Three dimensional insulation panel having unique surface for improved performance
First Claim
1. A method of making a three dimensional building panel comprising:
- (1) providing a mold having a cavity, the mold having two major opposed internal surfaces, the cavity having dimensions essentially identical to a finished three dimensional building panel suitable for installation;
(2) introducing polystyrene foam beads into the cavity;
(3) heating the polystyrene foam beads;
(4) causing the heated polystyrene foam beads to flatten and spread against the pre-heated major internal surface of the mold, thereby forming a sealed water-repellant skin at least on a face of the three dimensional building panel formed by the pre-heated major internal surface of the mold.
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Accused Products
Abstract
A shape molding operation is performed to form a three dimensional building panel. The operation involves providing a mold having a cavity, the cavity having dimensions essentially identical to a finished three dimensional building panel suitable for installation. The shape molding operation involves pre-heating at least one of two major internal surfaces of the mold; introducing polystyrene foam beads into the cavity; heating the polystyrene foam beads; and causing the heated polystyrene foam beads to flatten and spread against the pre-heated major internal surface of the mold, thereby forming a sealed water-repellant skin at least on a face of the three dimensional building panel. In view of the corresponding size of the mold cavity, no cutting action is required on the expanded polystyrene (EPS) foam formed therein, so that a least a building-contacting face of the resultant boards acquires the sealed water-repellant skin that is otherwise lost when forming boards from buns of the prior art. The insulated building panel is preferably formed with said building-contacting surface or face of the panel having a regular pattern of either water drainage grooves or raised protrusions. The protrusions can have various shapes, such as a quadrilateral (e.g., diamond, or rhombus) shape, a circular shape, an elliptical shape, or a triangular shape, for example.
78 Citations
37 Claims
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1. A method of making a three dimensional building panel comprising:
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(1) providing a mold having a cavity, the mold having two major opposed internal surfaces, the cavity having dimensions essentially identical to a finished three dimensional building panel suitable for installation;
(2) introducing polystyrene foam beads into the cavity;
(3) heating the polystyrene foam beads;
(4) causing the heated polystyrene foam beads to flatten and spread against the pre-heated major internal surface of the mold, thereby forming a sealed water-repellant skin at least on a face of the three dimensional building panel formed by the pre-heated major internal surface of the mold. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37)
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Specification