US20150082724A1

US20150082724A1 - Reinforced insulating panel and method of manufacturing same

Info

Publication number: US20150082724A1
Application number: US14/034,850
Authority: US
Inventors: Victor Amend
Original assignee: Individual
Current assignee: Individual
Priority date: 2013-09-24
Filing date: 2013-09-24
Publication date: 2015-03-26

Abstract

A reinforced insulating panel comprises an insulating foam slab, and at least one reinforcement sheet disposed on a respective face of the insulating foam slab. Each reinforcement sheet comprises a plurality of continuous fibers extending diagonally across the insulating foam slab.

Description

FIELD OF THE INVENTION

The present invention relates generally to building structures and in particular, to a reinforced insulating panel and method of manufacturing same.

BACKGROUND OF THE INVENTION

In the field of building and construction, the light-frame construction method, sometimes referred to as “stick framing” or “stick construction”, is commonly used for constructing small- to medium-sized buildings, such as for example houses. Walls that are constructed using this method typically comprise a series of vertically-oriented frame members, such as lumber “studs”, that are joined by horizontally-oriented frame members, such as lumber “header” plates and lumber “footer” plates. For exterior walls, a layer of rigid boards, such as plywood boards or oriented strand board (OSB) boards, is usually fastened to exterior-facing sides of the frame members to increase the structural rigidity of the wall. A layer of insulating material, such as for example slabs of expanded polystyrene (EPS) foam, is then fastened to the rigid boards to provide thermal insulation. A weather barrier, such as for example a polymer film, is then affixed to the layer of insulating material to provide a barrier to liquid.
For example, FIG. 1 shows a portion of a prior art exterior wall 10 constructed using the light-frame construction method. The wall 10 comprises a series of vertically-oriented frame members, namely lumber wall studs 12, that are joined by lumber header plates (not shown) and lumber footer plates (not shown). The wall 10 also comprises a plurality of OSB boards 14 fastened to exterior-facing sides of the studs 12, and a layer of insulating material slabs 16 fastened to the OSB boards 14 for providing thermal insulation. The wall 10 further comprises a weather barrier 18 affixed to the insulating material slabs 16 for providing a barrier to liquid. Interior finishing materials (not shown), such as for example drywall boards, may then be fastened to the interior-facing sides of the studs 12, and exterior finishing materials (not shown), such as for example masonry or brickwork, may be constructed adjacent the exterior-facing surface of the wall 10.
Improvements are generally desired. It is therefore an object of the present invention at least to provide a novel reinforced insulating panel and method of manufacturing same.

SUMMARY OF THE INVENTION

At the time of writing, many North American building codes are being updated to require that exterior walls of buildings constructed using the light-frame construction method include some form of diagonal bracing. There is therefore a general need for building materials that include some form of diagonal bracing.
Accordingly, in one aspect there is provided a reinforced insulating panel comprising: an insulating foam slab; and at least one reinforcement sheet disposed on a respective face of the insulating foam slab, each reinforcement sheet comprising a plurality of continuous fibers extending diagonally across the insulating foam slab.
The continuous fibers may extend between diagonally opposite corners of the face and between adjacent edges of the face.
The reinforcement sheet may comprise at least one film and the continuous fibers. The at least one film may comprise a single film. The continuous fibers may be disposed between the single film and the insulating foam slab. The single film may be disposed between the continuous fibers and the insulating foam slab. The single film may be adhered to the insulating foam slab. The single film may be metallized. The single film may be perforated. The at least one film may comprise a first film and a second film, the continuous fibers being disposed between the first film and the second film. At least one of the first film and the second film may be adhered to the insulating foam slab. At least one of the first film and the second film may be metallized. At least one of the first film and the second film may be perforated.
The at least one reinforcement sheet may comprise a single reinforcement sheet joined to a first face of the insulating foam slab, and wherein the panel further comprises a backing sheet joined to a second face of the insulating foam slab. The first face and the second face may be opposite faces of the insulating foam slab.
The at least one reinforcement sheet may comprise a first reinforcement sheet disposed on a first face of the insulating foam slab and a second reinforcement sheet disposed on a second face of the insulating foam slab. The first face and the second face may be opposite faces of the insulating foam slab.
The plurality of continuous fibers may comprise parallel continuous fibers. The parallel continuous fibers may be uniformly spaced. The parallel continuous fibers may have a pitch of less than about 0.4 inches. The parallel continuous fibers may have a pitch of less than about 0.25 inches. The parallel continuous fibers may define an angle of about 26.6 degrees relative to a longitudinal side of the panel. The parallel continuous fibers may be arranged as a diagonal grid. The parallel continuous fibers may comprise a first set of parallel continuous fibers and a second set of parallel continuous fibers. The first set of parallel continuous fibers may have a different diagonal orientation than the second set of parallel continuous fibers. The fibers of the first set may define an angle of about 53.1 degrees relative to the fibers of the second set.
The continuous fibers may be fabricated of any of glass, metal, polymer, plastic, and wool.
The insulating foam slab may be fabricated of any of expanded polystyrene foam, extruded polystyrene foam, and polyurethane foam.
In another aspect, there is provided a method of manufacturing a reinforced insulating panel, the method comprising: providing an insulating foam slab; providing at least one reinforcement sheet, each reinforcement sheet comprising a plurality of continuous fibers; and affixing each reinforcement sheet to a respective face of the insulating foam slab such that the continuous fibers are oriented diagonally across the insulating foam slab.
The method may further comprise, prior to the affixing, orienting the reinforcement sheet such that the continuous fibers are oriented to extend between diagonally opposite corners of the face and between adjacent edges of the face.
The reinforcement sheet may comprise at least one film and the continuous fibers. The at least one film may comprise a single film. The continuous fibers may be disposed between the single film and the insulating foam slab. The single film may be disposed between the continuous fibers and the insulating foam slab. The single film may be adhered to the insulating foam slab. The single film may be metallized. The single film may be perforated. The at least one film may comprise a first film and a second film, the continuous fibers being disposed between the first film and the second film. At least one of the first film and the second film may be adhered to the insulating foam slab. At least one of the first film and the second film may be metallized. At least one of the first film and the second film may be perforated.
The at least one reinforcement sheet may comprise a single reinforcement sheet, the method further comprising: affixing a backing sheet to a respective face of the insulating foam slab.
The plurality of continuous fibers may comprise parallel continuous fibers. The parallel continuous fibers may be uniformly spaced. The parallel continuous fibers may have a pitch of less than about 0.4 inches. The parallel continuous fibers may have a pitch of less than about 0.25 inches. The parallel continuous fibers may define an angle of about 26.6 degrees relative to a longitudinal side of the panel. The parallel continuous fibers may be arranged as a diagonal grid. The parallel continuous fibers may comprise a first set of parallel continuous fibers and a second set of parallel continuous fibers. The first set of parallel continuous fibers may have a different diagonal orientation than the second set of parallel continuous fibers. The fibers of the first set may define an angle of about 53.1 degrees relative to the fibers of the second set.
The continuous fibers may be fabricated of any of glass, metal, polymer, plastic, and wool.
The insulating foam slab may be fabricated of any of expanded polystyrene foam, extruded polystyrene foam, and polyurethane foam.
The providing the insulating foam slab may further comprise molding the insulating foam slab.
The providing the at least one reinforcement sheet may further comprise forming the at least one reinforcement sheet. The forming may comprise disposing the continuous fibers and at least one glue layer between a first film and a second film. The forming may comprise disposing the continuous fibers and at least one glue layer against a film. Disposing the continuous fibers may further comprise disposing each fiber individually or disposing two or more continuous fibers simultaneously. The forming may further comprise orienting the continuous fibers so as to have a suitable diagonal orientation.
In another aspect, there is provided a method of manufacturing a reinforced insulating panel, the method comprising: providing an insulating foam slab; and affixing a film to a face of the insulating foam slab, and affixing a plurality of continuous fibers to the film, the continuous fibers being oriented so as to be oriented diagonally across the face of the insulating foam slab, or affixing a plurality of continuous fibers to a face of the insulating foam slab, the continuous fibers being oriented so as to be oriented diagonally across the face of the insulating foam slab, and affixing a film to the continuous fibers.
The method may further comprise, where the continuous fibers have been affixed to the film that has been affixed to the insulating foam slab, affixing an additional film to the continuous fibers.
Affixing the continuous fibers may further comprise orienting the continuous fibers so as to have a suitable diagonal orientation.
Affixing the continuous fibers may further comprise orienting the continuous fibers such that the continuous fibers are oriented to extend between diagonally opposite corners of the face and between adjacent edges of the face.
Affixing the continuous fibers may further comprise affixing each fiber individually or affixing two or more continuous fibers simultaneously.
One or more of the film and the additional film may be metallized. One or more of the film and the additional film may be perforated.
The method may further comprise: affixing a backing sheet to an opposite face of the insulating foam slab. The backing sheet may be metallized. The backing sheet may be perforated.
The plurality of continuous fibers may comprise parallel continuous fibers. The parallel continuous fibers may be uniformly spaced. The parallel continuous fibers may have a pitch of less than about 0.4 inches. The parallel continuous fibers may have a pitch of less than about 0.25 inches. The parallel continuous fibers may define an angle of about 26.6 degrees relative to a longitudinal side of the panel. The parallel continuous fibers may be arranged as a diagonal grid. The parallel continuous fibers may comprise a first set of parallel continuous fibers and a second set of parallel continuous fibers. The first set of parallel continuous fibers may have a different diagonal orientation than the second set of parallel continuous fibers. The fibers of the first set may define an angle of about 53.1 degrees relative to the fibers of the second set.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described more fully with reference to the accompanying drawings in which:

FIG. 1 is a sectional plan view of a portion of a prior art wall;

FIG. 2 is a perspective view of a reinforced insulating panel;

FIG. 3 is a front elevational view of the reinforced insulating panel of FIG. 2;

FIG. 4 is side view of the reinforced insulating panel of FIG. 2;

FIG. 5 is an end view of the reinforced insulating panel of FIG. 2;

FIG. 6 is a rear elevational view of the reinforced insulating panel of FIG. 2;

FIG. 7 is an enlarged fragmentary view of a portion of the reinforced insulating panel of FIG. 3 identified by reference numeral 7;

FIG. 8 is an enlarged fragmentary view of a portion of the reinforced insulating panel of FIG. 6 identified by reference numeral 8;

FIG. 9 is an exploded view of a portion of a reinforcement sheet forming part of the reinforced insulating panel of FIG. 2; and

FIG. 10 is a sectional plan view of a portion of a wall incorporating the reinforced insulating panel of FIG. 2.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Turning now to FIGS. 2 to 9, a reinforced insulating panel is shown and is generally indicated by reference numeral 20. Panel 20 is configured to be fastened to exterior-facing sides of frame members of an exterior wall of a building constructed using the light-frame construction method.
Panel 20 comprises a generally planar insulating foam slab 22 having a monolithic shape and defining opposing faces, namely a first face 24 and a second face 26. In this embodiment the insulating foam slab 22 is fabricated of molded expanded polystyrene (EPS) foam, and has a longitudinal shape having dimensions of 4 feet×8 feet×1 inch.
The panel 20 further comprises a reinforcement sheet 30 disposed on the first face 24 of the insulating foam slab 22. In the embodiment shown, the reinforcement sheet 30 comprises two (2) polymer films, namely a first film 32 and a second film 34, and a plurality of diagonally-oriented continuous fibers 40 disposed between the first film 32 and the second film 34 in a “sandwich” configuration.
In this embodiment, the continuous fibers 40 are arranged as two (2) sets of parallel continuous fibers, namely a first set 52 of parallel continuous fibers and a second set 54 of parallel continuous fibers. Each set 52 and 54 of parallel continuous fibers is oriented in a respective diagonal orientation, and with each continuous fiber 40 of each set 52 and 54 being sized so as to extend diagonally across the first face 24. In this embodiment, the continuous fibers 40 within each set 52 and 54 of parallel continuous fibers are uniformly spaced and have a pitch of about 0.25 inches, and are fabricated of glass. The continuous fibers 40 are oriented so as to extend between diagonally opposite corners of the first face 24 and between adjacent edges of the first face 24. As a result of this orientation and the dimensions of the insulating foam slab 22, in this embodiment, the fibers 40 define an angle θ of about 26.6 degrees relative to the longitudinal side of the panel 20, as may be seen in FIG. 7, and the fibers of set 52 define an angle of about 53.1 degrees relative to the fibers of set 54.
At least one glue layer (not shown) is disposed generally between the first film 32 and the second film 34 for joining the first film 32, the plurality of continuous fibers 40, and the second film 34 within the reinforcement sheet 30. A glue layer (not shown) is also disposed between the second film layer 34 and the first face 24 for bonding the reinforcement sheet 30 to the insulating foam slab 22. As will be understood, as a result of this bonded construction, the panel 20 advantageously has a generally integrated, unitary structure. In this embodiment, the first film 32 and the second film 34 are fabricated of polypropylene.
The panel 20 also comprises a backing sheet 60 disposed on the second face 26 of the insulating foam slab 22. In this embodiment, the backing sheet 60 comprises a single film, and is fabricated of polypropylene. A glue layer (not shown) is disposed between the backing sheet 60 and the second face 26 for bonding the backing sheet 60 to the insulating foam slab 22.
FIG. 10 shows a portion of an exterior wall incorporating the panel 20, and which is generally indicated by reference numeral 70. Wall 70 forms part of an exterior wall of a building, such as for example a house, constructed using the light-frame construction method. The wall 70 comprises a plurality of vertically-oriented frame members 72 that are joined by a plurality of horizontally-oriented frame members (not shown). In this embodiment, the vertically-oriented frame members 72 are lumber wall studs, and the horizontally-oriented frame members are be lumber header plates (not shown) and lumber footer plates (not shown). The wall 70 further comprises a plurality of panels 20 fastened to exterior-facing sides of the vertically-oriented frame members 72 and the horizontally-oriented frame members by fasteners (not shown). In this embodiment, the fasteners are screws. As may be seen in FIG. 10, the panels 20 are fastened such that the panels 20 are arranged in a single layer against the frame members, such that the longitudinal sides of adjacent panels 20 abut, and such that the backing sheets 60 abut the frame members.
Interior finishing materials (not shown), such as for example drywall boards, may be fastened to interior-facing sides of the vertically-oriented frame members 72, and exterior finishing materials (not shown), such as for example masonry or brickwork, may be constructed adjacent the exterior-facing surface of the wall 70.
As will be appreciated, because the continuous fibers 40 extend between diagonally opposite corners and between adjacent edges of the first face 24, the continuous fibers 40 improve the overall structural rigidity of the panel 20, and increase the strength of the panel 20 along its diagonal directions and thereby provide diagonal bracing to the panel 20. As a result, use of the panel 20 in an exterior wall advantageously enables the exterior wall to satisfy building codes that require exterior walls to include diagonal bracing.
As will be appreciated, the generally unitary construction of the panel 20 comprises diagonal bracing, thermal insulation and a moisture barrier within a single unit. Thus, during construction of an exterior wall, fastening of a single panel 20 to frame members effectively results in the simultaneous fastening of diagonal bracing, thermal insulation and a moisture barrier. As will be understood, this advantageously reduces the amount of on-site labour needed to construct the wall. Additionally, the generally unitary construction advantageously enables diagonal bracing, thermal insulation and the moisture barrier to be transported as a single unit, thereby facilitating, and lowering the associated cost of, materials delivery to the construction site.
In this embodiment, the reinforced insulating panel 20 is manufactured by providing a molded insulating foam slab 22 having desired dimensions, and by providing a reinforcement sheet 30. The reinforcement sheet 30 is affixed to the first face 24 of the insulating foam slab 22 by peeling a disposable backing film (not shown) disposed on the second film 34 to expose a glue layer (not shown), orienting the reinforcement sheet 30 such that the continuous fibers 40 therein have a suitable diagonal orientation relative to the insulating foam slab 22, and then applying the oriented reinforcement sheet 30 such that the glue layer is brought into contact with the first face 24 of the insulating foam slab 22. The backing sheet 60 is affixed to the second face 26 of the insulating foam slab 22 by peeling a disposable backing film (not shown) disposed on the backing sheet 60 to expose a glue layer (not shown), and then by applying the backing sheet 60 such that the glue layer is brought into contact with the second face 26 of the insulating foam slab 22. Any of the reinforcement sheet 30 and the backing sheet 60 may be cut to suitable size, if needed, either prior to or after being affixed to the insulating foam slab 22.
The reinforced insulating panel is not limited to the configuration described above, and in other embodiments, other configurations may be used. For example, although in the embodiment described above, the panel comprises a reinforcement sheet fastened to the first face of the insulating foam slab and a backing sheet fastened to the second face, in other embodiments, the panel may alternatively not comprise any backing sheet. In one such embodiment, the second face of the insulating foam slab may alternatively define a surface of the panel. In still other embodiments, the panel may alternatively comprise two (2) reinforcement sheets, namely a first reinforcement sheet fastened to the first face of the insulating foam slab and a second reinforcement sheet fastened to the second face of the insulating foam slab.
Although in the embodiment described above, the backing sheet comprises a single film, in other embodiments, the backing sheet may alternatively comprise a plurality of films.
Although in the embodiment described above, the reinforcement sheet comprises a plurality of continuous fibers disposed between the first film and the second film in a “sandwich” configuration, in other embodiments, the reinforcement sheet may alternatively comprise only a single film and the continuous fibers. In one such embodiment, the continuous fibers may be disposed between the single film and the insulating foam slab. In another such embodiment, the single film may be disposed between the continuous fibers and the insulating foam slab.
Although in the embodiment described above, the first film, the second film and the backing sheet are fabricated of polypropylene, in other embodiments, one or more of the first film, the second film and the backing sheet may alternatively be fabricated of another suitable material, such as for example, polyester. In a related embodiment, one or more of the first film, the second film and the backing sheet may alternatively be fabricated of a polymeric fibrous material, such as for example Tyvek®, manufactured by Dupont® of Wilmington, Del., U.S.A. In a related embodiment, one or more of the first film, the second film and the backing sheet may alternatively be metallized for providing reflectivity of light having wavelengths in the infrared range for providing additional thermal insulation.
One or more of the first film, the second film and the backing sheet may comprise perforations for reducing or preventing moisture accumulation within the panel.
Although in the embodiment described above, the reinforcement sheet and the continuous fibers therein cover the entire face of the insulating foam slab, in other embodiments, the reinforcement sheet and the continuous fibers may cover only a portion of the face of the insulating foam slab.
Although in the embodiment described above, the continuous fibers are arranged as two (2) sets of parallel continuous fibers, in other embodiments, the continuous fibers may alternatively be arranged as only one (1) set of parallel continuous fibers that are oriented in a diagonal orientation, such that the parallel continuous fibers extend between diagonally opposite corners of a face of the insulating foam slab and between adjacent edges of the face of the insulating foam slab. In still other embodiments, the continuous fibers may alternatively be arranged as more than two (2) sets of parallel continuous fibers, with first and second sets of parallel continuous fibers each being oriented in a respective diagonal orientation, such that the parallel continuous fibers of each of the first and second sets extend between diagonally opposite corners of a face of the insulating foam slab and between adjacent edges of the insulating foam slab, and with one or more additional sets of parallel continuous fibers, with the fibers of each additional set being oriented in a different respective orientation, such as for example in a longitudinal orientation, in a transverse orientation, or in any other orientation therebetween. Here, it will be understood that in the “longitudinal orientation” the fibers extend between the transverse edges of the face of the insulating foam slab, while in the “transverse orientation” the fibers extend between the longitudinal edges of the face of the insulating foam slab. As an example, in one embodiment, the continuous fibers may alternatively be arranged as four (4) sets of parallel continuous fibers, with first and second sets of parallel continuous fibers each being oriented in a respective diagonal orientation, such that the parallel continuous fibers of each of the first and second sets extend between diagonally opposite corners of a face of the insulating foam slab and between adjacent edges of the insulating foam slab, and with a third set of parallel continuous fibers being oriented in the longitudinal orientation and with a fourth set of parallel continuous fibers being oriented in the transverse orientation.
Although in the embodiment described above, the continuous fibers are arranged as two (2) sets of parallel continuous fibers, in other embodiments, the continuous fibers may alternatively be arranged as one or more sets of non-parallel continuous fibers. For example, in one such embodiment, the continuous fibers may alternatively be arranged as a first set of non-parallel continuous fibers and a second set of non-parallel continuous fibers, with fibers of each set being generally oriented in a respective diagonal orientation, and with fibers of each set being sized so as to extend diagonally across the first face.
Although in the embodiment described above, the fibers within each set of parallel continuous fibers have a pitch of about 0.25 inches, in other embodiments, the fibers may alternatively have a pitch less than or greater than 0.25 inches. In one embodiment, the pitch of the fibers within each set of parallel continuous fibers may be from about 0.25 inches to about 0.40 inches. In still other embodiments, the pitch of the fibers within one set may alternatively be different from the pitch of the fibers of another set.
Although in the embodiment described above, the continuous fibers within each set and of parallel continuous fibers are uniformly spaced, in other embodiments, at least some of the continuous fibers within one or more sets may alternatively be variably spaced, and may thereby have a variable pitch.
Although in the embodiment described above, the fibers define an angle of about 26.6 degrees relative to the longitudinal side of the panel, in other embodiments, the fibers of one or more sets may alternatively each define a different angle relative to the longitudinal side of the panel. For example, in one embodiment, the fibers may alternatively define an angle of about 45 degrees relative to the longitudinal side of the panel.
Although in the embodiment described above, the fibers of the first set define an angle of about 53.1 degrees relative to the fibers of the second set, in other embodiments, the fibers of the first set may alternatively define a different angle relative to the fibers of the second set. For example, in one embodiment, the fibers of the first set may alternatively define an angle of about 90 degrees relative to the fibers of the second set.
Although in the embodiment described above, the continuous fibers are fabricated of glass, in other embodiments, one or more continuous fibers may alternatively be fabricated of another suitable material, such as for example, metal, polymer, plastic, wool, and the like.
Although in the embodiment described above, the insulating foam slab is fabricated of molded expanded polystyrene (EPS) foam, in other embodiments, the insulating foam slab may alternatively be fabricated of another suitable material, such as for example, extruded polystyrene foam (XPS), polyurethane foam, and the like. It will be understood that the insulating foam slab is not limited to dimensions of 4 feet×8 feet×1 inch, and may alternatively have other dimensions.
Although in the embodiment described above, the insulating foam slab has a longitudinal shape, in other embodiments, the insulating foam slab may alternatively have a different shape. For example, in one embodiment, the insulating foam slab may alternatively have a square shape.
Although in the embodiment described above, the panels are fastened such that the backing sheets abut the frame members of the wall, in other embodiments, one or more panels may alternatively be fastened such that the reinforcement sheets abut the frame members of the wall. In embodiments in which the panel does not comprise any backing sheet and in which the second face of the insulating foam slab defines a surface of the panel, one or more panels may alternatively be fastened such that the second face of the insulating foam slab abut the frame members of the wall.
Although in the embodiment described above, the panel is configured to be fastened to exterior-facing sides of frame members of an exterior wall of a building constructed using the light-frame construction method, it will be understood that the reinforcing wall panel is not limited to use in exterior walls, or to walls and/or buildings constructed using the light frame construction method.
It will be understood that the method of manufacturing the reinforced insulating panel is not limited to the method described above, and in other embodiments, other approaches may be used. For example, the manufacturing method may further include molding the insulating foam slab, such as for example by filling a mold with expandable polystyrene beads, and heating the mold and/or the expandable polystyrene beads to form the insulating foam slab. The molded insulating foam slab may then be cut, as needed, to the desired dimensions after molding. The reinforcement sheet may alternatively not comprise a glue layer that is exposed by peeling a disposable backing film, but rather a glue layer may be applied to the first face of the insulating foam slab, to the second film of the reinforcement sheet, or to both, prior to applying the oriented reinforcement sheet to the insulating foam slab. The backing sheet may alternatively not comprise a glue layer that is exposed by peeling a disposable backing film, but rather a glue layer may be applied to the second surface of the insulating foam slab, to the backing sheet, or to both, prior to applying the backing sheet to the insulating foam slab.
Providing the reinforcement sheet may further comprise forming the reinforcement sheet, whereby the forming comprises disposing the continuous fibers and at least one glue layer between the first film and the second film, and applying suitable pressure thereto so as to join the continuous fibers and the first and second films. Alternatively, forming the reinforcement sheet may comprise disposing the continuous fibers and at least one glue layer against a film, and applying suitable pressure thereto so as to join the continuous fibers and the film. In both such forming approaches, the forming may comprise, prior to the disposing, orienting the continuous fibers so as to have a suitable diagonal orientation.
Still other manufacturing approaches are possible. For example, in other embodiments, the reinforced insulating panel may be manufactured by affixing the second film to the first face of the insulating foam slab, by disposing a glue layer to the surface of the affixed second film, and then applying the continuous fibers to the glue layer disposed on the second film. In such an embodiment, the continuous fibers would be applied to the glue layer disposed on the second film in a suitable diagonal orientation, and may be applied either individually or as two or more continuous fibers simultaneously. A first film may then be applied to the plurality of continuous fibers disposed on the glue layer of the second film, and an additional glue layer may be disposed therebetween if necessary.
Still other manufacturing approaches are possible. For example, in other embodiments, the reinforced insulating panel may be manufactured by disposing a glue layer to the first surface of the insulating foam slab, and then applying the continuous fibers to the glue layer disposed on the insulating foam slab. In such an embodiment, the continuous fibers would be applied to the glue layer disposed on the insulating foam slab in a suitable diagonal orientation, and may be applied either individually or as two or more continuous fibers simultaneously. A film is then applied to the plurality of continuous fibers disposed on the glue layer of the insulating, and an additional glue layer may be disposed therebetween if necessary.
Although embodiments have been described above with reference to the accompanying drawings, those of skill in the art will appreciate that variations and modifications may be made without departing from the scope thereof as defined by the appended claims.

Claims

1. A reinforced insulating panel comprising:

an insulating foam slab having two opposing faces; and

a reinforcement sheet disposed on only one of said two opposing faces of the insulating foam slab, the reinforcement sheet comprising a plurality of continuous fibers extending diagonally across the face of the insulating foam slab.

2. The reinforced insulating panel of claim 1, wherein the continuous fibers extend between diagonally opposite corners of the face and between adjacent edges of the face.

3. The reinforced insulating panel of claim 1, wherein said reinforcement sheet comprises at least one film and said continuous fibers.

4. The reinforced insulating panel of claim 3, wherein said at least one film comprises a single film.

5. The reinforced insulating panel of claim 4, wherein said continuous fibers are disposed between said single film and said insulating foam slab.

6. The reinforced insulating panel of claim 4, wherein said single film is disposed between said continuous fibers and said insulating foam slab.

7. The reinforced insulating panel of claim 4, wherein said single film is metallized.

8. The reinforced insulating panel of claim 3, wherein said at least one film comprises a first film and a second film, said continuous fibers being disposed between the first film and the second film.

9. The reinforced insulating panel of claim 8, wherein at least one of the first film and the second film is adhered to the insulating foam slab.

10. The reinforced insulating panel of claim 8, wherein at least one of the first film and the second film is metallized.

11. The reinforced insulating panel of claim 1, wherein said reinforcement sheet is disposed on a first face of the insulating foam slab, and wherein said panel further comprises:

a backing sheet disposed on a second face of the insulating foam slab.

12. (canceled)

13. The reinforced insulating panel of claim 1, wherein said reinforcement sheet is disposed on a first face of the insulating foam slab, and wherein said panel further comprises:

another reinforcement sheet disposed on a second face of the insulating foam slab, said another reinforcement sheet comprising a plurality of continuous fibers extending diagonally across the second face of the insulating foam slab.

14. The reinforced insulating panel of claim 1, wherein said plurality of continuous fibers comprises parallel continuous fibers.

15. The reinforced insulating panel of claim 14, wherein said parallel continuous fibers are uniformly spaced.

16. The reinforced insulating panel of claim 14, wherein said parallel continuous fibers have a pitch of less than about 0.4 inches.

17. The reinforced insulating panel of claim 14, wherein said parallel continuous fibers are arranged as a diagonal grid.

18. The reinforced insulating panel of claim 14, wherein said parallel continuous fibers comprise a first set of parallel continuous fibers and a second set of parallel continuous fibers, said first set of parallel continuous fibers having a different diagonal orientation than said second set of parallel continuous fibers.

19. The reinforced insulating panel of claim 1, wherein said continuous fibers are fabricated of any of glass, metal, polymer, plastic, and wool.

20. A method of manufacturing a reinforced insulating panel, the method comprising:

providing an insulating foam slab having two opposing faces;

providing a reinforcement sheet, the reinforcement sheet comprising a plurality of continuous fibers; and

affixing the reinforcement sheet to only one of said two opposing faces of the insulating foam slab such that the continuous fibers are oriented diagonally across the face of the insulating foam slab.