VANDALISM-RESISTANT INSULATING PANELS FOR BUILDING EXTERIORS AND BUILDING HAVING VANDALISM-RESISTANT THERMALLY INSULATIVE WALLS
First Claim
1. A method for fabricating a fire retardant, thermally insulative vandalism and damage resistant composite panel that is undercut at an angle at opposing panel edges, for use as a portion of a building exterior, comprising the steps of:
- a. supplying viscous low density foam material to the interior of a frame in an amount sufficient to cover the area enclosed by the frame but insufficient to fill the frame;
b. supplying viscous high density foam material to the interior of the frame in an amount sufficient to cover the low density foam material enclosed by the frame but insufficient to fill the frame;
c. contacting an exposed surface of the high density foam within the frame with a fabric having sufficiently high porosity for migration thereinto of the high density foam material before complete curing of the high density foam material occurs;
d. supplying an exterior material to the interior of the frame in an amount sufficient to cover the fabric for migration into and through the fabric of a sufficient amount the exterior material to bond with the high density foam material.
1 Assignment
0 Petitions
Accused Products
Abstract
A fire retardant thermally insulative, vandalism and damage resistant panel for the building exteriors includes a relatively low density foam layer having relatively high thermal resistivity, a relatively high density foam layer having relatively high impact strength and resistance to bending facingly contacting the low density foam layer, a porous fabric contacting the high density foam layer at a surface thereof facing oppositely from the low density foam, and a weather resistant, water impermeable exterior layer contacting the fabric at a surface facing in a direction opposite from where the high density foam contacts the fabric, where the high density foam substantially occupies at least parts of some of the pores of the fabric and the exterior layer material substantially occupies at least parts of at least some of the pores of the fabric such that sufficient pores of the fabric are filled with the high density foam, the exterior surface material and chemical reaction products thereof to create a bond between the exterior surface material and the high density foam.
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Citations
22 Claims
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1. A method for fabricating a fire retardant, thermally insulative vandalism and damage resistant composite panel that is undercut at an angle at opposing panel edges, for use as a portion of a building exterior, comprising the steps of:
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a. supplying viscous low density foam material to the interior of a frame in an amount sufficient to cover the area enclosed by the frame but insufficient to fill the frame; b. supplying viscous high density foam material to the interior of the frame in an amount sufficient to cover the low density foam material enclosed by the frame but insufficient to fill the frame; c. contacting an exposed surface of the high density foam within the frame with a fabric having sufficiently high porosity for migration thereinto of the high density foam material before complete curing of the high density foam material occurs; d. supplying an exterior material to the interior of the frame in an amount sufficient to cover the fabric for migration into and through the fabric of a sufficient amount the exterior material to bond with the high density foam material. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. A method for fabricating a fire retardant, thermally insulative vandal and damage resistant composite panel for use as a portion of a building exterior, comprising the steps of:
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a. supplying viscous low density foam material to a preselected area in an amount sufficient to cover the area; b. applying viscous high density foam material to the low density foam in an amount sufficient to overly the portion of the low density foam material covering the preselected area; c. overlying an exposed surface of the high density foam facing oppositely from the low density foam with fabric having sufficient porosity for migration of the viscous high density foam material into at least parts of at least some of the pores before complete cure of the high density foam occurs; and d. applying an exterior material to the fabric in an amount sufficient for migration of the exterior material into at least parts of at least some of the pores of the fabric to mechanically join the fabric and chemically bond with portions of the high density foam at least partially occupying at least some of the pores in the fabric.
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21. A method for fabricating a fire retardant, thermally insulative vandal and damage resistant building exterior wall, comprising the steps of:
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a. applying viscous low density high thermal resistance foam material to an exteriorly facing surface of a building wall in an amount sufficient to cover at least a preselected portion of the surface with a preselected thickness of the low density high thermal resistance foam material; b. applying viscous high density foam material over the low density foam material in an amount sufficient to overlie the low density foam material covering the preselected portion of the exteriorly facing surface; c. overlaying an exposed surface of the high density foam facing oppositely from the low density foam with fabric having sufficient porosity for migration of the viscous high density foam material into at least parts of at least some of the pores before complete cure of the high density foam material occurs; and d. applying an exterior material to the fabric in an amount sufficient for migration of the exterior material into at least parts of at least some of the pores of the fabric to mechanically join the fabric and optionally mechanically and chemically bond through the fabric with high density foam at least partially occupying at least some of the pores in the fabric.
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22. A method for fabricating a fire retardant, thermally insulative vandalism and damage resistant composite panel for use as a portion of a building exterior, comprising the steps of:
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a. supplying viscous reinforced polyurethane foam material having a density of about two (2.0) pounds per cubic foot to the interior of a horizontal frame in an amount sufficient to cover the area enclosed by the frame to a thickness of between about one (1.0) to about one and one quarter (1¼
) inches of foam material;b. supplying viscous polyurethane foam material, having high impact strength, high resistance to bending when cured, and a density of about sixteen (16.0) pounds per cubic foot, to the interior of the frame in an amount sufficient to cover the lower density polyurethane foam material already enclosed by the frame with a thickness of between about one-quarter (0.25) to about one-half (0.5) inches of the second supplied material; c. contacting an exposed surface of the second supplied higher density polyurethane foam within the frame with two layers of rib knitted fabric jersey providing relatively high porosity for migration into pores of the fabric of the second supplied higher density polyurethane foam material before complete curing of the second supplied higher density polyurethane foam material occurs; d. supplying an exterior material to the interior of the frame in an amount sufficient to cover the fabric for migration of the exterior material into and through the fabric to bond the fabric with the second supplied higher density polyurethane foam.
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Specification