METHODS FOR THE MANUFACTURE AND USE THEREOF

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Application No. 62/846,495, filed on May 10, 2019, the entirety of which is incorporated by reference.

TECHNICAL FIELD

[0002] Insulated rainscreen panels are disclosed herein, as well as methods of making and using the same. A benefit to the insulated rainscreen panels can be providing an insulating panel with moisture control properties between a wall and a building material.

BACKGROUND

[0003] People have been constructing buildings for thousands of years, so the methods and materials used in the construction industry are well developed. However, construction methods and materials are always evolving in response to evolving demands by society. For example, as society pushes for more energy efficient buildings, then building codes impose the adoption of building materials possessing having high degrees of insulation. As society becomes more aware of the causes of microbial health hazards, such as black mold, then architects are required to design structures that are less susceptible to the formation of microbial health hazards. Of course, there is economic pressure to build homes using more cost-effective methods and materials.

[0004] There is a need for panels that can provide an insulating layer between the surfaces of walls and building materials used to finish wall surfaces. There is a need for panels capable of guiding unskilled workers in the application of building materials, such as bricks. There is a need for panels capable of reducing moisture accumulation to avoid microbial health hazards, such as black mold. There is a need for more cost-effective building materials.

SUMMARY

[0005] Embodiments herein are directed to insulated rainscreen panels and methods for the making and use thereof.

[0006] In an aspect, an insulated rainscreen panel includes a corrugated foam panel, wherein the corrugated foam panel has a panel length, a panel width, a panel thickness, a front panel surface, a back-panel surface, and at least two panel edges; wherein the front panel surface includes a front corrugated surface having front ridges and front trenches that extend the panel length of the corrugated foam panel; and wherein the back-panel surface includes a back corrugated surface having back ridges and back trenches that extend the panel length of the corrugated foam panel.

[0007] In certain embodiments, the corrugated foam panel is rectangular. In certain embodiments, the panel thickness is from about 2.5 cm to about 30.5 cm. In certain embodiments, the panel length is from about 1.2 meters to about 2.0 meters. In certain embodiments, the panel front ridges have a height of from about 6 mm to about 13 mm, measured from a front ridge top to a front trench bottom. In certain embodiments, the back ridges have a height of from about 6 mm to about 13 mm, measured from a back ridge top to a back trench bottom. In certain embodiments, the front ridges or the back ridges have a period center distance between them of from about 5 cm to about 8 cm. In certain

embodiments, a ridge period center distance of the front panel surface differs by from 0 cm to about 8 cm from the ridge period center distance of the back-panel surface. In certain embodiments, a ridge period center distance of the front panel surface is aligned with a ridge period center distance of the back-panel surface by a percentage offset of from 0 percent to 99 percent.

[0008] In certain embodiments, about 80% to 100% weight of the corrugated foam panel is a polystyrene foam material, based on a total weight of the corrugated foam panel. In certain embodiments, the polystyrene foam material has a weight per volume of about 1 pound per cubic foot (16 g/L), about 2 pounds per cubic foot (32 g/L), or about 3 pounds per cubic foot (48 g/L). In certain embodiments, the corrugated foam panel includes expanded polystyrene foam material, extruded polystyrene foam material, or combinations thereof.

[0009] In certain embodiments, the two panel edges include a first panel edge having a first interlocking shape and a second panel edge having a second interlocking shape. In certain embodiments, the first interlocking shape is complementary to the second interlocking shape. In certain embodiments, the first interlocking shape and second interlocking shape are configured to allow for interlocking of a plurality of corrugated foam panels together. In certain embodiments, the first interlocking shape protrudes from about 3 mm to about 13 mm from the first panel edge. In certain embodiments, the second interlocking shape protrudes from about 3 mm to about 13 mm from the second panel edge.

[0010] In other embodiments, at least a portion of the front ridges have flat or substantially flat front perches located on front tops of the front ridges. In certain embodiments, at least a portion of the back ridges have flat or substantially flat back perches located on back tops of the back ridges. In certain embodiments, the front trenches and the back trenches have a flat or substantially flat bottom. In certain embodiments, the front panel surface is

complementary to the back-panel surface. In certain embodiments, the complementary front panel surface and back-panel surface portions have flat or curved surfaces.

[0011] In certain embodiments, the front corrugated surface has at least one row of guide lips on top of the front ridges that extend above the front perches. In an embodiment, the rows of guide lips are arranged in rows that are perpendicular or substantially perpendicular to the front ridges and front trenches. In certain embodiments, a height of the guide lip is from about 3 mm to about 13 mm, as measured from a top of the guide lip to an adjacent perch. In certain embodiments, the perches have a length of about 5 cm to about 10 cm between rows of guide lips.

[0012] In certain embodiments, a distance between rows of guide lips is equal or

substantially equal to a width of a siding. In various embodiments, the siding includes a brick, a wood panel, or an aluminum panel. In certain embodiments, the brick includes standard brick, modular brick, norman brick, roman brick, jumbo brick, economy brick, engineer brick, king brick, queen brick, and utility brick.

[0013] Methods of forming an insulated rain screen between a wall and a building material are disclosed herein. In an embodiment, the method includes a corrugated foam panel, wherein the corrugated foam panel has a panel length, a panel width, a panel thickness, a front panel surface, a back-panel surface, and at least two panel edges; wherein the front panel surface includes a front corrugated surface having front ridges and front trenches that extend the panel length of the corrugated foam panel; and wherein the back-panel surface includes a back corrugated surface having back ridges and back trenches that extend the panel length of the corrugated foam panel;

attaching the corrugated foam panel to the wall with the back ridges and the back trenches of the back corrugated surface oriented perpendicular or substantially perpendicular to a floor; laying at least one building material against the front panel surface; and binding the at least one building material onto the front panel surface of the corrugated foam panel.

[0014] In an embodiment, the corrugated foam panel is attached to the wall by a fastener or an adhesive. In an embodiment, the at least one building material includes a plaster or a siding material.

[0015] A method of making an insulated rainscreen panel is disclosed herein. In an embodiment, the method includes extruding or molding a foam material to form a corrugated foam panel according to embodiments herein, or providing a block of foam material according to embodiments herein, and wire cutting the block of foam material to form the corrugated foam panel according to embodiments herein.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The foregoing summary, as well as the following detailed description of the embodiments, will be better understood when read in conjunction with the attached drawings. For the purpose of illustration, there are shown in the drawings some embodiments, which may be preferable. It should be understood that the embodiments depicted are not limited to the precise details shown. Unless otherwise noted, the drawings are not to scale.

[0017] Figure 1 shows a schematic depiction of an embodiment of an insulated rainscreen panel.

[0018] Figure 2 shows a schematic depiction of the insulated rainscreen panel in Figure 1 as viewed down the length of the panel.

[0019] Figure 3 shows a schematic expanded view of the insulated rainscreen panel in Figure 2

[0020] Figure 4 shows a schematic view of an embodiment of an insulated rainscreen panel as well as an expanded view down the length of the panel.

[0021] Figure 5 shows an illustration of an embodiment of an insulated rainscreen panel used as a double-sided rain screen.

[0022] Figure 6 shows an illustration of an embodiment of an insulated rainscreen panel used as a single sided rain screen.

[0023] Figure 7 shows an illustration of an embodiment of an insulated rainscreen panel used as a single sided rain screen and jig for attaching a brick siding.

PET All ED DESCRIPTION

[0024] Unless otherwise noted, all measurements are in standard metric units.

[0025] Unless otherwise noted, all instances of the words“a,”“an,” or“the” can refer to one or more than one of the word that they modify.

[0026] Unless otherwise noted, the phrase“at least one” means one or more than one of an object. For example,“at least one row of guide lips” means a single row of guide lips, two or more rows of guide lips, or any combination thereof.

[0027] Unless otherwise noted, the term“about” refers to ±10% of the non-percentage number that is described, rounded to the nearest whole integer. For example, about 10 cm, would include 9 cm to 11 cm. Unless otherwise noted, the term“about” refers to ±5% of a percentage number. For example, about 20% would include 15 to 25%. When the term “about” is discussed in terms of a range, then the term refers to the appropriate amount less than the lower limit and more than the upper limit. For example, from about 10 cm to about 100 cm would include from 9 cm to 110 cm.

[0028] The term“substantially” as used herein changes depending on context, as understood by those skilled in the art. When used to indicate a direction or alignment, such as “substantially perpendicular” or“substantially parallel,” then the term“substantially” would include up to plus or minus 10 degrees. The phrase“substantially flat” refers to a planar surface while allowing for a degree of non-planarity, such as bowing of plus or minus 20% or a radius of curvature of from 1 to 10°, and also allowing for structural defects in the surface, such as pitting and unevenness of 2 mm or less.

[0029] Unless otherwise noted, measurable properties (height, width, length, ratio etc.) as described herein are understood to be averaged measurements.

Embodiments of Insulated Rainscreen Panels

[0030] An embodiment of an insulated rainscreen panel as disclosed herein is shown in Figure 1. An insulated rainscreen panel includes a corrugated foam panel 100. The corrugated foam panel has a panel length 102, a panel width 104, a panel thickness 106, a front panel surface 108, a back-panel surface 110, and at least two panel edges 112.

[0031] An embodiment of an insulated rainscreen panel as disclosed herein is shown in Figure 2. An insulated rainscreen panel includes a corrugated foam panel 200. The front panel surface includes a front corrugated surface 202 having front ridges 204 and front trenches 206 that extend the panel length of the corrugated foam panel. The back-panel surface includes a back corrugated surface 208 having back ridges 210 and back trenches 212 that extend the panel length of the corrugated foam panel. The corrugated foam panel has overall thickness 214 measured from a front ridge top to a back ridge top, and panel material thickness 216 measured from a front trench bottom to a back trench bottom. The front ridges or the back ridges have a period center distance 218 between them. The panel edges include a first panel edge 220 having a first interlocking shape 222 and a second panel edge 224 having a second interlocking shape 226. The second interlocking shape has a protruding distance 228 from the second panel edge.

[0032] An embodiment of an insulated rainscreen panel as disclosed herein is shown in Figure 3. An insulated rainscreen panel includes a corrugated foam panel 300. The front ridges have a height 306 measured from a front ridge top 302 to a front trench bottom 304. The front ridges have a period center distance 308 between them, and the back ridges have a period center distance 310 between them. A ridge period center distance of the front panel surface has an alignment 312 with a ridge period center distance of the back-panel surface.

[0033] An embodiment of an insulated rainscreen panel as disclosed herein is shown in Figure 4. An insulated rainscreen panel includes a corrugated foam panel 400. The front panel surface has flat front perches 402 on front tops of the front ridges, and rows of guide lips 404 perpendicular to the front ridges and front trenches on the front corrugated surface.

[0034] An embodiment of an insulated rainscreen panel can function as a double-sided rain screen as illustrated in Figure 5. A corrugated foam panel according to embodiments herein forms a double-sided rain screen 500 between wall 502 and preformed siding 506, such as wood paneling. The panel front corrugated surface forms rain screen spaces 508 in the front trenches of the panel between the preformed siding and the wall. The panel back corrugated surface forms rain screen spaces 510 in the back trenches of the panel between the panel and the wall.

[0035] An embodiment of an insulated rainscreen panel can function as a single-sided rain screen as illustrated in Figure 6. A corrugated foam panel according to embodiments herein forms single sided rain screen 600 between a wall 602 and formed siding 606, such as plaster. The panel back corrugated surface forms rain screen spaces 603 in the back trenches of the panel between the panel and the wall.

[0036] An embodiment of an insulated rainscreen panel can function as a single-sided rain screen and jig as illustrated in Figure 7. A corrugated foam panel 704 according to

embodiments herein is attached to the wall 702, wherein the panel back corrugated surface forms rain screen spaces 703 in the back trenches of the panel between the panel and the wall. An adhesive 706 and mortal 710 is shown bound or adhered to the front corrugated surface of the panel and a siding 708, such as brick. A screw 712 can connect extend from the mortar 710, through the adhesive 706, through a washer 714, through the panel 704 into the wall 702.

[0037] Conventional rigid foam board insulation is often applied in layers to the outside of the walls of buildings, in order to lower the amount of heat loss through the walls. However, the conventional foam layer can also act as a vapor barrier that can result in moisture being trapped inside walls, limiting the ability of the wall to dry out. Trapped moisture creates the potential for the growth of mold, such as black mold, and decay of the wall structure. If the conventional foam layer is thick enough, as may be required to provide sufficient insulation, it can act as a vapor barrier even if the foam is made of a moisture permeable material. In cold climates, moisture moving outward through walls during the use of heaters can condense into liquid vapor/water on the inner surface of the foam board. Warm and humid climates also present challenges due to condensation of moisture inside walls.

[0038] Conventional exterior foam board insulation can also create critical issues for moisture control resulting from rain penetration into walls. Even with minor exterior rain penetration, a wall with conventional exterior foam may not ever dry out, and can remain sufficiently warm and humid to remain in the mold danger zone, even in the winter.

[0039] Various siding building materials are often applied to the outer surface of

conventional foam board insulation. Preformed siding, such as bricks, are applied with the use of a sealing material such as mortar. The sealing material is used to attach the units of building material together and to the panels. Conventional foam panels also may not include any indexing to indicate the placement of the units of building material, such as bricks, onto the panels. Conventional foam panels having flat surfaces and lips to guide the placement of building materials, such as bricks. Such conventional foam panels may not allow for sealant to be placed between the units of building material or between a unit of the building material and the form panel itself. This lack of sealant can result siding layers with weak attachments between siding units and week attachment to the panel. Conventional foam panels may also not provide a way to use fasteners, such as screws and washers, to attach the panels directly to a wall surface, without significant risk of damaging of the foam panel. Even when a formed siding, such as plaster or cement, is also applied directly to the outer surface of foam board insulation, conventional foam panels may not allow for sufficient formed siding material to be placed between the foam panels and the structures used to reinforce plaster and cement, such as rebar.

[0040] In summary, conventional foam panels do not provide for the control or reduction of moisture within wall structures. Conventional foam panels limit the amount of mortar that can be placed between units of siding and between the siding and the conventional foam panel, resulting in weakly attached siding. Conventional panels do not guide the placement of fasteners and the panel can be damaged when trying to get screws to flush with the flat surface of the panel.

[0041] It has been discovered that by changing the shape of foam panels that it is possible to form insulated rainscreen panels that overcome these issues and have significant advantages over conventional foam panels. The insulated rainscreens of the present disclosure can provide for the control of moisture within wall structures of buildings. In an embodiment, an insulated rainscreen provides a corrugated foam panel including a front corrugated surface and a back corrugated surface. The corrugated surfaces can have ridges and trenches that can extend the panel length of the corrugated foam panel. Such an insulated rainscreen can provide a benefit of forming rain screen spaces between the panel and surface on at least one side of the panel. These rain screen spaces allow for rain, humidity, and water to condense on the ridge and trench surfaces and travel downward along a length of the panel and dissipate out of the wall structure at wall joints. Such an embodiment can have a benefit of allowing moisture to flow away from or evaporate from the wall structure. Such an embodiment of an insulated rainscreen can have a dual benefit of controlling or reducing moisture both between a wall surface and the insulated rainscreen, and between a building material and the insulated rainscreen while still providing adequate insulation for the material to satisfy modem building requirements.

[0042] Insulated rainscreens embodied herein can provide a benefit for the control of moisture within wall structures, while providing an improved surface for the attachment of building materials. In such an embodiment, a back corrugated surface of the panel can be attached to a wall surface, where the trenches of the back corrugated surface can form rain screen spaces for the collection of and disposal of moisture. A building material such as a siding can be adhered to a front corrugated surface of the panel. A preformed siding, such as a brick or other material, can be adhered to the front corrugated surface using a sealant material. Such an embodiment can provide for the placement of sealant into the front surface trenches, as well as around and on units of the siding material. A benefit of such an embodiment can include allowing a sufficient amount of sealant to be placed both between and underneath units of the siding to allow a more robust seal to be formed between the units of the siding and between the siding and the front panel surface. Alternatively, a formed siding material, such as plaster or cement, can be adhered directly to the front corrugated surface of the panel. A benefit of such an embodiment can included allowing a sufficient amount of formed siding material to be applied to the front corrugated surface to result in a stronger finished wall structure.

[0043] Another benefit of an embodiment of the insulated rainscreen panels embodied herein can include providing the recessed surface the front trenches that allow for fasteners, such as screws, washers, bolt, and nails, to be attached to the surface of the panel without damaging the panel or disputing the planarity of the siding material. Moreover, the fastener can also be surrounded by an adhesive, such as glue or mortar. In conventional foam panels, the screw holds the conventional foam panel to the wall and placed brick on to of the screws. This situation creates the problem that a heavy siding material, such as brick, is weakly adhered to the foam panel and the heavy siding material layer and foam layer are only held onto the wall by the cohesive strength of the foam material the fasteners are embedded in. In contrast, an embodiment of the insulated rainscreens embodied herein can allow for an adhesive, such as mortar, plaster, cement, to surround the head of a fastener. This situation has the heavy siding layer, such as brick and mortar, connected by steel fasteners through the foam of the insulated rainscreens embodied and into the material of the wall. This creates the solution that the heavy siding layer is strongly bound to the wall and the insulated rainscreen panel.

[0044] In an embodiment, the insulated rainscreen can include a front panel surface having a front corrugated surface, the front corrugated surface having front ridges and front trenches that extend from about 50% to 100% of the panel length of the corrugated foam panel, including about 80% to 100% of the panel length, including about 90% to 98% of the panel length based on a total length of the panel. For example, the ridges might be cut in a direction diagonal or perpendicular to the direction of the ridges to allow for water to pass from one rain screen space to another. In an embodiment, at least a portion of the front ridges can have flat or substantially flat front perches located on front tops of the front ridges, and at least one row of guide lips on top of the front ridges extending above the front perches, and where the rows of guide lips are arranged perpendicular or substantially perpendicular to the front ridges and front trenches. In such an embodiment, a distance between rows of guide lips can be equal or substantially equal to a width of a siding. A benefit of such an embodiment can include providing for indexed placement of units of siding onto the front corrugated surface. Such an embodiment can additionally provide for the placement of sealant into the front trenches, as well as onto the front perches and onto the guide lips. A benefit of such an embodiment can include allowing a sufficient amount of sealant to be placed both between units of the siding, such as bricks, and also underneath the units of siding, allowing an effective seal to be formed between the siding and the front panel surface.

[0045] Generally, the terms“front” and“back” are interchangeable. In an embodiment, the at least two panel edges having an interlocking shape both terminate with in a front ridge. A benefit to having two panel edges having an interlocking shape terminate in a front ridge can be that panel are joined to from a rain screen space between them facing the wall. This feature reduces thermal loss and water retention at gaps between panels. Generally, the “front” of the panel can be distinguished from the“back” by this presence of two panel edges having interlocking shapes terminate in front ridges. Where a panel having two panel edges having interlocking shapes terminate in one front ridge and one front trench, then the terms “front” and“back” as used herein may become arbitrary, as either side can be designate the “front” or“back.”

Embodiments of Corrugated Foam Panels

[0046] In an embodiment, the insulated rainscreen includes a corrugated foam panel. Such a corrugated foam panel can be formed from a rigid foam material, such as a Styrofoam material. The corrugated foam panel can include a polystyrene foam or a polyisocyanurate foam. In an embodiment, the corrugated foam panel can include an expanded polystyrene (EPS) foam material, an extruded polystyrene (XPS) foam material, or combinations thereof. In an embodiment, from about 80% to 100% weight of a corrugated foam panel is a polystyrene foam material, based on a total weight of the corrugated foam panel. In an embodiment, from about 90% to 100% weight of a corrugated foam panel is a polystyrene foam material. In an embodiment, the polystyrene foam material has a weight per volume of about 1 pound per cubic foot, about 2 pounds per cubic foot, or about 3 pounds per cubic foot.

[0047] In an embodiment of an insulated rainscreen panel, a corrugated foam panel is rectangular, and having a panel thickness from about 2.5 cm to about 30.5 cm. In an embodiment, the panel has a thickness from about 5.0 cm to about 25.0 cm. In an embodiment, the panel has a thickness from about 10.0 cm to about 15.0 cm. In an embodiment, the panel length is from about 1.2 meters to about 2.0 meters. In an

embodiment, the panel length is from about 1.5 meters to about 1.7 meters. In an

embodiment, the panel width is from about 1.2 meters to about 2.0 meters. In an

embodiment, the panel length is from about 1.5 meters to about 1.7 meters.

[0048] In an embodiment, front ridges of a corrugated foam panel have a height of from about 6 mm to about 13 mm, measured from a front ridge top to a front trench bottom. In an embodiment, the front ridges have a height of from about 8 mm to about 11mm, measured from a front ridge top to a front trench bottom. In an embodiment, the back ridges have a height of from about 6 mm to about 13 mm, measured from a back ridge top to a back trench bottom. In an embodiment, the back ridges have a height of from about 8 mm to about 11 mm, measured from a back ridge top to a back trench bottom. In an embodiment, the front ridges or the back ridges have a period center distance between them of from about 5 cm to about 8 cm. In an embodiment, the front ridges or the back ridges have a period center distance between them of from about 6 cm to about 7 cm. In an embodiment, a ridge period center distance of the front panel surface differs from 0 cm to about 8 cm from the ridge period center distance of the back-panel surface. In an embodiment, a ridge period center distance of the front panel surface differs from 0 cm to about 4 cm from the ridge period center distance of the back-panel surface. In an embodiment, a ridge period center distance of the front panel surface is aligned with a ridge period center distance of the back-panel surface by a percentage offset of from 0% to 99%. In an embodiment, a ridge period center distance of the front panel surface is aligned with a ridge period center distance of the back- panel surface by a percentage offset of from 40% to 60%.

[0049] In an embodiment, an insulated rainscreen panel includes a first panel edge having a first interlocking shape, and a second panel edge having a second interlocking shape. In an embodiment, the first interlocking shape is complementary to the second interlocking shape. In an embodiment, the first interlocking shape and second interlocking shape are configured to allow for interlocking of a plurality of corrugated foam panels together. In such an embodiment, a plurality of corrugated foam panels may be interlocked together to attach to an area of a wall surface. In an embodiment, the first interlocking shape protrudes from about 3 mm to about 13 mm from the second panel edge. In an embodiment, the first interlocking shape protrudes from about 6 mm to about 9 mm from the second panel edge. In an embodiment, the second interlocking shape protrudes from about 3 mm to about 13 mm from the second panel edge. In an embodiment, the second interlocking shape protrudes from about 6 mm to about 9 mm from the second panel edge.

[0050] Certain embodiments of an insulated rainscreen panel include that at least a portion of the front ridges of the corrugated front surface of the panel have flat or substantially flat front perches located on front tops of the front ridges. In an embodiment, at least a portion of the back ridges of the back corrugated surface have flat or substantially flat back perches located on back tops of the back ridges. In an embodiment, the front trenches and the back trenches have a flat or substantially flat bottom. In an embodiment, the front panel surface is complementary to the back-panel surface.

[0051] Certain embodiments of an insulated rainscreen panel include that the front corrugated surface of the panel has at least one row of guide lips on top of the front ridges that extend about the front perches, and wherein the at least one row of guide lips is arranged in rows that are perpendicular or substantially perpendicular to the front ridges and front trenches. In an embodiment, a height of the guide lip is from about 3 mm to about 13 mm, as measured from a top of the guide lip to an adjacent perch. In an embodiment, a height of the guide lip is from about 5 mm to about 12 mm, as measured from a top of the guide lip to an adjacent perch. In an embodiment, a height of the guide lip is from about 7 mm to about 10 mm, as measured from a top of the guide lip to an adjacent perch. In an embodiment, the perches have a length of about 5 cm to about 10 cm between rows of guide lips. In an embodiment, the perches have a length of about 6 cm to about 9 cm between rows of guide lips. In an embodiment, a distance between rows of guide lips is equal or substantially equal to a width of a siding. In an embodiment, the building material or siding includes a brick, a wood panel, or an aluminum panel. In other embodiments, the siding includes a plastic building material, or a tile material. In an embodiment, the brick includes standard brick, modular brick, norman brick, roman brick, jumbo brick, economy brick, engineer brick, king brick, queen brick, and utility brick.

Embodiments of Methods of Forming an Insulated Rain Screen

[0052] Embodiments herein present methods of forming an insulated rain screen between a wall and a building material. Such methods may be practiced using the various embodiments of the insulated rainscreen panels disclosed herein. In an embodiment of the methods, a corrugated foam panel is provided, the corrugated foam panel including a panel length, a panel width, a panel thickness, a front panel surface, and back-panel surface, and at least two panel edges. In such an embodiment, the front panel surface includes a front corrugated surface having front ridges and front trenches that extend the panel length of the corrugated foam panel, and the back-panel surface includes a back corrugated surface having back ridges and back trenches that extend the panel length of the corrugated foam panel. Such an embodiment can provide for attaching the corrugated foam panel to a wall with the back ridges and the back trenches of the back corrugated surface oriented perpendicular or substantially perpendicular to a floor. Such an embodiment can include laying at least one building material against the front panel surface, and binding the at least one building material onto the front panel surface of the corrugated foam panel.

[0053] In some embodiments, the building material can include a formed siding, including a plaster or a cement material. In other embodiments, the building material can include a preformed siding such as brick, a wood panel, or an aluminum panel. In other embodiments, the siding includes a plastic building material, or a tile material. In an embodiment, the brick includes standard brick, modular brick, norman brick, roman brick, jumbo brick, economy brick, engineer brick, king brick, queen brick, and utility brick.

[0054] In various embodiments, a corrugated foam panel is attached to a wall surface. In such embodiments, the wall surface can include a concrete surface, a cinderblock surface, a wood surface, a plywood surface, an oriented strand board (OSB) surface, furring, studs, and combinations thereof.

[0055] In certain embodiments of the methods, the corrugated foam panel is attached to the wall by a fastener or an adhesive. In such embodiments, the fastener can include a cap nail, a screw, a screw and washer, and combinations thereof. In such embodiments, the adhesive can include a liquid adhesive, a tape adhesive, and combinations thereof. Such embodiments can provide a benefit of attaching a foam panel directly to a wall surface without breakage of the foam panel.

Embodiments of Making an Insulated Rainscreen Panel

[0056] Embodiments herein present methods of making an insulated rainscreen panel. One such embodiment provides extruding or molding a foam material to form a corrugated foam panel according to the various embodiments of insulated rainscreen panels herein. Another such embodiment provides a block of foam material, and wire cutting the block of foam material to form a corrugated foam panel according to the various embodiments of insulated rainscreen panels herein. In such embodiments, the corrugated foam panel can be formed from a rigid foam material, such as a Styrofoam material. In an embodiment, the corrugated foam panel can include a polystyrene foam or a polyisocyanurate foam. In an embodiment, the corrugated foam panel can include an expanded polystyrene (EPS) foam material, an extruded polystyrene (XPS) foam material, or combinations thereof. In an embodiment, from about 80% to 100% weight of a corrugated foam panel is a polystyrene foam material, based on a total weight of the corrugated foam panel. In an embodiment, from about 90% to 100% weight of a corrugated foam panel is a polystyrene foam material. In an embodiment, the polystyrene foam material has a weight per volume of about 1 pound per cubic foot, about 2 pounds per cubic foot, or about 3 pounds per cubic foot.

EXAMPLES

Example 1

[0057] A block of polystyrene foam was provided and wire cut into an insulated rainscreen panel having a front panel surface and a back-panel surface, both front and back panel surfaces including a corrugated surface. The panel had an overall length of 96 inches (243.8 cm), a panel width of 48 inches (121.9 cm), and a panel thickness of 1 ¾ inches (4.5 cm).

The front corrugated surface was formed with front ridges and front trenches extending the panel length of the corrugated foam panel, the front ridges having a height of 3/8 inch (0.95 cm) measured from a front ridge top to a front trench bottom, and a period center distance between the front ridges of 2 inches (5.1 cm). The panel had panel edges with an interlocking shape, the interlocking shape having a protrusion of ¼ inch (0.64 cm) from the panel edge.

Example 2

[0058] An insulated rainscreen panel was molded of polystyrene foam material into a corrugated panel having a front panel surface configured for the application of a modular brick, and a back-panel surface having a back corrugated surface with back ridges and back trenches extending the panel length of the corrugated foam panel. The panel had an overall length of 47 ¾ (121.3 cm) inches, a panel width of 48 inches (121.9 cm), and a panel thickness of 1 1/8 inches (2.86 cm). The front panel surface was formed with flat front perches and rows of guide lips, the front perches having a length of 2 5/8 inches (6.67 cm) between the rows of guide lips, and the guide lips having a height of 3/8 inch (0.95 cm), as measured from a top of a guide lip to an adjacent perch. The panel had panel edges with an interlocking shape, the interlocking shape having a protrusion of ¼ inch (0.64 cm) from the panel edge.

Example 3

[0059] An insulated rainscreen panel was molded of polystyrene foam material into a corrugated panel having a front panel surface configured for the application of a king brick, and a back-panel surface having a back corrugated surface with back ridges and back trenches extending the panel length of the corrugated foam panel. The panel had an overall length of 47 ¾ inches (121.3 cm), a panel width of 48 inches (121.9 cm), and a panel thickness of 1 3/8 inches (3.49 cm). The front panel surface was formed with flat front perches and rows of guide lips, the front perches having a length of 3 3/16 inches (8.1 cm) between the rows of guide lips, and the guide lips having a height of 3/8 inch (0.95 cm), as measured from a top of a guide lip to an adjacent perch. The panel had panel edges with an interlocking shape, the interlocking shape having a protrusion of ¼ inch (0.64 cm) from the panel edge.