Patterned Panel System with Integrated Decorative Surfaces

Abstract

An insulating concrete form can be used to form the walls of a structure when filled with concrete. An outer surface of the insulating concrete form can be formed into one or more patterns. The patterns may simulate popular finishes such as brick, natural stone, and stucco. In some cases, the exterior of the insulating concrete form is coated with a protective, conformal coating, such as a rubberized acrylic coating or an elastomeric paint.

1 . An insulating concrete form comprising:
 an exterior outer surface;   an interior outer surface, substantially parallel to the exterior outer surface; and   a cavity between the exterior outer surface and the interior outer surface, the cavity being configured to receive a volume of a concrete mixture,   wherein the exterior outer surface of the insulating concrete form has an applied pattern with a plurality of pattern features having a feature depth of at least about ⅛ inch, and   wherein the applied pattern can be reproduced on a plurality of surfaces in a repeatable manner.   
   
   
       2 . The insulating concrete form of  claim 1 , wherein the insulating concrete form further comprises:
 an exterior panel having an inner surface and the exterior outer surface;   an interior panel having an inner surface and the interior outer surface;   one or more connecting members connected to the inner surfaces of the exterior and interior panels.   
   
   
       3 . The insulating concrete form of  claim 1 , wherein the insulating concrete form is manufactured as a single piece. 
   
   
       4 . The insulating concrete form of  claim 1 , wherein the insulating concrete form further comprises a pattern on the interior outer surface. 
   
   
       5 . The insulating concrete form of  claim 1 , wherein an outer surface of the insulating concrete form is coated with a conformal rubberized acrylic coating or an elastomeric paint. 
   
   
       6 . The insulating concrete form of  claim 1 , wherein the insulated concrete form comprises expanded polystyrene or extruded polystyrene. 
   
   
       7 . The insulating concrete form of  claim 1 , wherein the applied pattern is a 4″×8″ standard brick pattern, a Monterrey texture, a 8″×16″ standard brick pattern, a 8″×8″ standard block pattern, a 8″×16″ standard stacked block pattern, a lace texture pattern, a standard split-face pattern, or a fluted pattern. 
   
   
       8 . A structure comprising:
 a foundation;   a plurality of interconnected walls resting on the foundation; and   a roof covering the plurality of interconnected walls,   wherein at least one of the plurality of interconnected walls is an exterior wall having a panel comprising styrenic material, the panel having an applied, reproducible pattern on an outer surface with a plurality of pattern features, and   wherein the applied pattern is visible from an exterior of the structure after the structure is complete.   
   
   
       9 . The structure of  claim 8 , wherein the exterior wall further comprises a conformal, protective coating having a thickness of no more than about ½ inch. 
   
   
       10 . The structure of  claim 8 , wherein the styrenic material comprises expanded polystyrene or extruded polystyrene. 
   
   
       11 . The structure of  claim 8 , wherein the panel is part of an insulating concrete form. 
   
   
       12 . The structure of  claim 8 , wherein the panel is affixed to a pre-existing substrate. 
   
   
       13 . The structure of  claim 8 , wherein the applied pattern has a feature depth of at least about ⅛ inch. 
   
   
       14 . The structure of  claim 8 , wherein the applied pattern is a 4″×8″ standard brick pattern, a Monterrey texture, a 8″×16″ standard brick pattern, a 8″×8″ standard block pattern, a 8″×16″ standard stacked block pattern, a lace texture pattern, a standard split-face pattern, or a fluted pattern. 
   
   
       15 . A method for manufacturing a styrenic panel comprising;
 moving a plurality of styrenic beads into a holding chamber;   expanding the styrenic beads;   moving the styrenic beads into a mold defining a reproducible pattern on a surface, the pattern having a feature depth of at least about ⅛ inch;   expanding the styrenic beads to substantially fill the mold; and   fusing the beads into a single structure of styrenic material,   wherein the reproducible pattern of the mold is applied to surface of the styrenic structure.   
   
   
       16 . The method for manufacturing a styrenic panel of  claim 15 , wherein the styrenic material comprises expanded polystyrene or extruded polystyrene. 
   
   
       17 . The method for manufacturing a styrenic panel of  claim 15 , wherein the pattern is a 4″×8″ standard brick pattern, a Monterrey texture, a 8″×16″ standard brick pattern, a 8″×8″ standard block pattern, a 8″×16″ standard stacked block pattern, a lace texture pattern, a standard split-face pattern, or a fluted pattern. 
   
   
       18 . The method for manufacturing a styrenic panel of  claim 15 , wherein a surface opposing the patterned surface is formed with one or more protrusions configured to be frictionally held. 
   
   
       19 . The method for manufacturing a styrenic panel of  claim 15 , wherein the panel is configured to form a part of an insulating concrete form. 
   
   
       20 . The method for manufacturing a styrenic panel of  claim 15 , wherein the panel is configured to form a part of a system for retrofitting a pre-existing structure.