Panels and methods of preparation thereof
AssigneeWestlake Royal Building Products Inc.
InventorsHamed Lakrout, Soufiane Mohand-Kaci, Russell L. Hill, Wayne Buoni, Russ Kendal Majors, Brian Allen Shaw
Life of this patent
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Abstract
Composite panels and methods of use and manufacturing are described herein. The composite panels may comprise a foam composite and one or more layers of a facing material. The foam composite may have a density less than or equal to 20 pcf, and the layer(s) of facing material, e.g., inorganic facing material, may have a thickness of 1/16 inch to 1 inch covering at least the front surface of the foam composite.
Claims16
A panel configured for attachment to a mounting surface, the panel comprising:
- a foam composite comprising a polymer and an inorganic filler, wherein the foam composite has a front surface opposite a back surface and a density less than or equal to 20 pcf;
- and
- a layer of a facing material having a thickness of 1/16 inch to 1 inch covering at least the front surface of the foam composite, wherein the facing material includes at least one design element comprising a pigment or dye and has a density of 80 pcf to 130 pcf, and wherein the at least one design element provides an appearance of brick, wood, or tile;
- wherein the back surface of the foam composite includes at least one channel that defines a flow path configured to direct flow of a fluid between the panel and the mounting surface, such that fluid entering the flow path from a top edge of the panel flows in a direction towards a side edge of the panel.
A panel configured for attachment to a mounting surface, the panel comprising:
- a foam composite comprising a polymer and an inorganic filler;
- and
- a layer of a facing material having a thickness of 1/16 inch to 1 inch covering at least a front surface of the foam composite, wherein the facing material comprises a cementitious material in direct contact with the foam composite, the facing material including at least one design element comprising a pigment or dye and providing an appearance of brick, wood, or tile;
- wherein a back surface of the foam composite includes at least one channel that defines a flow path configured to direct flow of a fluid between the panel and the mounting surface, such that the fluid entering the flow path from a top edge of the panel flows in a direction towards a side edge of the panel;
- and
- wherein the foam composite has a density less than or equal to 20 pcf, and the facing material has a density of 80 pcf to 130 pcf.
A method of making a panel, the method comprising:
- applying a layer of a facing material to a surface of a mold, the layer having a thickness of 1/16 inch to 1 inch;
- applying a pigment or dye to the layer of facing material;
- and
- applying a polymer mixture to the layer of facing material after applying the pigment or dye, wherein the polymer mixture forms a foam composite inside the mold;
- wherein the foam composite has a front surface in contact with the layer of facing material opposite a back surface, the back surface of the foam composite including at least one channel that defines a flow path configured to direct flow of a fluid between the panel and a mounting surface, such that the fluid entering the flow path from a top edge of the panel flows in a direction towards a side edge of the panel;
- wherein the facing material includes the pigment or dye to form at least one design element and has a density of 80 pcf to 130 pcf, the at least one design element having an appearance of brick, wood, or tile;
- and
- wherein the foam composite has a density less than or equal to 20 pcf.
Dependencies are inferred from the claim text.