Composite insulating building panel and system and method for attaching building panels

Abstract

An insulation panel includes a foam core with a reinforced and vapor-impervious facing disposed on one or both sides of the core. A portion of the facing extends beyond the core and has an adhesive so that the overhanging portion can be secured to an abutting panel to cover a seam between the abutting panels. A fixture for forming the panel includes two heated platens, preferably provided with a textured surface, held apart by a spacer and between which the facing is mechanically suspended. An installation of the insulation panel includes panel-securing elements attached to frame elements of the building and including first and second flanges spaced apart by the thickness of the panel. A portion of the insulation panel is disposed between the first and second flanges, the first flange is secured to the frame element, and a cover panel disposed over the insulation panel is secured to the second flange.

1 - 16 . (canceled) 
     
     
         17 . A composite building insulation panel comprising:
 a rigid foam core panel having a planar surface; and   a facing bonded to the planar surface, the facing, comprising:
 an outer skin layer; and 
 a reinforcing layer between the planar surface and the outer skin layer and comprising woven fibers, wherein the fibers comprise glass and polyester fibers, fiberglass, Kevlar® fibers, or carbon fibers. 
   
     
     
         18 . The composite building insulation panel of  claim 17 , wherein the reinforcing layer comprises tri-directional weave of fibers. 
     
     
         19 . The composite building insulation panel of  claim 18 , wherein at least one axis of the weave is oriented along a length direction of the composite panel. 
     
     
         20 . The composite building insulation panel of  claim 17 , wherein the facing extends beyond an edge of the foam core panel. 
     
     
         21 . The composite building insulation panel of  claim 20 , further comprising an adhesive applied to a portion of the facing extending beyond the edge of foam core panel. 
     
     
         22 . The composite building insulation panel of  claim 17 , wherein the outer skin is at least partially vapor impervious. 
     
     
         23 . The composite building, insulation panel of  claim 22 , wherein the outer skin is configured to have a class I water vapor transmission rating of 0.0 perm to 0.1 perm. 
     
     
         24 . The composite building insulation panel of  claim 17 , wherein the outer skin comprises plastic film. 
     
     
         25 . The composite building insulation panel of  claim 24 , wherein the outer skin is comprised of a material selected from the group consisting of metalized polypropylene, polystyrene, polyethylene, polypropylene, polyurethane, and polyvinylchloride. 
     
     
         26 . The composite building insulation panel of  claim 17 , wherein the outer skin comprises a layer of aluminum. 
     
     
         27 . The composite building insulation panel of  claim 26 , wherein the layer of aluminum has a thickness of 7.6 microns. 
     
     
         28 . The composite building insulation panel of  claim 26 , wherein the outer skin further comprises a barrier coating of elastomeric polymer. 
     
     
         29 . The composite building insulation panel of  claim 17 , wherein the outer skin has a thickness of between 2.5 and 400 microns. 
     
     
         30 . The composite building insulation panel of  claim 17 , wherein the facing further comprises a backing between the planar surface and the reinforcing layer. 
     
     
         31 . The composite building insulation panel of  claim 30 , further comprising an adhesive between the backing and the outer skin to bond the backing with the outer skin and lock interstices of the woven fibers of the reinforcing layer between the backing and the outer skin. 
     
     
         32 . The composite building insulation panel of  claim 17 , wherein the facing is configured so that the composite panel has a class I or class A rating with regard to flame spreading and smoke propagation relative to ASTM E84 criteria. 
     
     
         33 . The composite building insulation panel of  claim 17 , wherein the panel is configured to satisfy Sections 2603.4 through 2603.7 of the international building code with respect to thermal barrier requirements. 
     
     
         34 . The composite building insulation panel of  claim 17 , wherein the core panel has a thickness of ½ inch to 6 inches. 
     
     
         35 . The composite building insulation panel of  claim 17 , wherein the core panel has a density of 1.8 to 2.6 pounds per cubic foot. 
     
     
         36 . The composite building insulation panel of  claim 17 , wherein the core panel comprises polyurethane foam. 
     
     
         37 . The composite building insulation panel of  claim 17 , wherein a surface of the composite panel is textured.