U.S. patent application number 12/139377 was filed with the patent office on 2009-12-17 for patterned panel system with integrated decorative surfaces.
Invention is credited to Duane Armijo, Brian Shockey, Christopher Shockey.
Application Number | 20090308008 12/139377 |
Document ID | / |
Family ID | 41413482 |
Filed Date | 2009-12-17 |
United States Patent
Application |
20090308008 |
Kind Code |
A1 |
Shockey; Brian ; et
al. |
December 17, 2009 |
Patterned Panel System with Integrated Decorative Surfaces
Abstract
An insulating concrete form can be used to form the walls of a
structure when filled with concrete. An outer surface of the
insulating concrete form can be formed into one or more patterns.
The patterns may simulate popular finishes such as brick, natural
stone, and stucco. In some cases, the exterior of the insulating
concrete form is coated with a protective, conformal coating, such
as a rubberized acrylic coating or an elastomeric paint.
Inventors: |
Shockey; Brian; (Surprise,
AZ) ; Armijo; Duane; (Scottsdale, AZ) ;
Shockey; Christopher; (Applegate, OR) |
Correspondence
Address: |
Zarian Midgley & Johnson PLLC
University Plaza, 960 Broadway Ave., Suite 250
Boise
ID
83706
US
|
Family ID: |
41413482 |
Appl. No.: |
12/139377 |
Filed: |
June 13, 2008 |
Current U.S.
Class: |
52/309.12 ;
52/274; 52/742.13 |
Current CPC
Class: |
B29C 44/445 20130101;
E04B 1/765 20130101; E04B 2/8617 20130101; B29C 33/424 20130101;
E04F 13/185 20130101; E04B 1/762 20130101 |
Class at
Publication: |
52/309.12 ;
52/274; 52/742.13 |
International
Class: |
E04C 2/20 20060101
E04C002/20; E04B 1/14 20060101 E04B001/14; E04B 1/00 20060101
E04B001/00 |
Claims
1. An insulating concrete form comprising: an exterior outer
surface; an interior outer surface, substantially parallel to the
exterior outer surface; and a cavity between the exterior outer
surface and the interior outer surface, the cavity being configured
to receive a volume of a concrete mixture, wherein the exterior
outer surface of the insulating concrete form has an applied
pattern with a plurality of pattern features having a feature depth
of at least about 1/8 inch, and wherein the applied pattern can be
reproduced on a plurality of surfaces in a repeatable manner.
2. The insulating concrete form of claim 1, wherein the insulating
concrete form further comprises: an exterior panel having an inner
surface and the exterior outer surface; an interior panel having an
inner surface and the interior outer surface; one or more
connecting members connected to the inner surfaces of the exterior
and interior panels.
3. The insulating concrete form of claim 1, wherein the insulating
concrete form is manufactured as a single piece.
4. The insulating concrete form of claim 1, wherein the insulating
concrete form further comprises a pattern on the interior outer
surface.
5. The insulating concrete form of claim 1, wherein an outer
surface of the insulating concrete form is coated with a conformal
rubberized acrylic coating or an elastomeric paint.
6. The insulating concrete form of claim 1, wherein the insulated
concrete form comprises expanded polystyrene or extruded
polystyrene.
7. The insulating concrete form of claim 1, wherein the applied
pattern is a 4''.times.8'' standard brick pattern, a Monterrey
texture, a 8''.times.16'' standard brick pattern, a 8''.times.8''
standard block pattern, a 8''.times.16'' standard stacked block
pattern, a lace texture pattern, a standard split-face pattern, or
a fluted pattern.
8. A structure comprising: a foundation; a plurality of
interconnected walls resting on the foundation; and a roof covering
the plurality of interconnected walls, wherein at least one of the
plurality of interconnected walls is an exterior wall having a
panel comprising styrenic material, the panel having an applied,
reproducible pattern on an outer surface with a plurality of
pattern features, and wherein the applied pattern is visible from
an exterior of the structure after the structure is complete.
9. The structure of claim 8, wherein the exterior wall further
comprises a conformal, protective coating having a thickness of no
more than about 1/2 inch.
10. The structure of claim 8, wherein the styrenic material
comprises expanded polystyrene or extruded polystyrene.
11. The structure of claim 8, wherein the panel is part of an
insulating concrete form.
12. The structure of claim 8, wherein the panel is affixed to a
pre-existing substrate.
13. The structure of claim 8, wherein the applied pattern has a
feature depth of at least about 1/8 inch.
14. The structure of claim 8, wherein the applied pattern is a
4''.times.8'' standard brick pattern, a Monterrey texture, a
8''.times.16'' standard brick pattern, a 8''.times.8'' standard
block pattern, a 8''.times.16'' standard stacked block pattern, a
lace texture pattern, a standard split-face pattern, or a fluted
pattern.
15. A method for manufacturing a styrenic panel comprising; moving
a plurality of styrenic beads into a holding chamber; expanding the
styrenic beads; moving the styrenic beads into a mold defining a
reproducible pattern on a surface, the pattern having a feature
depth of at least about 1/8 inch; expanding the styrenic beads to
substantially fill the mold; and fusing the beads into a single
structure of styrenic material, wherein the reproducible pattern of
the mold is applied to surface of the styrenic structure.
16. The method for manufacturing a styrenic panel of claim 15,
wherein the styrenic material comprises expanded polystyrene or
extruded polystyrene.
17. The method for manufacturing a styrenic panel of claim 15,
wherein the pattern is a 4''.times.8'' standard brick pattern, a
Monterrey texture, a 8''.times.16'' standard brick pattern, a
8''.times.8'' standard block pattern, a 8''.times.16'' standard
stacked block pattern, a lace texture pattern, a standard
split-face pattern, or a fluted pattern.
18. The method for manufacturing a styrenic panel of claim 15,
wherein a surface opposing the patterned surface is formed with one
or more protrusions configured to be frictionally held.
19. The method for manufacturing a styrenic panel of claim 15,
wherein the panel is configured to form a part of an insulating
concrete form.
20. The method for manufacturing a styrenic panel of claim 15,
wherein the panel is configured to form a part of a system for
retrofitting a pre-existing structure.
Description
BACKGROUND
[0001] The present application relates generally to the molding and
finish of insulating panels and Insulated Concrete Forms
(ICFs).
[0002] Concrete has been used as a structural building material for
many years. The plain appearance of unfinished concrete is not
generally desirable for use as a finish on the outside of a
structure. Consumers tend to like the look of a house with a
patterned or textured exterior, such as that of brick, stone, and
other masonry products, as well as stucco. However, skilled
craftsman are required for masonry and the price of skilled labor
increases the cost of structures produced with these products. To
reduce the costs of structures, but still incorporate the look of
more expensive products, paneling structures and veneer materials
have been employed as a means for finishing concrete
structures.
[0003] ICF blocks are generally a hollow, modular form that can be
pieced together with other corresponding ICF blocks to form the
frame of a structure. Typically, ICF blocks are made up of two
parallel panels, spaced apart, with multiple connectors in the
center for rigidity. Normally, ICFs remain in place, as part of the
final structure. Insulation values (R-values) of 50 or more have
been claimed for ICFs, which compares favorably to typical stick
framed buildings that may have an R-value of 12 or lower on
exterior walls.
[0004] One example of creating a structure with the look and feel
of masonry without using traditional methods is disclosed in U.S.
Pat. No. 6,360,505, which teaches a system using ICF blocks to
create a concrete structure with integrated masonry elements. In
this example, brick, stone or other "motif components" are retained
within recessed regions molded into the inner surface of the
exterior panel of an ICF block. When the frame of a structure is
built, concrete can be poured into the center of the ICF block
frame, which adds strength and durability to the structure. After
the concrete has cured, the exterior molded panel is removed to
expose the "motif components" and does not remain as part of the
final structure. This system can be use with unskilled labor, and
has a reduced cost when compared with traditional masonry. However,
the method still requires real brick and is labor intensive,
requiring that a brick or "motif component" be placed into each
recessed region. Additionally, the insulation advantage associated
with ICF block is reduced by the removal of the exterior panel.
[0005] Aside from new construction, panels and veneer materials
have also been used in retro-fit applications for non-concrete
structures. For example, pre-fabricated panels with factory affixed
thin (veneer) bricks may be connected to structural members on the
exterior of a building. U.S. Pat. No. 3,908,326 discloses an
example of a paneling system that creates the look of a brick
structure. This system uses thin panels with brick veneer and can
be installed quickly. After installation, mortar can be spread in
the joints between the bricks, hiding joints and connecting means.
When finished the panels give the look and feel of real masonry at
a reduced cost and without the use of skilled craftsmen. On the
other hand, because the panels are factory built, damage to the
panels cannot be repaired on site. Also, transportation to and from
the site is difficult and expensive.
[0006] Attempts to create a masonry fascia without a pre-fabricated
panel have also been made. For example, U.S. Pat. No. 5,373,676
discloses a panel system for use with thin bricks that is assembled
on-site. This system still has the advantage of creating the look
of masonry without the use of skilled labor and can be repaired on
site. However, it does still require the use of brick and the
associated cost of a laborer to install the brick, which adds a
significant amount of finishing product and labor to the cost of a
structure.
SUMMARY
[0007] In one embodiment, an insulating concrete form comprises an
exterior outer surface, an interior outer surface substantially
parallel to the exterior outer surface, and a cavity between the
exterior outer surface and the interior outer surface. The cavity
is configured to receive a volume of a concrete mixture. The
exterior outer surface of the insulating concrete form has an
applied pattern with a plurality of pattern features having a
feature depth of at least about 1/8 inch. The applied pattern can
be reproduced on a plurality of surfaces in a repeatable
manner.
[0008] In another embodiment, a structure comprises a foundation, a
plurality of interconnected walls resting on the foundation, and a
roof covering the plurality of interconnected walls. At least one
of the plurality of interconnected walls is an exterior wall having
a panel comprising styrenic material. The panel having an applied,
reproducible pattern on an outer surface with a plurality of
pattern features. The applied pattern is visible from an exterior
of the structure after the structure is complete.
[0009] In another embodiment, a method is disclosed for
manufacturing a styrenic panel. The method comprises moving a
plurality of styrenic beads into a holding chamber, expanding the
styrenic beads, and moving the styrenic beads into a mold defining
a reproducible pattern on a surface The pattern has a feature depth
of at least about 1/8 inch. The method further comprises expanding
the styrenic beads to substantially fill the mold and fusing the
beads into a single structure of styrenic material. The
reproducible pattern of the mold is applied to surface of the
styrenic structure.
[0010] These and other embodiments of the present application will
be discussed more fully in the description. The features,
functions, and advantages can be achieved independently in various
embodiments of the claimed invention, or may be combined in yet
other embodiments.
BRIEF DESCRIPTION OF FIGURES
[0011] FIG. 1 is a cut away view of an insulating concrete form
with a 4''.times.8'' standard brick pattern on the outer
surface
[0012] FIG. 2A is a front view of the insulating concrete form of
FIG. 1, showing the 4''.times.8'' standard brick pattern on the
outer surface.
[0013] FIG. 2B is a front view of an insulating concrete form with
a Monterrey texture pattern on the outer surface.
[0014] FIG. 2C is a front view of an insulating concrete form with
a 8''.times.16'' standard brick pattern on the outer surface.
[0015] FIG. 2D is a front view of an insulating concrete form with
a 8''.times.16'' standard stacked block pattern on the outer
surface.
[0016] FIG. 2E is a front view of an insulating concrete form with
a split-face pattern on the outer surface.
[0017] FIG. 2F is a front view of an insulating concrete form with
a lace pattern on the outer surface.
[0018] FIG. 2G is a front view of an insulating concrete form with
a fluted pattern on the outer surface.
[0019] FIG. 3 is a cut away view of a panel installed on an
existing structure.
[0020] FIG. 4 is a flow chart illustrating one embodiment of a
method for manufacturing a patterned styrenic panel.
[0021] Like reference numbers and designations in the various
drawings indicate like elements.
DETAILED DESCRIPTION
[0022] In the following description, reference is made to the
accompanying drawings that form a part thereof, and in which is
shown by way of illustration specific exemplary embodiments in
which the invention may be practiced. These embodiments are
described in sufficient detail to enable those skilled in the art
to practice the invention, and it is to be understood that
modifications to the various disclosed embodiments may be made, and
other embodiments may be utilized, without departing from the
spirit and scope of the present invention. The following detailed
description is, therefore, not to be taken in a limiting sense.
[0023] In the past, ICFs have been used in many structural
applications, however due to the low aesthetic appeal of the
material typically used for making ICFs, the outer surface of the
ICF has not been used as a part of a visible finished surface. The
exterior panel of ICF blocks has typically been covered with
veneers or thick stucco products. In the interior, a wall formed by
ICF blocks is often finished with traditional drywall, textured,
and then painted. The system described in this disclosure
advantageously enables the outer surfaces of ICFs to be used as an
aesthetically appealing finished surface without the use of
additional finish structures and materials such as panels, and
veneers.
[0024] FIG. 1 is a cut away view of a Faux Finish Insulating
Concrete Form (FFICF) 100 according to an embodiment of the current
disclosure. FFICFs 100 may be manufactured in single or multi-piece
designs. In some embodiments, FFICF 100 has an exterior panel 110
with an inner surface 114 and an outer surface 112 and an interior
panel 120 with an inner surface 124 and an outer surface 122.
Typical thicknesses of the exterior panel 110 or the interior panel
120 used with FFICFs 100 may range from about one inch to about
eight inches. For example, in some embodiments, the thickness of
the panels 110, 120 may be within the range of about two inches to
about three inches, or within the range of about four inches to
about five inches, or within the range of about six inches to about
seven inches. Those of ordinary skill in the art will understand
that the thickness of the panel(s) 110, 120 may vary from the
stated thicknesses.
[0025] In some embodiments, the exterior panel 110 and the interior
panel 120 of the FFICF 100 are held apart and substantially
parallel by a connector 130, forming a cavity 140 into which a
concrete mixture (e.g., regular concrete, pervious concrete,
asphalt concrete, polymer concrete, etc.) may be poured. Typically,
the cavity 140 has a width within the range of about three inches
to about nineteen inches. For example, in some embodiments, the
cavity 140 may range from about four inches to about six inches, or
within the range of about seven inches to about eight inches, or
within the range of about nine inches to about twelve inches, or
within the range of about fourteen inches to about eighteen inches.
Those of ordinary skill in the art will understand that the width
may vary from the stated values. In the illustrated embodiment, the
connector 130 comprises one or more plastic web members. In other
embodiments, the connector 130 may comprise a wide variety of other
suitable components such as, for example, metal or polystyrene
rods.
[0026] The exterior panel 110 and interior panel 120 of an FFICF
100, as well as the connector 130, may be made from a wide variety
of well-known materials, such as materials that are suitable for
patterning, for example, materials comprising styrene or
polystyrene. In some embodiments, the FFICF 100 may comprise
material such as expanded polystyrene (EPS) and extruded
polystyrene (XPS). Alternatively, part or all of an FFICF 100 may
be made with mixtures of materials, such as with a mixture
comprising cement and insulative materials (e.g., synthetic bead
material, polystyrene material).
[0027] As described above, in some embodiments an FFICF 100 is
manufactured as a single piece. In single piece designs, the FFICF
100 may have a cavity 140 configured to receive a concrete mixture.
Alternatively, in some embodiments, an FFICF 100 may not have a
cavity, but may be combined with a concrete mixture in another way,
such as, for example, when an FFICF 100 comprises one or more
members formed from a mixture of concrete and styrenic
material.
[0028] Many materials used to make ICFs are not traditionally seen
as durable materials. Therefore, in some cases, it is desirable to
apply a protective, conformal coating to the FFICF 100 to increase
the durability of the coated material. In some embodiments, the
conformal coating may comprise, for example, an elastomeric paint,
a rubberized acrylic, or another suitably conformal material. Such
conformal coatings advantageously allow external features patterned
into the FFICF 100 to stand out as if the wall was made of block,
brick, stone, or other materials, greatly reducing the cost of
producing an aesthetically appealing structure. One example of a
suitable rubberized acrylic coating that can be used to coat FFICFs
100 is the "Errth Flex Coating System" marketed by Errth Flex in
Scottsdale, Arizona. Additional information about the Errth Flex
Coating System is available at http://errthflex.com/. The
information on this website existing as of the filing date of the
present application is incorporated herein by reference in its
entirety.
[0029] Stucco and conformal coatings have been used with ICFs in
the past, but the ICF itself has not been a visible part of the
decorative exterior. Previously coatings, panels, and veneers have
entirely obscured the ICF, hiding it from view. Due to these
finishes, the outer surface of an ICF has typically been used as a
structural component or substrate only and has not had an influence
on the visible finish. When a conformal coating is used with a
patterned FFICF 100, the outer surface of the FFICF 100 may be
protected from damage such as ultra violet radiation (sun) damage,
fire damage, water damage, and pest damage. Compounds that make up
the conformal coating can be modified to create coatings that will
provide extra protection from a specific damage. For example, in
especially sunny regions, an additional component or an additional
amount of a component may be added to provide extra protection
against ultra-violet damage. Further, when damage does occur,
coatings are generally easily repaired with an additional
application of the conformal coating to the damaged area.
[0030] When applied according to the manufacturers' instructions,
the thickness of a conformal coating applied to the patterned outer
surface 112 of and FFICF 100 may typically range from about 1/8
inch to about 1/2 inch. For example, in some embodiments the
coating may have a thickness within the range of about 1/4 inch to
about 3/8 inch. The texture of the coating itself may be a feature
of the finished outer surface of a coated exterior panel 110.
Typically, the texture of the surface finish of a coating can be
smooth or rough, but it is conceived that it may have other,
complementary patterns or textures in addition to the pattern
supplied by the FFICF 100. For example, in some embodiments, the
exterior panel 110 may be patterned with a rough, natural stone
finish, for which a rough, natural stone textured coating may be
complementarily applied.
[0031] As mentioned previously, in the current art, the frame of a
structure can be built with ICF blocks which may be configured to
receive a volume of a concrete mixture. However, unlike current
systems, when FFICFs 100 are used in the frame of a structure, the
exterior surface 112 of the FFICF 100 can be patterned to provide
the decorative exterior finish.
[0032] As used herein, the term "pattern" refers to any
reproducible pattern having a plurality of pattern elements or
features that can be applied to a plurality of surfaces in a
repeatable manner. Thus, the term "pattern" does not encompass a
truly random surface texture, such as a random, unreproduced
texture made by polystyrene beads on the surface of a traditional
expanded polystyrene ICF.
[0033] For example, in some embodiments, a suitable pattern may
emulate, for example, natural stone, river rock, sandstone, or
other non-uniform masonry. Suitable patterns may also be repeatable
or uniform patterns such as for example, patterns that emulate
brick, block, or other uniform masonry patterns. Additionally,
suitable patterns may be decorative patterns such as, for example
patterns that emulate stucco, monterrey texture, or lace texture.
Suitable patterns may also be random or pseudo random patterns
which are reproducible in a plurality of FFICFs 100 or FFICF panels
110, 120.
[0034] As illustrated in FIG. 1 and FIG. 2A, some embodiments of
the FFICF 100 have patterned features 118 that resemble brick. FIG.
1 shows a blow up of a patterned feature 118 on an FFICF 100 with a
marked distance "d." In some embodiments of an FFICF 100 where the
patterned feature 118 on the outer surface 112 comprises an
emulated brick pattern with an emulated mortar line in between the
brick patterned features 118, the distance "d" refers to the depth
of the mortar line when compared to the tallest part of the brick
patterned features 118. This distance "d" is referred to as the
feature depth.
[0035] For example, in an embodiment of an FFICF 100 having a
pattern such as a fluted pattern as may be illustrated by FIG. 2H,
the feature depth is the distance "d" from the deepest part of the
semi-circular pattern to the tallest part of the plateau. In some
embodiments of an FFICF 100 having a reproduced random pattern such
as a reproducible emulated monterrey texture pattern, the feature
depth may be a distance "d" from the deepest impression on the
exterior surface 112 of the FFICF 100 to the highest point of a
patterned feature 118.
[0036] In some embodiments, the minimum feature depth on the
exterior surface 112 of an FFICF 100 may range from a distance "d"
of about 1/8 inch to about 2 inches. For example, in some
embodiments the minimum feature depth may be a distance within the
range of about 1/4 inch to about 3/8 inch, or within the range of
about 1/2 inch to about 5/8 inch, or within the range of about 3/4
inch to about 7/8 inch, or within the range of about 1 inch to
about 11/8 inches, or within the range of about 1 1/4 inches to
about 13/8 inches, or within the range of about 11/2 inches to
about 2 inches. Those of ordinary skill in the art will understand
that the feature depth may vary from the stated values.
[0037] FIG. 2 shows several examples illustrating how the outer
surface 112 of the exterior panel 110 can be advantageously
patterned to resemble a wide variety of aesthetically pleasing
patterns. Specifically, FIG. 2A shows a 4''.times.8'' standard
brick pattern, FIG. 2B shows a Monterrey texture, FIG. 2C shows a
8''.times.16'' standard brick pattern, FIG. 2D shows a
8''.times.8'' standard block pattern, FIG. 2E shows a
8''.times.16'' standard stacked block pattern, FIG. 2F shows a lace
texture pattern, FIG. 2G shows a standard split-face pattern, and
FIG. 2H shows a 2'' fluted pattern. It will be appreciated that
other patterns can be used with the surfaces of the FFICF panels
110 and 120, including natural and unnatural patterns, mosaics, or
motifs, and patterns that are predictable or pseudo-random.
[0038] In some embodiments, the FFICFs 100 are molded, expanded, or
extruded with the desired pattern(s) at the time of manufacture. In
some multi piece embodiment of an FFICF 100, the pattern may be
integrated into FFICF panels 110 and 120 before they are used to
assemble a finished FFICF 100. In this way, the panels 110 and 120
can be mixed and matched to create a custom FFICF 100, which will
enable a user to choose one or more interior or exterior patterns
for the structure.
[0039] In other embodiments, standard polystyrene panels may be
utilized as a base for panels 110 and 120 of a multi-piece FFICF
100, which may be manufactured and installed using conventional
techniques. Such standard panels can be shaped after manufacture
using heating elements or other well-known methods, such as that
described in U.S. Pat. No. 7,238,312, to create the desired
pattern(s) in the surface of the FFICF panels 110 and 120.
[0040] FFICFs 100 may be manufactured using steam chest molding or
with extrusion and thermoforming techniques, or by using other
suitable methods. An early step in making steam chest molded
products is impregnating small beads of styrenic material with an
expansion agent which may be pentane. As shown in block 420 of FIG.
4, the molding process may begin by moving a plurality of styrenic
beads into a pre-expander holding chamber. At block 430, the
styrenic beads are expanded. Limited expansion of the styrenic
beads may occur by exposing the beads to steam. At block 440, the
styrenic beads are moved to a mold having a pattern, as discussed
previously. The mold may be used to further expand and fuse the
expanded styrenic beads to a final shape and density as illustrated
in block 450. This final expansion may be attained by further
exposing the sytrenic beads to steam while in the mold. At block
460, the styrenic beads, having been fused into a styrenic
structure, are removed from the mold and may be used in the
construction of a structure, such as, for example, the structure
200 of FIG. 3.
[0041] Alternatively, FFICFs 100 may be made from an extrusion
and/or thermoforming process. Patterned FFICFs 100 or FFICF panels
110, 120 may be formed through an extrusion process such as a
direct injection foam process that involves an expansion or blowing
agent added to the styrenic material during extrusion. An FFICF 100
made from this process has both strength and good insulation
properties. Further, FFICFs 100 may also be manufactured using a
traditional precast mold with a mixture of material, such as a
mixture comprising concrete and insulative material. It is
conceived that other methods of patterning an FFICF 100, such as
branded and cutting, may be used and would be apparent to one of
ordinary skill in the art given the benefit of this disclosure.
[0042] The ability to pattern the outer surface of an FFICF 100 is
especially advantageous when multiple separate finishes are
designed into a structure. For example, if a structure were to be
finished with multiple exterior finishes, such as slump block,
smooth sand stucco, and 8''.times.8'' standard block, using
traditional methods, the costs would be very high in comparison to
the cost of using three separate types of patterned FFICFs 100 to
simulate three separate finishes. Even when compared with
traditional ICF blocks used with finishes such as clad attachments
or patterned epoxy painting systems like Exterior Insulation and
Finish Systems (EIFS), patterned FFICFs 100 are much more cost
effective. Further, FFICFs 100 do not carry the risk of water
damage that is associated with conventional EIFS systems.
[0043] While FIGS. 2A-2H show patterns that may be applied to the
outer surface 112 of the exterior panel 110, the outer surface 122
of the interior panel 120 may also have a pattern. Such interior
patterns create an aesthetically pleasing finished surface for the
interior of the structure that can also greatly reduce the cost of
labor. Like the exterior outer surface 112, the interior outer
surface 122 may need a coating to further seal and protect the
FFICF 100.
[0044] It is also contemplated that an exterior panel 110 could be
used independently of an FFICF 100 in a system for retrofitting a
pre-existing structure. For example, in some embodiments, a
plurality of exterior panels 110 can be affixed to the outer
surfaces of a preexisting structure using components and techniques
well-known to those of ordinary skill in the art to create a new
exterior surface that is both useful and aesthetically pleasing. In
such cases, the preexisting structure will gain some of the
advantages of FFICFs 100 described above, such as aesthetic appeal
and an increased insulation value.
[0045] FIG. 3 is a cut away view of a structure 200 having
foundation upon which rests a plurality of interconnected walls and
a roof covering the walls. As shown in the blown up portion of FIG.
3, an exterior panel 110 is installed on an exterior interconnected
wall comprising a pre-existing exterior wall system 240. As shown
in FIG. 3, the existing wall system 240 comprises an attached
existing substrate 250 and rests on an existing foundation 230. In
some embodiments, a system used to install the exterior panel 110
to the existing wall system 240 may comprise guide tracks 210 that
can be connected or affixed to the existing substrate 250. After
connecting the exterior panel 110 to the guide tracks 210, there
may be a space formed between the existing substrate 250 and the
exterior panel 110, which may be filled with a compound 220. In
some embodiments, the compound 220 may comprise a polyurethane
adhesive or an expanding foam.
[0046] Although this invention has been described in terms of
certain preferred embodiments, other embodiments that are apparent
to those of ordinary skill in the art, including embodiments that
do not provide all of the features and advantages set forth herein,
are also within the scope of this invention. Therefore, the scope
of the present invention is defined only by reference to the
appended claims and equivalents thereof.
* * * * *
References