PANNEAU DE CONSTRUCTION EXTERIEUR ISOLE EMBREVE EN PIERRE ET POLYMERE

POLYMER-STONE INTERLOCKING INSULATING EXTERIOR BUILDING PANEL

Abrégé anglais

A polygonal configured building panel that consists of a expandable
foam insulation, a front facing and a metal backing. The front facing consists
of a mixture of polymer resin and stone or stone-like material which is
reinforced with a fibre reinforcing mesh. The above components are used to
define two adjacent projecting edges that are made to adapt to two adjacent
complimentary cavities from an adjoining panel. A metal backing is used to
provide the panel with strength. The backing also gives the panel the ability
to
be secure to an exterior building surface without the use for brackets or
clips.
The expandable foam insulation adheres to both the polymer-stone facing and
the metal backing. Additional polymer resin and stone granules are placed on
the exterior facade of the panel in order to improve the appearance and
provide
a greater resistance to impact.

Revendications

THE EMBODIMENTS OF THE INVENTION IN WHICH AN
EXCLUSIVE PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED
AS FOLLOWS:
1. A method of constructing a prefabricated lightweight insulating and
weather resistant exterior wall panel which is adapted for assembly with
similar panels. The panel is fabricated using a moulded surface into which a
facing composition of a polymer resin and stone granules is mixed and poured
into, with said facing having a thickness in the range of 1/8 inch to 1/2
inch. A
fiber reinforcing mesh is placed on top of and secured into said polymer-stone
composition facing. Metal backing is placed on top of the mould after which
the mould is injected with an expandable foam insulating material. The panel
is removed from the mould with the polymer-stone facing composition,
insulating material and backing securely intact to one another. The exterior
facade of the panel with have a smooth and glossy finish at which point it may
be coated with additional polymer resin onto which stone granules are secured
into.
2. A method according to claim 1, wherein said moulded surface shall have a
polygonal configuration of a rectangular or square shape.
3. A method according to claim 1, wherein said moulded surface shall have
at least one pair of adjacent sides defining projecting edges and the other
two
adjacent sides defining complimentary cavities for receiving said projecting
edges of an adjacent panel.
4. A method according to claim 1, wherein said moulded surface shall have a
pattern or design that shall become the exterior cladding of the building
facade.
5. A method according to claim 1, wherein said polymer resin comprises any
polymer type compound.
6. A method according to claim 1, wherein said stone granules comprises of
any stone or stone like material.

7. A method according to claim 1, wherein said reinforcing mesh is a fibre
reinforcing mesh.
8. A method according to claim 1, wherein said metal backing is extended
approximately 1 inches on the horizontal and vertical axis of the two adjacent
sides containing the complimentary cavities.
9. A method according to claim 7, wherein said metal backing will
permanently adhere to said expandable foam insulating material.
10. A method according to claim 1, wherein said expandable foam insulating
material is polyurethane or polystyrene.

Description

CA 02321445 2000-09-29
Polymer-Stone Interlocking Insulating Exterior Building Panel
Background of the Invention
There are various types of Exterior Insulating Finishing Systems
currently being used. These systems are reasonably priced and are able to
insulate the building exterior as they cover. These systems do however require
expert installation, under ideal conditions. There have been many stories of
poor installation and subsequent failures have proven to be quite expensive.
Another difficulty that the systems have incurred is the fact that they are
applied directly to the building exterior and therefore do not provide for air
and
moisture escape situations.
This invention does have many of the advantages of usual Exterior
Insulating Finishing System however it is the purpose of the invention to
provide for a much more improved concept and design.
As with many EIFS, it is an objective of the invention to be able to
insulate the building exterior while at the same time cover the building
facade.
The panel is prefabricated under ideal conditions and is brought to the
building site for installation. Both the production and installation of the
panels
are relatively simple and therefore another objective of the invention would
be
that it does not require experts to both produce and install.
As previously mentioned, the panel is prefabricated under ideal
conditions and therefore is able to be installed under various weather
conditions, year round.
The panel also provides for several rainscreen advantages. During the
installation process of the panel, Earrings are used to provide for an air
cavity
between the wall and the building panel. The cavity creates an equal air
pressure between the inside and outside of the wall and therefore gives a
lesser
chance of moisture penetration and a greater chance of moisture escape.

CA 02321445 2000-09-29
Furrings also give the panel a place that a screw may be used to secure
to building structure. The advantage that the screws possess is that it gives
the
wall the ability to shift according to the building structure and weather
conditions without any cracking or loss of adherence.
Another rainscreen advantage is the ability to lock adjoining panels to
each other with a dry joint. 'The dry joint permits air flow into the cavity
while
still impeding water penetration. The locking system also serves as a drainage
for any water that may penetrate the outer facade.
The metal backing provides the panel and wall structure with additional
strength and protection while eliminating the requirement of installing a
sheathing to an exterior building surface. Another advantage that the backing
presents is that it provides the panel with the ability to be secure to an
exterior
surface wall without the need for additional clips or tools.
The insulating material used provides a substantial amount of insulation
protection. The thickness and strength density is able to be controlled to
precise degrees and may therefore be customized according to requirements.
Another advantage to the panel is the exterior facing used. The polymer
compound and stone composition provides for a very highly weather and
impact resistant panel. The facing composition is also impervious to moisture
and resists various types of vandalism.
The stone granules also provides for multiple types of styles and
designs. There are unlimited amounts of stone and stone like materials able to
be used for the production of the panel. Quartz granules, used in the
production of shingles, are quite impressive and provide for a distinct
appearance. They are available in all various colours and styles and are
easily
applied to the panel. The additional acrylic compound and granules also gives
the panel a more improved resistance to impact.
Moulding the panel also gives additional benefits. All of the elements
used is creating the building panel are able to be moulded into various
different
sizes and designs and is therefore limited only to the imagination of the
building architect.

CA 02321445 2000-09-29
LIST OF SEVERAL VIEWS OF THE FIGURES
The objectives and advantages of the invention will be more easily understood
when considered in relation to the preferred embodiments, as set forth in the
specification and shown in the drawings.
FIGURE 1 Shows a perspective view of a single panel when taken into
consideration with the present invention.
FIGURE 2 Shows a front view of a single panel with portions of the facing
broken away to reveal its structural makeup.
FIGURE 3 Shows a cross sectional view of a single panel.
FIGURE 4 Shows a brick exterior building surface wall with building panels
installed.
FIGURE 5 Shows a cross-sectional view of installed panels on a brick
building surface.
The present invention understands that the panel 10, with all of its
components
must be created using a moulded surface. This mould may be designed to
provide various different sizes and styles. In the diagrams, the panel 10 is
styled to have bevelled edges 19. The body of the panel 10 may also be
moulded to include various different types of designs 20, as ones commonly
seen in vinyl siding.
Referring now to the drawings and more particularly to Figure 1. The
drawing shows a single rectangular panel 10 that contains a front facing 11, a
reinforcing backing 12, two adj acent proj ecting edges 13 which mate with the
opposite two adjacent edges 14 which contain complimentary cavities that are
adapted for the projecting edges 13 of an adjoining panel.
Figure 2 shows a building panel 10 from plan view with portions of the facing
removed to reveal the structural makeup. The first portion of the panel 10 is
created by mixing a polymer compound with a stone or stone-like material.

CA 02321445 2000-09-29
The polymer-stone composition is spread evenly throughout the mould,
ranging in thickness from 1 /8 inch to 1/2 inch. A fibre reinforcing mesh 17
is
placed on top of and secured into the composition The fiber mesh and
polymer-stone composition 11 are spread out in such a manner that they will
have defined both the two adjacent projecting edges 13 and the complimentary
adj acent cavities 14.
In order to properly create the complimentary cavities 14, a fibreglass shaft
is
placed into the mould in the exact position the cavities would be located. The
purpose of the shaft is to prevent the foam from expanding throughout the
entire panel 10 and thus creating the complimentary cavity 14. In order to
promote easy installation and proper air and moisture flow, the shaft should
be
slightly larger than the projecting edges 13.
Once the shafts have been placed into the mould, the metal backing 12 is
placed on top. The metal backing 12 extends approximately 1 inch from both
adjacent sides containing the complimentary cavity 14. This backing
extension will be used to secure the panel to a building structure at the time
of
installation. To be able to be suited according to building requirements, the
backing 12 may be of various different types of metals and thickness'.
'The panel 10 is then prepared to be injected with an expandable foam
insulation 15. A lightweight foam material with excellent thermal heat
transfer
resistance is preferred. The most suitable forms of foam for such are
Polyurethane and Polystyrene. These materials are preferred because of its low
cost, high insulation rating and it's a relatively simple application process.
The
entire mould is then placed into a unit that sustains constant pressure on
panel
and mould. It is then injected with the expandable foam insulation 15. The
foam 15 expands throughout the mould and adheres to both the polymer-stone
facing composition 11 and the metal backing 12.
After all components have cured, the panel 10 is removed from the mould with
the polymer-stone facing 11, foam insulation 15 and metal backing 12 securely
intact to one another. The foam insulation 15 and polymer-stone facing 11
should not adhere to the shafts and therefore they should be easily removed
from the panel. The exterior facade of the panel 10 will have a hard and

CA 02321445 2000-09-29
smooth surface that will contain any design 19 or style 20 that was contained
in the mould.
At this point the panel may be created to have a more appealing facade. The
polymer-stone facing 11 is coated with additional polymer resin and stone
granules 18 are spread throughout and secured into the compound. The
additional components provide the panel 10 with added strength. Once the
compound has dried, any additional granules that have not adhered to the panel
are removed.
The panel is now ready for installation.

Dessin représentatif