Patent Document

This application claims the benefit of U.S. Provisional Application No. 60/032,601, filed Dec. 11, 1996. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to insulation panels, and more particularly, but not by way of limitation, to an insulation panel having a moisture removal system. 
     2. Description of the Related Art 
     One building construction system utilizing rigid insulation panels attached to the exterior of the building&#39;s walls is known as Exterior Insulation Finish System (EIFS). In this type construction the insulation is mounted on the exterior of the building wall and a finish coat of some suitable material, such as stucco, is applied. One common type of exterior insulation panel is made from expanded polystyrene (EPS). Panels of EPS insulation are attached to a substrate, such as plywood, by using mechanical fasteners or mastic. 
     However, a problem arises when water, often around windows and doors, seeps into the panels. Although conventional rigid insulation absorbs one to three percent moisture by volume, EIFS panels retard moisture. If moisture leaks in, it becomes trapped for a prolonged period within the cellular structure of the panel. Accumulated water saturates the insulation panels and may bleed to the insulation&#39;s exterior and discolor it. Also, trapped water mildews or rots the underlying substrate, such as plywood or gypsum. In addition, although the water does not damage the insulation, water trapped for prolong periods does, however, degrade the mastic attaching the panel to the building. This degradation of the mastic results in the insulation detaching from the building. As a result, local permitting authorities require some mechanism to discharge accumulated water underneath the EIFS panels. 
     One attempt at a solution is shown in FIG. 1, which utilizes vertical angular-cut grooves on the insulation panel surface. This surface is attached to the building substrate. These grooves form a channel adjacent to the substrate for directing water down to the ground for discharge, thereby eliminating the build-up of water within the panel. 
     This solution suffers several disadvantages. The grooves reduce the bonding surface between the insulation panel and the building, which may result in inadequately attached panels. In addition, the grooves extend into the insulation panel, thereby impairing the structural integrity of the panel, especially when the panels are less than two inches thick. Furthermore, mastic applied to the panel may block the grooves, thereby preventing grooves from forming open channels for the escape of water between the insulation panel and building. 
     Accordingly, an insulation panel that permits the removal of trapped water and provides increased bonding surface between the insulation panel and the building, improved structural integrity of the panels, and substantially unimpaired water conduits will improve over conventional insulation panels. 
     SUMMARY OF THE INVENTION 
     In accordance with the present invention, an insulation panel includes a first surface, a second surface opposite the first surface, a first side, a second side, a third side opposite the first side, and a fourth side opposite the second side. The first, second, third, and fourth sides define a perimeter of the panel. The insulation panel also includes a first conduit and a second conduit internal with respect to the first and second surfaces and extending between the first and third sides. The insulation panel further includes a third conduit and a fourth conduit internal with respect to the first and second surfaces and extending between the second and fourth sides. The conduits remove moisture that accumulates underneath the panel. The insulation panel includes a slit extending from the perimeter to the first, second, third, and fourth conduits for discharging water accumulated within the insulation panel. 
     It is, therefore, an object of the present invention to provide an insulation panel with improved structural integrity. 
     Another object of the present invention is to provide an insulation panel with increased bonding surface area. 
     A further object of the present invention is to provide an insulation panel with internal water conduits that are not blocked by mastic when attaching the panel to the building. 
     Still other objects, features, and advantages of the present invention will become evident to those skilled in the art in light of the following. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a prior art insulation panel. 
     FIG. 2 is a perspective view of a first embodiment of an insulation panel. 
     FIG. 3 is a side, elevational view of the first embodiment of the insulation panel. 
     FIG. 4 is a top, plan view of the first embodiment of the insulation panel. 
     FIG. 5 is a front, elevational view of a building having a first embodiment of the water removal system attached to its outer surface. 
     FIG. 6 is a perspective, close-up view of one corner of the first embodiment of the insulation panel. 
     FIG. 7 is a perspective, close-up view of another corner of the first embodiment of the insulation panel. 
     FIG. 8 is a perspective view of a second embodiment of an insulation panel. 
     FIG. 9 is a side, elevational view of the second embodiment of the insulation panel. 
     FIG. 10 is a top, plan view of the second embodiment of the insulation panel. 
     FIG. 11 is a front, elevational view of a building having a second embodiment of the water removal system attached to its outer surface. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As illustrated in FIGS. 2-4 and  6 - 7 , a first embodiment of an insulation panel  10 , preferably constructed from EPS, includes a first side  11 , a second side  12 , a third side  13 , a fourth side  14 , a first or facing surface  16 , and a second or exterior surface  28 . The panel  10  has a physical structure that contains voids permitting the migration of water therethrough. 
     The panel  10  also has an internal conduit system  15  for removing water. The internal conduit system  15  includes a first conduit  20 , a second conduit  22 , a third conduit  24 , and a fourth conduit  26 . Preferably first and second conduits  20  and  22  are substantially vertical and third and fourth conduits  24  and  26  are substantially horizontal. Although in this first embodiment four conduits  20 ,  22 ,  24  and  26  form a grid-like pattern, one of ordinary skill will readily recognize that other patterns and/or numbers of internal conduits may be used. Preferably, conduits  20 ,  22 ,  24 , and  26  are substantially circular in shape having diameters of approximately 0.25 inch to 0.375 inch. However, other shaped conduits, such as rectangular or triangular, may be utilized. Typically, the panel  10  has a thickness  19  of 1 to 4 inches. Conduits  20 ,  22 ,  24 , and  26  are positioned within 0.125 to 0.25 inch from the surface  16  facing the building. 
     The panel  10  also includes a slit  18 , typically having a width  21  of 0.047 inch, running around its perimeter  17  created by a hot wire cutting device when creating the conduits  20 ,  22 ,  24  and  26 . The slit  18  extends from the perimeter  17  of the panel  10  to the conduits  20 ,  22 ,  24  and  26 . 
     When attaching the panel  10  to a substrate, typically mastic is applied to the facing surface  16 . Due to their location, neither the slit  18  nor the conduits  20 ,  22 ,  24  and  26  come into contact with the mastic, thereby preventing the conduits  20 ,  22 ,  24  and  26  from being blocked with mastic. 
     As illustrated in FIG. 4, a panel system  30  includes staggered rows of insulation panels  10 A-M. Preferably, each panel  10 A-M is attached so that their slits  18 A-M abut and align with another panel&#39;s slits  18 A-M. The panel system  30  removes water seeping in around a window  32 , or water that has penetrated and built-up within the panels  10 A-M. The panel system  30  is designed to route water to vertical conduits for expedited discharge to the ground. The following example illustrates one way the system  30  discharges water accumulated underneath the panels  10 A-M. 
     For this example, water is assumed to seep in and accumulate underneath the panel  10 B at point A of a frame  33  of the window  32 . In addition, the ground  34  slopes so that a panel  10 A elevated slightly higher than a panel  10 D. Initially, accumulated water at A travels downward through a panel  10 B, via a slit  18 B or through voids in the panel  10 B, to a substantially horizontal conduit  24 B. Next, due to the slope of the ground, the water travels along the substantially horizontal conduit  24 B and into a substantially vertical conduit  22 B. Water flows relatively rapidly downward through the substantially vertical conduit  22 B until it reaches a panel  10 G. Water then travels downward through the panel  10 G, via a slit  18 G or through voids in the panel  10 G, until it reaches a substantially horizontal conduit  24 G. Next, due to the slope of the ground, the water travels along the substantially horizontal conduit  24 G and into a substantially vertical conduit  22 G. Water then flows relatively rapidly downward through the substantially vertical conduit  22 G until it reaches a panel  10 L. Water then travels downward through the panel  10 L, via a slit  18 L or through voids in the panel  10 L, until it reaches a substantially horizontal conduit  24 L. Next, due to the slope of the ground, the water travels along the substantially horizontal conduit  24 L and into a substantially vertical conduit  22 L. Subsequently, the water travels relatively rapidly downward through the conduit  22 L to the ground  34 . The system  30  quickly and effectively removes moisture between the panels  10 A-M and the underlying substrate. 
     As illustrated in FIGS. 8-10, a second embodiment of a panel  110 , preferably insulation constructed from EPS, includes a first side  111 , a second side  112 , a third side  113 , a fourth side  114 , a first or facing surface  116 , and a second or exterior surface  128 . The panel  110  has a physical structure that contains voids permitting the migration of water therethrough. 
     The panel  110  also has an internal conduit system  115  for removing water. The internal conduit system  115  includes a first conduit  120 , a second conduit  122 , a third conduit  130 , a fourth conduit  132 , a fifth conduit  124 , and a sixth conduit  126 . Preferably, the first, second, fifth and sixth conduits  120 ,  122 ,  124 , and  126  are substantially vertical and the third and fourth conduits  130  and  132  are substantially horizontal. Although in this second embodiment six conduits  120 ,  122 ,  124 ,  126 ,  130  and  132  form a grid-like pattern, one of ordinary skill will readily recognize that other patterns and/or numbers of internal conduits may be used. Preferably, conduits  120 ,  122 ,  124 ,  126 ,  130  and  132  are substantially circular in shape having diameters of approximately 0.25 inch to 0.375 inch. However, other shaped conduits, such as rectangular or triangular, may also be utilized. Typically, the panel  110  has a thickness  119  of 1 to 4 inches. The conduits  120 ,  122 ,  124 ,  126 ,  130  and  132  are positioned within 0.125 to 0.25 inch from the surface  116  facing the building. 
     The panel  110  also includes slits  121 ,  123 ,  125 ,  127 ,  131 , and  133 , each typically having a width of 0.047 inch, created by the hot wire cutting device when creating conduits  120 ,  122 ,  124 ,  126 ,  130  and  132 . Slits  121 ,  123 ,  125 ,  127 ,  131 , and  133  extend from the facing surface  116  to respective conduits  120 ,  122 ,  124 ,  126 ,  130  and  132 . 
     When attaching the panel  110  to a substrate, typically mastic is applied to the facing surface  116 . But unique features of the slits  121 ,  123 ,  125 ,  127 ,  131 , and  133  prevent mastic from reaching and plugging the conduits  120 ,  122 ,  124 ,  126 ,  130 , and  132 . The mastic easily plugs and seals the small openings of the slits  121 ,  123 ,  125 ,  127 ,  131 , and  133  when attaching the panel  110  to a substrate. In addition, applying pressure to the panel  110  during attachment to the substrate closes the slits  121 ,  123 ,  125 ,  127 ,  131 , and  133  due to their angled cut with respect to the facing surface  116 . These features of the slits  121 ,  123 ,  125 ,  127 ,  131 , and  133  prevent mastic from reaching and blocking conduits  120 ,  122 ,  124 ,  126 ,  130  and  132 . 
     As illustrated in FIG. 11, a panel system  140  includes staggered rows of insulation panels  110 A-M. The panel system  140  removes water seeping in around a window  142 , or water that has penetrated and built-up within the panels  110 A-M. The panels  110 A-M are attached to the substrate so that their vertical conduits are aligned. The panel system  140  is designed to quickly route water to vertical conduits for expedited discharge to the ground. The following example illustrates one way the system  140  discharges water accumulated underneath the panels  110 A-M. 
     For this example, water is assumed to seep in and accumulate underneath the panel  110 B at point A of a frame  143  of the window  142 . In addition, the ground  134  slopes so that a panel  110 A is elevated slightly higher than a panel  110 D. Accumulated water at A initially travels downward through a panel  110 B to a substantially horizontal conduit  130 B within the panel  110 B. Next, due to the slope of the ground, the water travels along the substantially horizontal conduit  130 B and into a substantially vertical conduit  122 B. Water flows relatively rapidly downward through the substantially vertical conduit  122 B until it reaches a corresponding vertical conduit  126 F in a panel  110 F. Water then travels relatively rapidly downward through the conduit  126 F until it reaches a corresponding vertical conduit  122 K in a panel  110 K. Subsequently, the water travels relatively rapidly downward through the conduit  122 K to the ground  134 . The system  140  quickly and effectively removes moisture between the panels  10 A-M and underlying substrate. 
     Because water may travel through voids within the structure of the panel  110 , a modified internal conduit system  115  could include only two substantially vertical conduits and two substantially horizontal conduits for each panel  110 . When the panels  110  are arranged in staggered rows to form the panel system  140 , the vertical conduits for each row are offset. Water accumulated at point A of the system  140  would flow similarly as previously described for the panel system  30 . 
     Although the preferred embodiments utilized insulation panels constructed from EPS, the conduit systems  15  and  115  may be used in other types of external paneling besides insulation. Furthermore, although the preferred embodiments utilized substantially rectangular panels having a length of 48 inches and a width of 24 inches, other shapes, such as squares or triangles, or sizes of panels may also be utilized. 
     From the foregoing description and illustration of this invention it is apparent that various modifications may be made by reconfigurations or combinations producing similar results. It is, therefore, the desire of the applicant not to be bound by the description of this invention as contained in this specification, but be bound only by the claims as appended hereto.

Technology Category: 0