groove
located at one of the horizontal sides.
According to a fourth aspect of the invention there is provided an
insulated cladding system affixed to an exterior building surface comprising:
a plurality of insulated building panels affixed in rows of the panels side
by side and top to bottom to form an array of the panels defining an exterior
surface;

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one or more exterior coating layers applied over the exterior surfaces
of the panels to form an exterior finish of the building;
each building panel comprising a panel body formed of an insulating
foam material, the panel body having:
opposed front and back surfaces generally parallel to each other;
opposed top and bottom horizontal sides arranged for butting
engagement with other similar panel bodies;
opposed left and right vertical sides arranged for butting engagement
with other similar panel bodies;
the panel body having therein a plurality of conduits for transmission of
water vapour through the array of panel bodies including at least one
generally
horizontal conduit spaced from the front and back surfaces; and a series of
transversely spaced generally vertical conduits, forming a plurality greater
than two,
spaced from the front and back surfaces;
wherein the at least one horizontal conduit is defined by a groove
located at one of the horizontal sides and which has an open mouth at the side
and
converges inwardly toward an apex as it extends into the panel body.
In exemplary embodiments of the present invention, the building panel
is for thermal insulation and for collection and drainage of moisture from
water
vapour, and the building panel is made of expanded polystyrene or
polyisocyanurate. The generally horizontal groove is preferably V-shaped in
cross
section and configured to facilitate lateral movement of moisture from water
vapour

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to the at least one generally vertical channel for downward flow of the
moisture
through the at least one generally vertical channel, and the at least one
generally
vertical channel is preferably rectangular in cross section. The building
panel is
preferably of unitary, shape-moulded construction.
By providing a building panel that can both insulate and efficiently
direct moisture from water vapour away from the panels and underlying
substrate,
while serving the need for an even surface for application of the base and
finish
coats, the present invention is intended to address a pressing need in the
industry.
A detailed description of an exemplary embodiment of the present
invention is given in the following. It is to be understood, however, that the
invention
is not to be construed as limited to this embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings, which illustrate an exemplary
embodiment of the present invention:
Figure 1 is a side cross section along line I-I in Figure 2 of an in situ
assembly of building panels according to the present invention.
Figure 2 is a front elevation of the assembly of Figure 1.
Figure 3 is a plan view of a building panel according to the present
invention.
DETAILED DESCRIPTION OF AN EXEMPLARY EMBODIMENT
Referring now in detail to the accompanying drawings, and particularly
to Figures 1 and 2, there is illustrated an assembly of building panels
according to
the present invention, each panel being referred to generally by the numeral
10.

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_7_
The building panel 10 comprises opposed front and back sides 14, 16 generally
parallel to each other and opposed top and bottom edges 18, 20 generally
parallel to
each other. Conduits for transportation of water vapor are provided in the
panel
including a generally horizontal V-shaped groove 22 in the top edge 18 spaced
from
the front and back sides 14, 16, and generally vertical channels 24 extending
downwardly from the groove 22 though the building panel 10 to the bottom edge
20
at a point on the bottom edge 20 spaced from the front and back sides 14, 16.
Thus
the V-shaped groove is located at the surface and has an open mouth at the
surface
and converges inwardly and downwardly into the panel body to an apex. While
Figure 2 shows the channels 24 only in the centrally positioned building panel
10,
the channels 24 are also in each of the adjacent building panels 10. The
building
panel 10 is of a unitary, shape-moulded construction, an advantage over
traditional
wire-cut construction since the vertical channels are free from the necessary
wire cut
entry slot from an adjacent surface of the panel.
As can be seen in Figure 1, the back side 16 of the building panel 10 is
affixed to trowel-on membrane 26 is applied to an exterior surface 12 of a
building
13 as an air/vapour barrier by an adhesive 28. In the illustrated embodiment
the
adhesive 28 is applied as a layer prior to positioning of the building panel
10.
The utility of the present invention becomes clear in the following
situation. When it is determined that a particular exterior building surface
12 is
suitable for application of the building panels 10 (suitable substrates
including but
not limited to exterior grade drywall, cement board, plywood sheathing, Dens-
Glass
sheathing, precast concrete, concrete block, or poured-in-place concrete). An

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air/vapour barrier membrane 26 is applied to the exterior building surface 12,
preferably as a trowel-on layer. An adhesive 28 is then applied on top of the
membrane 26, and a reinforcing mesh (not shown) such as glass fabric
reinforcing
mesh is embedded in the adhesive 28. The building panels 10 are then applied
over
this adhesive layer 28 and secured in place thereby. For a building of four
stories or
greater it is advisable to use mechanical fasteners as well to secure the
panels to
the exterior building surface 12. The building panels 10 are preferably
arranged in
the offset pattern shown in Figure 2, a pattern well known in the art. The
joints
between the building panels 10 should be sealed with a suitable material (not
shown) known to those skilled in the art to further enhance the insulating
properties
of the building panels 10. Various methods of providing base and finishing
coats
(not shown) are then possible, according to the general knowledge of those
skilled in
the art of EIFS use. With the building panels 10 now in place on the exterior
building
surface 12 and finished in a suitable manner, the groove 22 is now configured
to
facilitate lateral movement of moisture from water vapour to the channels 24
for
downward flow of the water vapor through the channels 24. Water vapor can flow
horizontally through a groove 22 and into adjacent grooves 22 as necessary,
while
the channels 24 then provide vertical conduits for the water vapor flowing
through
the grooves 22.
While a particular embodiment of the present invention has been
described in the foregoing, it is to be understood that other embodiments are
possible within the scope of the invention and are intended to be included
herein.
Thus, while the embodiment illustrated in Figures 2 and 3 includes fifteen
equally-

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_g_
spaced channels 24 per building panel 10, but it may be preferable to have
nineteen
or some other number of channels 24 depending on the application. While
particular substrates have been identified in the foregoing, it is to be
understood that
the application of the panel to any substrate is to be considered within the
scope of
the invention. Currently it is considered that the invention may not be
especially
useful with certain types of substrate, including oriented strand board and
chipboards. It will therefore be clear to those skilled in the art that
modifications of
and adjustments to this invention, not shown, are possible without departing
from the
spirit of the invention as demonstrated through the exemplary embodiment. The
invention is therefore to be considered limited solely by the scope of the
appended
claims.

Representative Drawing