Patent Publication Number: US-2010126114-A1

Title: Apparatus for cladding an insulation member, a composite cladded insulation member, and methods of forming and installing same

Description:
FIELD OF THE INVENTION 
     The present invention relates to the field of insulation and cladding for use in building construction, and more particularly, to an apparatus for cladding an insulation member, to a composite cladded insulation member, and to methods of forming and installing same. 
     BACKGROUND OF THE INVENTION 
     The field of building construction is one in which various previously known methods may have been used to apply different types of cladding and wall finishes to the exterior of buildings. A few exemplary wall finishes in the prior art include paint, stone veneer, brick and stucco. These and other wall finishes may have been conventionally applied over a substrate material or wall sheathing (e.g., plywood, insulating fiber board, dry-wall, and concrete). 
     Previously, in an Exterior Insulation and Finish System (EIFS), it has been known to apply a mesh and multiple base coats, manually by trowel, over an insulating foam board (mounted on a substrate attached to building supports), before applying an acrylic top coat (or synthetic stucco) thereover. In this manner, EIFS is a system which may have previously been used to create exterior insulated walls with a cladded and finished surface. Traditionally, EIFS may have included synthetic wall cladding, with foam plastic insulation or EPS boards adhered to a substrate material by adhesive or mechanical anchors. As aforesaid, EIFS is a system that involves a labor-intensive layered application of synthetic coatings (e.g., fiber mesh material, cementitious material, and stucco). 
     As aforesaid, the cementitious material, stucco, insulated foam (e.g., expanded polystyrene or EPS) board, and/or fiber mesh materials of the EIFS may have been conventionally applied, by hand, in the field at the construction site. It may be worthwhile to highlight the fact that the installation or application of a conventional EIFS may have required independent professional contractors to apply, by hand, the synthetic coatings and wall finish. This field-application process may have required a considerable amount of cost, time and/or effort. Moreover, any final product which may have been achieved by such prior methods may have tended to be somewhat weak, and subject to irregular and/or inconsistent thicknesses, possibly with substantially little control over the application process in what may inherently be an uncontrolled outdoor environment. 
       FIG. 1  illustrates some of the prior art materials which may have been previously assembled (in the field) to effect a field-installed system. The traditional wall assembly  20  shown in  FIG. 1 , whether manufactured by EIFS or by some other system, may have included a wall support member  22  (e.g., a stud, possibly one constructed of metal) and a substrate  24  (usually plywood) installed thereagainst to form a backing. A water-resistant barrier (not shown) may have then been applied to the substrate  24 , followed by an adhesive  26 . Thereafter, a conventional insulation board  28 —e.g., expanded polystyrene (EPS)—would have been attached to the substrate  24 . Next, a plurality of base coats of a coating material  32  (e.g., a cementitious material), with a reinforcing mesh  30  embedded therein, may typically have been required to be applied manually. Various venting assemblies (not shown) may have been applied and/or utilized, before application of the final stucco finish coat  34 . Each step was previously required to be performed in the field, and each step may typically have heretofore required good weather and/or skilled labor, so as to properly install and/or perform the steps of the prior art systems. 
     Disadvantages associated with the prior art may have included that the assembly took place under uncontrolled environmental conditions, subject to comparatively little or no consistent quality control, with a high dependence on the weather, and on skilled labor, inter alfa, to provide a rudimentary method of fastening the prior art systems to buildings. 
     In addition, the insulation board  28  that was previously used was inherently incompatible with the mesh material  30  that was thereafter applied and/or bonded thereto. That is—and quite apart from the mesh  30  and the insulation board  28  used in prior art systems not having been particularly adapted for use with one another—the sizing of the one to the other was typically such that, in the course of installing the systems, sequential edges of the mesh  30  would not consistently line up with portions of the insulation board  28 . In the result, the edge of the mesh  30  might overlie either an edge, or the middle portion, of the insulation board  28 . This mismatching of the mesh  30  and insulation board  28  may have previously tended to result in a relatively high incidence of wasted or scrap materials, and/or in an inefficient use of skilled labor. In fact, it may have been only through the workman&#39;s attentive and dedicated application of skill, while also burdened with the difficult and contemporaneous task of manually applying a consistent thickness of cementitious material  32  to the insulation board  28  in-the-field, that the mesh  30  and the insulation board  28  might have been particularly adapted, one pair at a time, for use together in the prior art systems. 
     Moreover, the typical prior art wall assembly  20 —whether assembled, by hand, in keeping with the EIFS or another system—may have been highly susceptible to moisture intrusion. Accordingly, a high degree of skill and/or precision may heretofore have been required in performing an installation, according to conventional EIFS methods, to ensure a snug fit between connecting insulation boards  28 . Imprecise field installation of the insulation boards  28 , and/or in the application of the numerous and labor-intensive layered coatings, may heretofore have resulted, in some cases, in the intrusion of rain water, and/or the in build up of moisture, behind such prior art wall assemblies  20 , thus producing (as a direct or indirect cause) structural damage and/or damage to associated wall finishes  34 . 
     The serious EIFS moisture problems may have been previously identified and documented. According to a study commissioned by the NAHB (National Association of Home Builders), homes surveyed “ages two to six are experiencing structural damage due to excessive moisture buildup within walls. 
     The cause of the moisture accumulation is rain water intrusion from a combination of factors including: improper sealing at joints and around windows, doors, and other penetrations; improperly sloped horizontal EIFS surfaces; inadequate flashing at roof lines, dormers, decks, etc.; and window frames that leak into wall cavities.” 
     It is an object of one preferred embodiment according to the invention to provide a cladding apparatus to form composite cladded insulation pieces. 
     It is an object of one preferred embodiment according to the invention to provide a cladding apparatus for use with a coating material and an insulation member. 
     It is an object of one preferred embodiment according to the invention to provide a composite cladded insulation piece comprised of a coating layer in substantially bonded relation with an insulation member. 
     It is an object of one preferred embodiment according to the invention to provide a composite cladded insulation piece. 
     It is an object of one preferred embodiment according to the invention to provide a method of forming a composite cladded insulation piece. 
     It is an object of one preferred embodiment according to the invention to provide a method of installing composite cladded insulation pieces. 
     It is an object of one preferred embodiment according to the invention to provide a cladding apparatus, a composite cladded insulation piece, and/or method of forming or installing same that may avoid, and/or overcome, previous problems associated with conventional (EIFS or other) wall assembly installations. 
     It is an object of one preferred embodiment according to the invention to provide a cladding apparatus to form composite cladded insulation pieces for use in interior or exterior wall cladding applications. 
     It is an object of one preferred embodiment according to the invention to minimize or reduce costs and/or time associated with the use of insulation and/or (other) cladding in the field of building construction. 
     It is an object of the present invention to obviate or mitigate one or more of the aforementioned mentioned disadvantages associated with the prior art, and/or to achieve one or more of the aforementioned objects of the invention. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, there is disclosed a cladding apparatus for use with a coating material and with an insulation member having at least one coatable surface. According to the invention, the apparatus includes a receiving member and a forming member. The receiving member is operative to securely retain the insulation member. The forming member includes a base portion and a coat delivery portion. The base portion defines a coating aperture therethrough. The base portion has a cladding surface operatively positioned in spaced relation from the coatable surface to define a coating cavity therebetween. The coat delivery portion includes a delivery conduit, in fluid communication with the coating aperture, and operatively delivering the coating material into the coating cavity substantially adjacent to the coatable surface. The coat delivery portion and the cladding surface together operatively form a coating layer of the coating material, in substantially bonded relation, on the coatable surface. In this manner, the cladding apparatus operatively forms a composite cladded insulation piece comprised of the coating layer in substantially bonded relation with the insulation member. 
     According to an aspect of one preferred embodiment of the invention, the receiving member includes a substantially elongate conveyor, preferably having a conveyor entry end portion and a conveyer exit end portion. The conveyor may preferably, but need not necessarily, be operative to move the insulation member from the conveyor entry end portion, in a manufacturing direction, toward the conveyor exit end portion. 
     According to an aspect of one preferred embodiment of the invention, the base portion is positioned in a substantially vertical direction above the conveyor. The cladding surface may preferably, but need not necessarily, be operatively positioned in a substantially vertical direction above the insulation member. 
     According to an aspect of one preferred embodiment of the invention, the base portion has a base entry end portion and a base exit end portion spaced, in the manufacturing direction, from the base entry end portion. The coating aperture may preferably, but need not necessarily, be located between the base entry end portion and the cladding surface. The cladding surface may preferably, but need not necessarily, be located between the coating aperture and the base exit end portion. 
     According to an aspect of one preferred embodiment of the invention, the coating layer is operatively extruded in the manufacturing direction from the base exit end portion, preferably as the conveyor operatively moves the insulation member toward the conveyor exit end portion. 
     According to an aspect of one preferred embodiment of the invention, the cladding surface has two opposing transverse surface edge portions, each preferably shaped to form a recessed portion in a coating edge portion of the coating layer. 
     According to an aspect of one preferred embodiment of the invention, the receiving member includes one or more elongate containment members, preferably operative to retain the insulation member. 
     According to an aspect of one preferred embodiment of the invention, the receiving member includes two opposing elongate containment members, preferably operative to together retain the insulation member therebetween. The containment members may preferably, but need not necessarily, extend along the conveyor between the conveyor entry end portion and the conveyor exit end portion. 
     According to an aspect of one preferred embodiment of the invention, the containment members extend from substantially adjacent to the conveyor entry end portion. 
     According to an aspect of one preferred embodiment of the invention, the receiving member also includes at least one advancing member, preferably operative to securely engage the insulation member, and preferably to assist in moving the insulation member in the manufacturing direction toward the conveyor exit end portion. 
     According to an aspect of one preferred embodiment of the invention, the advancing member includes one or more advancing projection members, preferably operative to matingly and securely engage the insulation member. 
     According to an aspect of one preferred embodiment of the invention, the apparatus is also for use with a reinforcing member. The forming member may preferably, but need not necessarily, be operative to embed the reinforcing member within the coating layer. 
     According to an aspect of one preferred embodiment of the invention, the apparatus is also for use with a reinforcing member, and it preferably includes a reinforcing feeder. The cladding surface may preferably, but need not necessarily, be located substantially in the manufacturing direction from the reinforcing feeder. The reinforcing feeder may preferably, but need not necessarily, operatively convey the reinforcing member between the coatable surface and the cladding surface substantially in the manufacturing direction. The forming member may preferably, but need not necessarily, be operative to embed the reinforcing member within the coating layer. 
     According to an aspect of one preferred embodiment of the invention, the reinforcing feeder includes a spindle, preferably operative to rollably dispense the reinforcing member to an insertion position, above the conveyor, from which the reinforcing member is preferably conveyed between the coatable surface and the cladding surface. 
     According to an aspect of one preferred embodiment of the invention, the reinforcing feeder includes one or more sprocket wheels, preferably operative to convey the reinforcing member, from an insertion position above the conveyor, between the coatable surface and the cladding surface. 
     According to an aspect of one preferred embodiment of the invention, the reinforcing feeder includes one or more feeder arms, preferably operative to convey the reinforcing member, from an insertion position above the conveyor, between the coatable surface and the cladding surface. 
     According to an aspect of one preferred embodiment of the invention, the feeder arms are located substantially adjacent to the conveyor entry end portion. 
     According to an aspect of one preferred embodiment of the invention, the apparatus is for use with a reinforcing fiber mesh material as the reinforcing member. 
     According to an aspect of one preferred embodiment of the invention, the apparatus also includes support members. The forming member may preferably, but need not necessarily, include suspension arms operative to securely engage the support members. The base portion may preferably, but need not necessarily, be suspended above the receiving member. 
     According to an aspect of one preferred embodiment of the invention, the base portion is shaped to define at least one pressure relief aperture therethrough. 
     According to an aspect of one preferred embodiment of the invention, the base portion is shaped to define at least one pressure relief aperture through the cladding surface. The pressure relief aperture may preferably, but need not necessarily, be substantially linear and extend in a substantially transverse direction. The pressure relief aperture may preferably, but need not necessarily, be located between the coating aperture and the base exit end portion. 
     According to an aspect of one preferred embodiment of the invention, the coat delivery portion includes a hopper, preferably operative to contain and deliver the coating material, in fluid communication, to the delivery conduit. 
     According to an aspect of one preferred embodiment of the invention, the delivery conduit includes a venturi-shaped portion, preferably substantially adjacent to the coating aperture. 
     According to an aspect of one preferred embodiment of the invention, the coat delivery portion includes a delivery mechanism, preferably a progressive cavity pump, and preferably operative to deliver the coating material from the delivery conduit into the coating cavity. 
     According to an aspect of one preferred embodiment of the invention, the apparatus is for use with a cementitious material as the coating material. 
     According to an aspect of one preferred embodiment of the invention, the apparatus is for use with a panel section as the insulation member. 
     According to an aspect of one preferred embodiment of the invention, the apparatus is for use with a wall panel as the insulation member. 
     According to an aspect of one preferred embodiment of the invention, the apparatus is for use with a roofing panel as the insulation member. 
     In accordance with the present invention, there is also disclosed a composite cladded insulation piece apparatus. The apparatus is for use with a building substrate member and a wall finish material. According to the invention, the apparatus includes an elongate insulation member and a hardened coating layer. The insulation member has at least one inner mounting surface that is operatively mounted on the building substrate member. The insulation member also has at least one outer coated surface that is formed discretely from the aforesaid at least one mounting surface. The hardened coating layer has at least one outer finishing surface, and at least one inner coating surface. The inner coating surface is substantially coterminous with, and completely covers, the coated surface in securely bonded relation. The coating surface is shaped to define two or more transversely spaced coating projection portions. Each of the coating projection portions extends from the inner coating surface in an inward direction or an outward direction to securely engage the coated surface in substantially encasing relation. The outer finishing surface is operatively coated with the wall finish material. 
     According to an aspect of one preferred embodiment of the invention, the apparatus also includes a reinforcing member embedded within the hardened coating layer. 
     According to an aspect of one preferred embodiment of the invention, the reinforcing member is constructed from a fiber mesh material. 
     According to an aspect of one preferred embodiment of the invention, the outer finishing surface is substantially planar. 
     According to an aspect of one preferred embodiment of the invention, the hardened coating layer has a substantially uniform thickness. 
     According to an aspect of one preferred embodiment of the invention, the hardened coating layer is formed from a cementitious material. 
     According to an aspect of one preferred embodiment of the invention, the coating projection portions extend from the inner coating surface in the inward direction. The coated surface may preferably, but need not necessarily, be shaped to define two or more transversely spaced strengthening grooves therein. The coating projecting portions may preferably, but need not necessarily, matingly engage the strengthening grooves. 
     According to an aspect of one preferred embodiment of the invention, the apparatus also includes a reinforcing member embedded within the hardened coating layer. The coating projection portions may preferably, but need not necessarily, extend from the inner coating surface in the inward direction. The coated surface may preferably, but need not necessarily, be shaped to define two or more transversely spaced strengthening grooves therein. The coating projection portions may preferably extend, beyond the reinforcing member, in mating engagement with the strengthening grooves, preferably so as to strengthen the hardened coating layer. 
     According to an aspect of one preferred embodiment of the invention, one or more of the coating projection portions and the strengthening grooves operatively receive at least one fastener, preferably to fasten the inner mounting surface to the building substrate member. 
     According to an aspect of one preferred embodiment of the invention, the fastener is countersunk within the coating projection portions. 
     According to an aspect of one preferred embodiment of the invention, the coating projection portions matingly engage the strengthening grooves in securely bonded relation. 
     According to an aspect of one preferred embodiment of the invention, the inner mounting surface is shaped so as to define one or more substantially vertical drainage channels therein. 
     According to an aspect of one preferred embodiment of the invention, the inner mounting surface is additionally shaped so as to define one or more substantially horizontal drainage channels therein. Preferably, at least one of the horizontal drainage channels intersects at least one of the vertical drainage channels. 
     According to an aspect of one preferred embodiment of the invention, the insulation member is constructed from expanded polystyrene insulation. 
     According to an aspect of one preferred embodiment of the invention, the insulation member is a panel section. 
     According to an aspect of one preferred embodiment of the invention, the panel section is a wall panel. 
     According to an aspect of one preferred embodiment of the invention, the panel section is a roofing panel. 
     According to an aspect of one preferred embodiment of the invention, the outer finishing surface has two opposing transverse coating edge portions, with each of the transverse coating edge portions preferably, but not necessarily, being shaped to define a recessed portion. 
     According to an aspect of one preferred embodiment of the invention, the apparatus is for use with a stucco material as the wall finish material. 
     In accordance with the present invention, there is also disclosed a method of installing composite cladded insulation pieces. According to the invention, the method includes a mounting step and a finishing step. In the mounting step, at least one inner mounting surface of an elongate insulation member of at least a first one of the pieces is mounted on a building substrate member. In the finishing step, a wall finishing coating of a wall finish material is applied substantially directly onto an outer finishing surface of a hardened coating layer of the first one of the pieces. 
     According to an aspect of one preferred embodiment of the invention, in the mounting step, a fastener may preferably, but need not necessarily, extend (a) through an outer finishing surface of the hardened coating layer, (b) through a coating projection portion that extends in an inward direction from an inner coating surface of the hardened coating layer, (c) through a strengthening groove formed in a coated surface of the insulation member, (d) through the inner mounting surface of the insulation member, and/or (e) into the building substrate member, preferably so as to fasten the inner mounting surface to the building substrate member. 
     According to an aspect of one preferred embodiment of the invention, in the mounting step, at least one inner mounting surface of at least a second one of the pieces is mounted on the building substrate member, preferably substantially adjacent to the first one of the pieces. The method may preferably, but need not necessarily, also include a taping step, preferably after the mounting step and before the finishing step, of applying a joining tape to adjacent coating edge portions of the first one and the second one of the pieces. In the finishing step, the wall finishing coating of the wall finish material may preferably, but need not necessarily, be applied substantially directly onto (a) an outer finishing surface of the first one of the pieces, (b) an outer finishing surface of the second one of the pieces, and/or (c) the joining tape applied to the adjacent coating edge portions of the first one and the second one of the pieces. 
     According to an aspect of one preferred embodiment of the invention, in the taping step, the joining tape is applied to recessed portions of adjacent coating edge portions of the first one and the second one of the pieces. 
     In accordance with the present invention, there is also disclosed a method of forming a composite cladded insulation piece. According to the invention, the method includes an insulation retaining step, a form positioning step, a coat delivery step, and a coat forming step. In the insulation retaining step, an insulation member is securely retained. In the form positioning step, a cladding surface of a forming member is positioned in spaced relation from a coatable surface of the insulation member to define a coating cavity therebetween. In the coat delivery step, a coating material is delivered through a delivery conduit into the coating cavity substantially adjacent to the coatable surface. In the coat forming step, the cladding surface forms a coating layer of the coating material, in substantially bonded relation, on the coatable surface. 
     According to an aspect of one preferred embodiment of the invention, in the insulation retaining step, a substantially elongate conveyor may preferably retain the insulation member. In the form positioning step, the conveyor may preferably, but need not necessarily, move the coatable surface in a manufacturing direction into the aforesaid spaced relation from the cladding surface. 
     According to an aspect of one preferred embodiment of the invention, in the coat forming step, the coating layer may preferably be extruded in the manufacturing direction by the cladding surface, preferably from a base exit end portion of the forming member, and preferably as the conveyor moves the insulation member toward a conveyor exit end portion thereof. 
     According to an aspect of one preferred embodiment of the invention, in the coat forming step, two opposing transverse surface edge portions of the cladding surface may preferably form recessed portions in the coating layer. 
     According to an aspect of one preferred embodiment of the invention, in the form positioning step, the cladding surface is positioned in spaced relation above the coatable surface. 
     According to an aspect of one preferred embodiment of the invention, in the form positioning step, at least one advancing member may preferably securely engage the insulation member, and may preferably assist in moving the insulation member in the manufacturing direction. 
     According to an aspect of one preferred embodiment of the invention, in the form positioning step, one or more advancing projection members of the advancing member matingly and securely engage the insulation member. 
     According to an aspect of one preferred embodiment of the invention, the method also includes a reinforcement positioning step, preferably before the coat delivery step, of positioning a reinforcing member to be embedded within the coating layer in the coat forming step. 
     According to an aspect of one preferred embodiment of the invention, the method also includes a reinforcement positioning step, preferably before the coat delivery step, of conveying a reinforcing member between the coatable surface and the cladding surface, preferably substantially in the manufacturing direction, and preferably to be embedded within the coating layer in the coat forming step. 
     According to an aspect of one preferred embodiment of the invention, in the reinforcement positioning step, a spindle rollably dispenses the reinforcing member. 
     According to an aspect of one preferred embodiment of the invention, in the reinforcement positioning step, one or more sprocket wheels convey the reinforcing member between the coatable surface and the cladding surface. 
     According to an aspect of one preferred embodiment of the invention, in the reinforcement positioning step, one or more feeder arms convey the reinforcing member between the coatable surface and the cladding surface. 
     According to an aspect of one preferred embodiment of the invention, in the reinforcement positioning step, a reinforcing fiber mesh material is used as the reinforcing member. 
     According to an aspect of one preferred embodiment of the invention, in the coat delivery step, a cementitious material is delivered as the coating material. 
     Other advantages, features and characteristics of the present invention, as well as methods of operation and functions of the related elements of the cladding apparatus, the composite cladded insulation member, and the methods of forming and installing same, and the combination of steps, parts and economies of manufacture, will become more apparent upon consideration of the following detailed description and the appended claims with reference to the accompanying drawings, the latter of which are briefly described hereinbelow. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The novel features which are believed to be characteristic of the cladding apparatus, the composite cladded insulation member, and the methods of forming and installing same according to the present invention, as to their structure, organization, use, and method of operation, together with further objectives and advantages thereof, will be better understood from the following drawings in which presently preferred embodiments of the invention will now be illustrated by way of example. It is expressly understood, however, that the drawings are for the purpose of illustration and description only, and are not intended as a definition of the limits of the invention. In the accompanying drawings: 
         FIG. 1  is an outer top right perspective view of a prior art cladded insulation board system, shown in section, as heretofore manually applied in the field; 
         FIG. 2  is a rear top left perspective view of a cladding apparatus according to a preferred embodiment of the present invention, showing a forming member thereof; 
         FIG. 2A  is an enlarged view of encircled area  2 A in  FIG. 2 ; 
         FIG. 2B  is an enlarged view of encircled area  2 B in  FIG. 2 ; 
         FIG. 3  is a front top left perspective view of the cladding apparatus of  FIG. 2 ; 
         FIG. 3A  is an enlarged view of encircled area  3 A in  FIG. 3 ; 
         FIG. 3B  is an enlarged view of encircled area  3 B in  FIG. 3 ; 
         FIG. 4  is a top front right perspective view of the forming member shown in  FIG. 2 ; 
         FIG. 5  is a bottom front right perspective view of the forming member of  FIG. 2 , showing suspension arms thereof; 
         FIG. 6  is a front top right perspective view of a composite cladded insulation piece according to a preferred embodiment of the present invention, shown in partial section; 
         FIG. 7  is an enlarged view of encapsulated area  7  in  FIG. 6 ; 
         FIG. 8  is an outer front left perspective view of the cladded insulation piece of  FIG. 6 , shown in use and in partial section; 
         FIG. 8A  is an enlarged view of encircled area  8 A in  FIG. 8 ; 
         FIG. 9  is a front bottom left perspective view of the cladded insulation piece of  FIG. 6 ; 
         FIG. 10A  is a front side elevational view of the cladded insulation piece of  FIG. 6 ; 
         FIG. 10B  is a bottom plan view of the cladded insulation piece of  FIG. 6 ; 
         FIG. 10C  is an enlarged view of encircled area  10 C in  FIG. 10A ; 
         FIG. 11  is an inner plan view of cladded insulation pieces, as installed according to the invention; 
         FIG. 12  is a side view of a cladded insulation piece, as installed according to the invention; and 
         FIG. 13  is a front top right perspective view of a composite cladded insulation piece according to an alternate preferred embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to  FIGS. 2-5  of the drawings, there is shown a cladding apparatus  40  according to a preferred embodiment of the present invention. In  FIGS. 2-3B , the cladding apparatus  40  is shown in use with a coating material  106 , an insulation member  110 , and a reinforcing member  108 . The coating material  106  is preferably a cementitious material. The insulation member  110  may be a panel section (e.g., intended for use as a wall panel or roofing panel) or virtually any other insulation form or insulation construction, provided that it has one or more coatable surfaces  148  (as best seen in  FIGS. 6-8A ,  10 A,  10 C and  12 - 13 ). The reinforcing member  108  is preferably a reinforcing fiber mesh material (as best seen in  FIGS. 2-3 ). 
     As shown in  FIGS. 2-3B , the apparatus  40  includes a receiving member  160 , support members  66 , a reinforcing feeder  136 , and a forming member  68 . The receiving member  160  includes two elongate containment members  44 , and a substantially elongate conveyor  46  having a conveyor entry end portion  130  and a conveyor exit end portion  132 . The conveyor  46  is preferably provided with an electric drive motor  48  (best seen in  FIGS. 2 and 3 ) to urge the conveyor towards the conveyor exit end portion  132 . The containment members extend along the conveyor  46 , from substantially adjacent to the conveyor entry end portion  130 , towards the conveyor exit end portion  132 . 
     As best seen in  FIG. 2A , the receiving member  160  also has at least one advancing member  134 , preferably including a plurality of advancing projection members  52 . The advancing projection members  52  may preferably take the form of spike-like fingers on a driven chain  50 . The chain  50  may preferably be driven by the electric drive motor  48  (best seen in  FIGS. 2 and 3 ). Of course, other types of advancing projection members  52 , and advancing members  52 , are also possible, and fall within the scope of the present invention. Persons having ordinary skill in the art may appreciate that there are other ways of overcoming any resistance which may be associated with passing the insulation members  110  through the forming member  68 . For example, conveyor and/or vacuum mechanisms might be used in conjunction with, or instead of, spike-like fingers or other advancing projection members  52 . 
     As best seen in  FIGS. 3 and 3A , the reinforcing feeder  136  preferably includes a spindle  54  carrying a mesh roll  56 , and at least one sprocket wheel (not shown). The sprocket wheel may preferably be supported upon the support members  66  above the conveyor  46 . In an alternate preferred embodiment shown in  FIGS. 2 and 3 , the reinforcing feeder  136  may include two feeder arms  58  in place of the sprocket wheel. Either or both of the feeder arms  58  and the sprocket wheel (not shown) are preferably located substantially adjacent to the conveyor entry end portion  130 . 
     As best seen in  FIGS. 2 and 3 , the forming member  68  includes a coat delivery portion  60 ,  64 , suspension arms  70 , and a base portion  72 . The base portion  72  is positioned in a substantially vertical direction (as indicated generally by arrow “B” in  FIGS. 2-5 ) above the conveyor  46 . As shown in  FIG. 5 , the base portion  72  defines a coating aperture  140  therethrough. The base portion  72  has a base entry end portion  74 , a cladding surface  142 , and a base exit end portion  82 . The coating aperture  140  is located between the base entry end portion  74  and the cladding surface  142 . The base exit end portion  82  is spaced, in a manufacturing direction (as indicated generally by arrow “A” in  FIGS. 2-5 ), from the base entry end portion  74 . 
     As best seen in  FIG. 5 , the cladding surface  142  has two opposing transverse surface edge portions  144 . As shown in  FIGS. 2 and 3 , the cladding surface  142  is preferably located, in the manufacturing direction “A” from the reinforcing feeder  136 , between the coating aperture  140  and the base exit end portion  82  (shown in  FIG. 5 ). The base portion  72  is also shaped to define at least one pressure relief aperture  80  through the cladding surface  142 . The pressure relief aperture  80  is substantially linear and extends in a substantially transverse direction (as indicated generally by arrow “C” in  FIGS. 2-5 ). The pressure relief aperture  80  is located between the coating aperture  140  and the base exit end portion  82 . 
     As shown in  FIGS. 2 and 3 , the coat delivery portion  60 ,  64  includes a hopper  60 , and a delivery conduit  64  in fluid communication with both the hopper  60  and the coating aperture  140  (shown in  FIG. 5 ). Preferably, the coat delivery portion  60 ,  64  also includes a delivery mechanism—most preferably a progressive cavity pump  62 . The delivery conduit  64  includes a venturi entry aperture  76  (shown in  FIG. 4 ) leading into a venturi-shaped portion  78  substantially adjacent to the coating aperture  140 . The pressure relief aperture  80  is preferably provided “downstream” of the venturi-shaped portion  78 . 
     In use of the apparatus  40 , the opposing elongate containment members  44  of the receiving member  160  together securely retain the insulation member  110 . The conveyor  46  operatively moves the insulation member  110  from the conveyor entry end portion  130 , in the manufacturing direction “A”, toward the conveyor exit end portion  132 . The advancing projection members  52  matingly and securely engage the insulation member  110 . The advancing member  134  assists in moving the insulation member  110  in the manufacturing direction “A” toward the conveyor exit end portion  132  (best seen in  FIG. 3B ). 
     The suspension arms  70  securely engage the support members  66 , such that the base portion  72  is suspended above the receiving member  160 . The cladding surface  142  is positioned in spaced relation from the coatable surface  148 , in the substantially vertical direction “B” above the insulation member  110 , to define a coating cavity  146  therebetween (such as may be appreciated from a consideration of  FIGS. 3 and 5 ). 
     The spindle  54  rollably dispenses the reinforcing member  108  to an insertion position  138  above the conveyor  46 . From the insertion position  138 , a sprocket wheel (not shown) may preferably rollingly engage the reinforcing member  108  on top of the insulation member  110 . In this manner, the sprocket wheel may preferably convey the reinforcing member  108  between the coatable surface  148  and the cladding surface  142  substantially in the manufacturing direction “A”. Similarly, in the alternate preferred embodiment shown in  FIGS. 2 and 3 , the feeder arms  58  may convey the reinforcing member  108  between the coatable surface  148  and the cladding surface  142 . It may be preferable to introduce the reinforcing member  108  (as best seen in  FIGS. 3 and 3A ) just prior to the coating material  106  being flowed through the forming member  68 . In this manner, a composite cladded insulation piece  100  (such as may be ultimately formed by the cladding apparatus  40 ) may preferably be produced inline in predetermined lengths, such as, for example, in the predetermined length shown in  FIG. 10B . It may also be worthwhile to note that, alternately, the reinforcing member  108  might be introduced, through an aperture (not shown) provided in, and located somewhere between the base entry end portion  74  and the base exit end portion  82  of, the forming member  68 . 
     The hopper  60  contains and delivers the coating material  106 , in fluid communication, to the delivery conduit  64 . The delivery mechanism (e.g., the progressive cavity pump  62 ) urges the coating material  106  from the delivery conduit  64  into the coating cavity  146 . It may be worthwhile to note that, while the  FIGS. 2 and 3  depict the use of a progressive cavity pump  62  to deliver the coating material  106 , the present invention is not so limited. In fact, it is contemplated that any delivery mechanism, method or means suitable to supply the coating material  106  under pressure to the forming member (alternately herein referred to as a “die assembly”)  68  may be used. Other suitable delivery mechanisms may include other pumps and gravity fed methods (not shown). 
     In the aforesaid manner, the delivery conduit  64  delivers the coating material  106  into the coating cavity  146  substantially adjacent to the coatable surface  148 . Flow of the coating material  106  onto the coatable surface  148  is preferably such that the coating material  106  will flow into strengthening grooves  112 ,  114  (as described in considerably greater detail elsewhere herein) of the insulation member  110 . Preferably, the flow of the coating material  106  into the strengthening grooves  112 ,  114  may aid in joining the coating material  106  with the insulation member  110 . In this regard, the depth and/or surface area of the grooves  112 ,  114  may preferably assist in strengthening the composite cladded insulation piece  100 . 
     The cladding surface  142 , together with the coat delivery portion  60 ,  64 , forms a coating layer  156  of the coating material  106 , in substantially bonded relation, on the coatable surface  148 . The forming member  68  embeds the reinforcing member  108  within the coating layer  156 . 
     Preferably, the pressure relief aperture  80  may assist in providing a smooth finished outer finishing surface  102  of the coating layer  156  in the composite cladded insulation piece  100 —i.e., preferably directly off the cladding apparatus  40 . The coating layer  156  is extruded in the manufacturing direction “A” from the base exit end portion  82 , as the conveyor  46  moves the insulation member  110  toward the conveyor exit end portion  132 . Each of the surface edge portions  144  is shaped to form a recessed portion  154  in a coating edge portion of the coating layer  156  (as best seen in  FIGS. 10A and 10C ). 
     In this manner, the cladding apparatus  40  forms the composite cladded insulation piece  100  comprised of the coating layer  156  in substantially bonded relation with the insulation member  110 . 
     Of course, the apparatus  40  may also preferably be used in, and described in the context of, a method of forming the composite cladded insulation piece  100 . It may be worthwhile to note that this forming method (as described in detail hereinafter) may also be used independently of the specific cladding apparatus  40  shown in  FIGS. 2-5 . The forming method preferably includes an insulation retaining step, a form positioning step, a reinforcement positioning step, a coat delivery step, and a coat forming step. In the insulation retaining step, the conveyor  46  retains the insulation member  110 . 
     In the form positioning step, the conveyor  46  moves the coatable surface  148  of the insulation member  110 , in the manufacturing direction “A”, into the aforesaid spaced relation relative to the cladding surface  142  of the forming member  68 . The cladding surface  142  is preferably positioned above the coatable surface  148 . In this manner, the coating cavity  146  is defined between the cladding surface  142  and the coatable surface  148 . 
     In the form positioning step, the advancing projection members  52  of the advancing member  134  matingly and securely engage the insulation member  110 . The advancing member  134  preferably assists in moving the insulation member  110  in the manufacturing direction “A”. 
     The reinforcement positioning step preferably occurs before the coat delivery step. In the reinforcement positioning step, a spindle  54  rollably dispenses the reinforcing member  108  (preferably a reinforcing fiber mesh material), and the reinforcing member  108  is positioned to enable it to be embedded within the coating layer  156  in the coat forming step. Preferably, the sprocket wheel (not shown) conveys the reinforcing member  108 , substantially in the manufacturing direction “A”, between the coatable surface  148  and the cladding surface  142 . Alternately, in the reinforcement positioning step, the feeder arms  58  (shown in  FIGS. 2 and 3 ) may convey the reinforcing member  108  between the coatable surface  148  and the cladding surface  142 . 
     In the coat delivery step, the coating material  106  is delivered through a delivery conduit  64  into the coating cavity  146  substantially adjacent to the coatable surface  148 . 
     In the coat forming step, the cladding surface  142  forms the coating layer  156  of the coating material  106  (preferably, a cementitious material), in substantially bonded relation, on the coatable surface  148 . The forming member  68  extrudes the coating layer  156 , in the manufacturing direction “A”, from the cladding surface  142  adjacent to the base exit end portion  82 . The coating layer  156  is extruded as the conveyor  46  moves the insulation member  110  toward the conveyor exit end portion  132 . As the coating layer  156  is extruded, the opposing transverse surface edge portions  144  of the cladding surface  142  form the recessed portions  154 ,  154  (best seen in  FIGS. 9 ,  10 A and  10 C) in the coating layer  156 . 
     Referring now to  FIGS. 6-13  of the drawings, there is best seen the composite cladded insulation piece  100  according to the invention. The piece  100  may be manufactured using the apparatus  40  or by other means. In  FIGS. 8 and 12 , the piece  100  is shown in use with a building substrate member  24  and a wall finishing coating  34  of a wall finish material. The wall finish material may preferably be a stucco material (e.g., an exterior stucco material). 
     More particularly, the piece  100  includes the elongate insulation member  110 , a hardened coating layer  156  (i.e., preferably the coating layer  156  once hardened), and the reinforcing member  108  embedded within the hardened coating layer  156 . Preferably, and as aforesaid, the reinforcing member  108  is constructed from a fiber mesh material, and the hardened coating layer  156  is formed from a cementitious material. As aforesaid, the insulation member  110  is preferably constructed from expanded polystyrene insulation, and may be provided as a panel section (e.g., a wall panel or a roofing panel) or in virtually any other pre-formed insulation shape or insulated article of manufacture. 
     The insulation member  110  has at least one inner mounting surface  104 . As best seen in  FIGS. 9 and 10B , the inner mounting surface  104  defines a plurality of substantially vertical drainage channels  118 , and a plurality of substantially horizontal drainage channels  116 , therein. The horizontal drainage channels  116  intersect the vertical drainage channels  118 . 
     The insulation member  110  also has at least one outer coated surface  148  (alternately, herein referred to as the “coatable surface  148 ”) that is formed discretely from the mounting surface  104 . As best seen in  FIGS. 6 and 13 , the coated surface  148  is shaped to define a plurality of transversely spaced strengthening grooves  112 ,  114  therein. 
     As best seen in  FIGS. 6 ,  9 ,  10 A,  12  and  13 , the hardened coating layer  156  has a substantially uniform thickness. The hardened coating layer  156  has at least one outer finishing surface  102 , and at least one inner coating surface  150 . The inner coating surface  150  is substantially coterminous with, and completely covers, the coated surface  148  in securely bonded relation. The coating surface  150  is shaped to define a plurality of transversely spaced coating projection portions  152 . Each of the coating projection portions  152  extends from the inner coating surface  150  in an inward direction (as indicated generally by arrow “D” in  FIGS. 6-10A  and  12 - 13 ). As best seen in  FIG. 7 , the coating projection portions  152  securely and matingly engage the strengthening grooves  112 ,  114  of the coated surface  148  in substantially encasing and securely bonded relation. The coating projection portions  152  extend, beyond the reinforcing member  108 , so as to strengthen the hardened coating layer  156 . 
     The outer finishing surface  102  is substantially planar. The outer finishing surface  102  has two opposing transverse coating edge portions  158 ,  158  (as best seen in  FIG. 9 ). As best seen in  FIGS. 9 ,  10 A and  10 C, each of the transverse coating edge portions  158  is shaped to define a recessed portion  154 . 
     In use of the piece  100 , according to the invention, a water-resistant barrier coating  120  may preferably be applied to the building substrate member  24  (as shown in  FIG. 12 ), and the inner mounting surface  104  is operatively mounted on the building substrate member  24 . 
     As shown in  FIG. 6 , the coating projection portions  152  and the strengthening grooves  112  receive at least one fastener  122  (e.g., a screw) to fasten the inner mounting surface  104  to the building substrate member  24 . Preferably, six fasteners  122  may be used per piece  100  (as best seen in  FIG. 6 ). The coating projection portions  152  and the strengthening grooves  112  are preferably such as to enable the fasteners  122  to be countersunk. The strengthening grooves  112  are preferably sized to have a width sufficient to accommodate and/or facilitate the installation of the fasteners  122 . When installed, the fasteners  122  may preferably penetrate through the coating layer  156 , substantially adjacent to the strengthening grooves  112 , and into the supporting substrate  24 , preferably so as to provide added strength. 
     Preferably, when the piece  100  is installed, the drainage channels  116 ,  118  may help to avoid and/or reduce the amount of moisture that might otherwise accumulate behind the piece  100 . As may be best appreciated from a consideration of  FIGS. 8 and 8A , a joint compound coating  124  is preferably then applied, together with joint reinforcing fiber mesh  126 , between the adjoining edge portions of adjacent pieces  100 . As shown in  FIG. 11 , the adjacent pieces  100 ,  100  may be staggered such as to offset the drainage channels  116 ,  118  of each. 
     Thereafter, the outer finishing surface  102  of the piece  100  is operatively coated with the wall finishing coating  34  of the wall finish material. 
     Of course, each piece  100  may also preferably be used in, and described in the context of, a method of installing two or more pieces  100 ,  100 . It may be worthwhile to note that this installation method (as described in detail hereinafter) may also be used independently of the specific pieces  100  shown in  FIGS. 6-13 . The installation method includes a mounting step, a taping step, and a finishing step. 
     In the mounting step, first and second pieces  100 ,  100  are mounted on the building substrate member  24  in substantially adjacent relation to one another. As aforesaid, and as shown in  FIG. 11 , the adjacent pieces  100 ,  100  may be staggered relative to one another. When the pieces  100  are mounted on the substrate member  24 , and as may be best appreciated from a consideration of  FIGS. 8 and 8A , the joint compound coating  124  is preferably then applied, together with the joint reinforcing fiber mesh  126 , between the adjoining edge portions of adjacent pieces  100 ,  100 . 
     The inner mounting surface  104  of the insulation member  110  of each of the pieces  100 ,  100  is mounted on the building substrate member  24 . The fastener  122  extends (a) through the outer finishing surface  102 , (b) through the coating projection portion, (c) through the strengthening groove  112 , (d) through the inner mounting surface  104 , and (e) into the building substrate member  24 , so as to fasten the inner mounting surface  104  to the building substrate member  24 . 
     Preferably, the taping step occurs after the mounting step and before the finishing step. In the taping step, a joining tape (not shown) is applied to the adjacent coating edge portions  158 ,  158  of the first and second pieces  100 ,  100 . The joining tape is preferably applied to the recessed portions  154 ,  154  of the adjacent coating edge portions  158 ,  158 . The joining tape may be applied to vertically and/or horizontally adjacent coating edge portions  158 ,  158 . 
     In the finishing step, the wall finishing coating  34  of the wall finish material is applied substantially directly onto (a) the outer finishing surface  102  of each of the first and second pieces  100 ,  100 , and (b) the joining tape applied to the adjacent coating edge portions  158 ,  158 . 
     It should be appreciated that the present invention extends to include extruded panel sections, base panel extrusions, and systems for use with various exterior and interior wall finishes. Disclosed are means of assembling and installing cladding materials that include a novel EPS (expanded polystyrene) panel, or other insulation board, that is shaped to define strengthening grooves on an exterior surface thereof. Various cement compounds and fiber mesh-like materials may be used in other extruding-like processes, through forming dies, that fall within the scope of the invention. 
     Other modifications and alterations may be used in the design and manufacture of other embodiments according to the present invention without departing from the spirit and scope of the invention, which is limited only by the accompanying claims of this application. For example, in one contemplated alteration, the outer finishing surface  102  of the piece  100  might be marked to locate the position of the drainage channels  116 ,  118  on the opposite side thereof. As well, whether in alternate embodiments and/or in the preferred embodiment of the invention, it may be advantageous for the containment rails  44  to end substantially adjacent to the base entry end portion  74  of the forming member  68  (after guiding the insulation members  110  thereto), rather than extending therebeyond along the remaining length of the conveyor  46 .