INSULATION PANEL SYSTEM

• US 20110252728A1
• Filed: 12/17/2010
• Published: 10/20/2011
• Est. Priority Date: 01/17/2007
• Status: Active Grant

• Current Assignee: Edward G. Scherrer
• Original Assignee: Edward G. Scherrer
• Inventors: Scherrer, Edward G.
• Granted Patent: US 8,635,824 B2
• Time in Patent Office: Days
• US Class Current: 52/220.1
• CPC Class Codes: E04B 1/7675 Insulating linings for the interior face of exterior walls
• CPC Class Codes: E04B 1/80 slab-shaped

Abstract

A wall system includes a first wall section a structural portion, such as concrete block construction. A second wall section mounts to the first wall section and includes insulating panels connected in an edge to edge relationship to form a continuous insulating layer. A third wall section of conventional finishing materials such as drywall, paneling or exterior finish layer mounts over the second wall section. Each of the insulating panels includes mounting elements at least partially embedded therein that provide for mounting the panels to the first layer and for mounting the third wall section to the second wall section. Each of the panels is lightweight and may be water impervious. The panels have ridges formed therein that define channels for routing wiring and other components. The panels also include complementary edges and complementary alignment features.

Claims

1. A substantially rectangular panel of expanded foam having a first face and a second opposite face, the panel comprising:

at least one mounting element at least partially embedded into the panel;

the mounting element including;

a first section having a substantially planar portion extending substantially parallel to the first face;

a second section having a substantially planar portion extending substantially parallel to the second face;

a third section extending between the first section and the second section;

the third section including connecting elements and defining openings between the first section and the second section, with the expanded foam extending through the openings and surrounding the connecting elements and the first and second sections, the second section forming adhesive engagement portions defining a plurality of neck portions configured for interlocking with adhesive;

connecting portions along edges of each panel for fitting edges of the panel to similar adjacent panels.

2. A panel according to claim 1, further comprising outer indicia on the first face of the panel aligned with the first sections of the recessed mounting elements.

3. A panel according to claim 1, further comprising alignment notches and complementary tab portions configured for aligning with the notches of an adjacent panel.

4. A panel according to claim 1, wherein the neck portions are spaced apart along the second section in a side by side arrangement.

5. A panel according to claim 2, wherein the outer indicia comprise first markings aligned with mounting elements spaced apart a first distance and second markings spaced apart a second distance.

6. A panel according to claim 1, wherein the second face defines first channels directing water.

7. A panel according to claim 1, wherein the second face defines chases configured for receiving utility lines extending along the panel.

8. A panel according to claim 1, wherein at least one edge defines a water conduit extending along the panel.

9. A panel according to claim 8, wherein the conduit extends along a length of the edge.

10. A panel according to claim 1, wherein the connecting portion of a first edge defines a groove and the connecting portion of a second edge defines a complementary tongue.

11. A panel according to claim 10, wherein the first edge defines a first water conduit extending in the edge on a first side of the tongue and a second water conduit on a second side of the tongue.

12. A panel according to claim 1, wherein the first section extends parallel to the second section and the third section extends transverse to the first and second sections.

13. A panel according to claim 12, wherein the third section includes support elements intermediate the openings and planar portions extending along the plane of the third section.

14. A panel according to claim 13, wherein the planar portions form a border around the spaces defined by the third section.

15. A panel according to claim 4, wherein the second section defines side slots extending parallel to each neck portion.

16. A panel according to claim 4, further comprising a plurality of parallel slots formed in a first edge of the second section and extending transverse to a longitudinal direction of the mounting element.

17. A panel according to claim 16, wherein each of the slots extends into an opening defined by a corresponding neck portion.

18. A panel according to claim 4, further comprising a slot extending upward from each of the neck portions through the second section.

19. A panel according to claim 18. wherein the slot includes sides having a plurality of ridges.

20. A panel according to claim 4, wherein locations intermediate the neck portions at a side of the second section at which the neck portions open each include a channel extending intermediate adjacent neck portions.

21. A panel according to claim 1, wherein the forming adhesive engagement portions define a widened opening portion leading from the neck portions.

22. An insulation system, comprising:

a plurality of rectangular expanded foam panels having a first face and a second opposite face, the panels fitting together to form an extended insulation barrier, each of the panels comprising;

at least one mounting element at least partially embedded in the panel;

the mounting element including;

a first section having a substantially planar portion extending substantially parallel to the first face;

a second section having a substantially planar portion extending substantially parallel to the second face;

a third section extending between the first section and the second section;

the third section including connecting elements and defining openings there between, the expanded foam extending through the openings and surrounding the connecting elements and the first and second sections, the second section forming adhesive engagement portions defining a plurality of neck portions interlocking with adhesive;

connecting portions along edges of each panel for fitting edges of the panel to adjacent panels.

23. An insulation system according to claim 22, wherein the mounting element is recessed from the first face.

24. An insulation system according to claim 22, wherein a portion of the mounting element extends outward beyond a plane of the first face

25. A substantially rectangular panel of expanded foam having a first face and a second opposite face and four edges, the panel comprising:

connecting portions along the edges of each panel for fitting edges of the panel to adjacent panels.

wherein the connecting portion of a first one of the edges defines a groove and the connecting portion of a second one of the edges defines a complementary tongue, and wherein the first edge defines a first water conduit extending in the edge on a first side of the tongue and a second water conduit on a second side of the tongue; and

wherein the second face defines races configured for receiving utility lines extending along the panel.

26. A panel according to claim 25, further comprising outer indicia on the first face of the panel aligned with the first sections of the mounting elements.

27. A panel according to claim 25, further comprising alignment notches and complementary tab portions configured for aligning with the notches of an adjacent panel.

28. A panel according to claim 25, wherein the water conduit extends along a length of the first edge.

29. A panel according to claim 25, wherein the tongue includes a chamfered corner to create a conduit when fitted against a groove.

30. A panel according to claim 25, wherein the groove defines a longitudinal recessed channel creating a conduit when engaged by a tongue.

31. A panel according to claim 25, wherein the panel defines a plurality of parallel grooves extending along the second face of the panel.

32. A panel according to claim 25, wherein the panel further defines an inner chase extending within the panel extending from the top to the bottom of the panel.

33. A panel according to claim 25, wherein the panel further defines an inner chase extending within the panel extending substantially horizontally from the one edge to an opposite edge of the panel.

34. A panel according to claim 25, further comprising at least one mounting element at least partially embedded in the panel.

35. A panel according to claim 34, wherein the at least one mounting element comprises:

a first section having a substantially planar portion extending substantially parallel to the first face;

a second section having a substantially planar portion extending substantially parallel to the second face;

a third section extending between the first section and the second section;

the third section including connecting elements and defining openings in the third section, the expanded foam extending through the openings and surrounding the connecting elements and the first and second sections, the second section forming adhesive engagement portions defining a plurality of neck portions.

36. A panel according to claim 25, wherein the connecting portion along the top edge defines tongue with a plurality of vertical channels formed in a side of the tongue.

37. A panel according to claim 36, wherein the connecting portion along the bottom edge defines groove complementary to the tongue of the top edge with a plurality of vertical channels formed in a side of the groove.

38. A panel according to claim 37. wherein the top edge defines an alignment tab having at least one vertical channel formed therein.

39. A panel according to claim 38. wherein the bottom edge defines an alignment notch complementary to the alignment tab and having at least one vertical channel formed therein.