초록 ▼

A wall system includes a first wall section a structural portion, such as concrete block construction. A second wall section mounts to the first wall section and includes insulating panels connected in an edge to edge relationship to form a continuous insulating layer. A third wall section of conven

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

대표청구항 ▼

1. A substantially rectangular panel of expanded foam having a first face and a second opposite face, the panel comprising: at least one plastic mounting element at least partially embedded into the panel; the mounting element including:a first substantially planar portion extending in a plane paral

1. A substantially rectangular panel of expanded foam having a first face and a second opposite face, the panel comprising: at least one plastic mounting element at least partially embedded into the panel; the mounting element including:a first substantially planar portion extending in a plane parallel to the faces of the panel;a second substantially planar portion extending in a plane parallel to the faces of the panel;ribs extending between and perpendicular to the first portion and the second portion, the mounting element having an I-beam type cross-section through the ribs, the ribs being spaced apart and defining openings between the first portion and the second portion, with the expanded foam extending through the openings and surrounding the ribs and the first and second portions, the second portion forming mechanical interlocks opening to the second face of the panel, each of the mechanical interlocks defining a widened portion narrowing to a neck portion at one of the faces of the panel configured for receiving adhesive and interlocking with the adhesive;connecting portions along edges of each panel for fitting edges of the panel to similar adjacent panels. 2. A panel according to claim 1, further comprising indicia on the first face of the panel aligned with the first portions of the mounting elements. 3. A panel according to claim 2, wherein the indicia comprise first markings aligned with mounting elements spaced apart a first distance and second markings spaced apart a second distance. 4. A panel according to claim 1, further comprising alignment notches and complementary tab portions configured for aligning with the notches of an adjacent panel. 5. A panel according to claim 1, wherein the neck portions are spaced apart along the second portion in a side by side arrangement. 6. A panel according to claim 5, wherein the second portion defines slots extending parallel to each neck portion. 7. A panel according to claim 5, further comprising a plurality of slots formed in a first edge of the second portion and extending transverse to a longitudinal direction of the mounting element. 8. A panel according to claim 7, wherein each of the slots extends into an opening defined by a corresponding neck portion. 9. A panel according to claim 5, further comprising a slot extending upward from each of the mechanical interlocks through the second portion. 10. A panel according to claim 9, wherein the slot includes sides having a plurality of ridges. 11. A panel according to claim 5, wherein locations intermediate adjacent neck portions at a side of the second portion at which the neck portions open each include a channel extending intermediate adjacent neck portions. 12. A panel according to claim 1, wherein the connecting portion of a first edge defines a groove and the connecting portion of a second edge defines a complementary tongue. 13. A panel according to claim 12, wherein the first edge defines a first water channel extending in the edge on a first side of the tongue and a second water channel on a second side of the tongue. 14. A panel according to claim 1, wherein flanges extend around a central opening formed by two adjacent ribs. 15. A panel according to claim 14, wherein the flanges form a border around the central opening. 16. A panel according to claim 1, wherein the panel comprises a plurality of parallel spaced apart mounting elements. 17. A panel according to claim 1, wherein the neck portion has angled sides extending inward to the widened portion. 18. An insulation system, comprising: a plurality of rectangular expanded foam panels configured for attaching to a mounting surface, each of the panels having a first face and a second opposite face, the panels fitting together to form an extended insulation layer, each of the panels comprising:at least one plastic mounting element at least partially embedded in the panel; the mounting element including:a first substantially planar portion extending in a plane parallel to the faces of the panel;a second substantially planar portion extending in a plane parallel to the faces of the panel;ribs extending between the first portion and the second portion and defining openings there between, the expanded foam extending through the openings and surrounding the ribs and the first and second portions, the second portion forming mechanical interlock portions configured to receive adhesive for mounting the panel to the mounting surface and defining neck portions interlocking with the adhesive when cured;connecting portions along edges of each panel for fitting edges of the panel to adjacent panels. 19. An insulation system according to claim 18, wherein the mounting element is recessed from the first face. 20. An insulation system according to claim 18, wherein a portion of the mounting element extends outward beyond a plane of the first face. 21. An insulation system according to claim 18, wherein the connecting ribs extend along a length of the mounting element from a midpoint of a width of the first mounting portion and of the second mounting portion. 22. An insulation system according to claim 18, wherein the mechanical interlock has angled sides extending inward from the neck portion to the widened portion. 23. A substantially rectangular panel of expanded foam having a first face and a second opposite face and four edges, the panel comprising: connecting portions along the edges of each panel for fitting edges of the panel to adjacent panels;an elongated plastic mounting element at least partially embedded in the panel, the mounting element comprising:a first mounting portion extending in a plane substantially parallel to the faces of the panel;a second mounting portion extending in a plane substantially parallel to the faces of the panel;connecting ribs extending between the first mounting portion and the second mounting portion and substantially perpendicular to the faces of the panel, the connecting ribs defining openings there between, the expanded foam extending through the openings and surrounding the ribs, the second portion forming mechanical interlock portions defining neck portions opening to one of the faces of the panel and configured to receive and form a mechanical interlock with adhesive;wherein the connecting portion of a first one of the edges defines a tongue and the connecting portion of a second one of the edges defines a complementary groove, and wherein the first ones of the edges defines a first water channel extending in the first one of the edges on a first side of the tongue and a second water channel on a second side of the tongue; andwherein the second face defines chases configured for receiving utility lines extending along the panel. 24. A panel according to claim 23, further comprising indicia on the first face of the panel aligned with the first substantially planar portions of the mounting elements. 25. A panel according to claim 23, further comprising alignment notches and complementary tab portions configured for aligning with the notches of an adjacent panel. 26. A panel according to claim 23, wherein the water channel extends along a length of the first edge. 27. A panel according to claim 23, wherein the tongue includes a chamfered corner to create a channel when fitted against a groove. 28. A panel according to claim 23, wherein the groove defines a longitudinal recessed channel creating a channel when engaged by a tongue. 29. A panel according to claim 23, wherein the panel defines a plurality of parallel channels extending along the second face of the panel. 30. A panel according to claim 23, wherein the panel further defines a chase extending within the panel extending from the top to the bottom of the panel. 31. A panel according to claim 23, wherein the panel further defines a chase extending within the panel extending substantially horizontally. 32. A panel according to claim 23, wherein the connecting portion along the top edge defines tongue with a plurality of vertical channels formed in a side of the tongue. 33. A panel according to claim 32, wherein the connecting portion along the bottom edge defines groove complementary to the tongue of the top edge with a plurality of vertical channels formed in a side of the groove. 34. A panel according to claim 33, wherein the top edge defines an alignment tab having at least one vertical channel formed therein. 35. A panel according to claim 34, wherein the bottom edge defines an alignment notch complementary to the alignment tab and having at least one vertical channel formed therein. 36. A panel according to claim 23, wherein the ribs extend substantially perpendicular to the faces of the panel. 37. A panel according to claim 23, wherein a cross-section of the mounting element through the first mounting portion, the second mounting portion and the ribs comprises an I-beam. 38. A panel according to claim 23, wherein the mechanical interlock has angled sides extending inward from the neck portion to the widened portion.