Building panel structures, arrangements, and methods

Abstract

An insulative panel includes a base insulation board having first and second opposed edges extending between third and fourth opposed edges, at least one edge insulation board each having an inner edge secured to a corresponding one of the first, second, third, and fourth edges of the base insulation board and an outer edge defining an outer edge of the insulative panel, and a coating applied to a front surface of each of the base insulation board and each of the at least one edge insulation boards, the coating providing a uniform front surface of the insulative panel.

Description

BUILDING PANEL STRUCTURES, ARRANGEMENTS, AND METHODSCross-reference to Related Application

[0001] This application claims priority to and all benefit of U.S. Provisional Patent Application Serial No. 63 / 664,428, filed June 26, 2024 and entitled BUILDING PANEL STRUCTURES, ARRANGEMENTS, AND METHODS, the entire disclosure of which is incorporated herein by reference.Background

[0002] Building panels are often used to provide functional and / or aesthetic features to a building facade. One example of a panel-based facade cladding is an Exterior Insulation and Finish System (EIFS). As defined by the International Building Code and ASTM International, an EIFS is a non-load bearing, exterior wall cladding system that is formed from insulation boards or panels attached to an exterior substrate (e.g., building wall); an integrally reinforced base coat; and a textured protective finish coat. EIFS structures may be used to provide a weather resistant, seamless, insulated finish to a residence or commercial building.Summary of the Disclosure

[0003] In an exemplary embodiment of the present disclosure, an insulative panel includes a base insulation board having first and second opposed edges extending between third and fourth opposed edges, at least one edge insulation board each having an inner edge secured to a corresponding one of the first, second, third, and fourth edges of the base insulation board and an outer edge defining an outer edge of the insulative panel, and a coating applied to a front surface of each of the base insulation board and each of the at least one edge insulation boards, the coating providing a uniform front surface of the insulative panel.

[0004] In another exemplary embodiment of the present disclosure, a method of fabricating an insulative panel is contemplated. In the exemplary method, a base insulation board is provided, having first and second opposed edges extending between third and fourth opposed edges. An inner edge of at least one edge insulation board is secured to a corresponding one of the first, second, third, and fourth edges of the base insulation board. A coating is applied to a front surface of each of the base insulation board and the at least one edge insulation board to define a uniform front surface of the insulative panel.

[0005] In another exemplary embodiment of the present disclosure, an insulative panel includes a base insulation board having first and second opposed edges extending between third and fourth opposed edges, and first, second, third, and fourth edge insulation boards having inner edges secured to corresponding ones of the first, second, third and fourth edges of the base insulation board, and outer edges defining the first , second, third, and fourth edges of the insulation panel. A coating is applied to a front surface of each of the base insulation board, the first edge insulation board, the second edge insulation board, the third edge insulation board, and the fourth edge insulation board, the coating providing a uniform front surface of the insulative panel.

[0006] In another exemplary embodiment of the present disclosure, a method of fabricating an insulative panel is contemplated. In the exemplary method, a base insulation board is provided, having first and second opposed edges extending between third and fourth opposed edges. An inner edge of a first edge insulation board is secured to the first edge of the base insulation board, an inner edge of a second edge insulation board is secured to the second edge of the base insulation board, an inner edge of a third edge insulation board is secured to the third edge of the base insulation board, and an inner edge of a fourth edge insulation board is secured to the fourth edge of the base insulation board. A coating is applied to a front surface of each of the base insulation board, the first edge insulation board, the second edge insulation board, the third edge insulation board, and the fourth edge insulation board to define a uniform front surface of the insulative panel.Brief Description of the Drawings

[0007] Further features and advantages of the invention will become apparent from the following detailed description made with reference to the accompanying drawings, wherein:

[0008] FIG. 1 illustrates a perspective view of a conventional exterior insulation and finish system;

[0009] FIG. 2 illustrates a rear view of an insulative panel, according to an exemplary embodiment of the present disclosure;

[0010] FIG. 3A illustrates a rear view of the base insulation board of the insulative panel of FIG. 2;

[0011] FIG. 3B illustrates a side view of the base insulation board of the insulative panel of FIG. 2;

[0012] FIG. 3C illustrates a partial perspective side view of the base insulation boardof the insulative panel of FIG. 2;

[0013] FIG. 3D illustrates a partial perspective bottom view of the base insulation board of the insulative panel of FIG. 2;

[0014] FIG. 4 illustrates a perspective view of a rigid channel of the insulative panel of FIG. 2;

[0015] FIG. 5A illustrates a perspective view of an end edge insulation board of the insulative panel of FIG. 2;

[0016] FIG. 5B illustrates a cross-sectional view of the end edge insulation board of the insulative panel of FIG. 2;

[0017] FIG. 6A illustrates a perspective view of a side edge insulation board of the insulative panel of FIG. 2;

[0018] FIG. 6B illustrates a cross-sectional view of the side edge insulation board of the insulative panel of FIG. 2;

[0019] FIG. 7 illustrates a perspective view of a rigid brace member of the insulative panel of FIG. 2;

[0020] FIG. 8 is an exploded rear view of the insulative panel of FIG. 2;

[0021] FIG. 9 is a partial exploded perspective view of a corner portion of the insulative panel of FIG. 2;

[0022] FIG. 10 is a plan view of a corner reinforcing mesh element of the insulative panel of FIG. 2;

[0023] FIG. 11 is a front perspective view of the insulative panel of FIG. 2, shown with a basecoat layer and reinforcing mesh applied to front surfaces of the insulation board components;

[0024] FIG. 12 is a front perspective view of the insulative panel of FIG. 2, shown with a finish layer applied over the basecoat layer;

[0025] FIG. 13 is a partially exploded rear view of the insulative panel of FIG. 2;

[0026] FIG. 14A is a perspective view of a hook portion of the insulative panel ofFIG. 2;

[0027] FIG. 14B is a side view of the hook portion of the insulative panel of FIG. 2;

[0028] FIG. 15A is a perspective view of a mounting plate of the insulative panel ofFIG. 2;

[0029] FIG. 15B is an end view of the mounting plate of the insulative panel of FIG. 2; and

[0030] FIG. 16 is a plan view of a mounting tab of the insulative panel of FIG. 2.Detailed Description

[0031] This Detailed Description merely describes exemplary embodiments and is not intended to limit the scope of the claims in any way. Indeed, the invention as claimed is broader than and unlimited by the described embodiments, and the terms used have their full ordinary meaning. For example, while certain exemplary features presented in the present disclosure are described and / or shown as being used with building panels for an Exterior Insulation and Finish System (EIFS), any one or more of the features described herein may be utilized with or incorporated into other types of building facade cladding, including, for example, continuous insulation (CI) panels.

[0032] In conventional EIFS applications, as shown in FIG. 1, an air / weather barrier 4 (e.g., a polymer-based, liquid applied water-resistive barrier, such as the Backstop® formulations manufactured by Dryvit, or a butyl-based, acrylic polymer based, or other “peel and stick” composite membrane, such as ExoAir air barrier membranes, manufactured by Tremco) is applied to a sheathing 3 (e.g., gypsum board, plywood, oriented strand board, cement board, glass mat) and is allowed to dry over a first period (e.g., day one). A notched or spaced wet adhesive 5 (e.g., cementitious adhesives, spray foam adhesives, including isocyanate spray foam adhesive, gunnable moisture cure adhesives) is applied to a front surface of the air / weather barrier or to a rear surface of the insulative panel and a plurality of insulative panels or boards 6 are adhered to the air / weather barrier, by the notched adhesive, in a continuous array using the notched adhesive, which is allowed to dry over a second period (e.g., day two). Front surfaces of the insulative boards 6 are rasped to provide planar alignment between adjacent uneven boards over a third period (e.g., day three). Backwrap reinforcing mesh (not shown), secured to the substrate or to the rear edge surfaces of the insulative panel prior to attachment, are wrapped around the panel edges and secured to the front edge surfaces of the panel. A wet basecoat 8 (e.g., cementitious material for impact and / or fire resistance) is then applied to the prepared or rasped front surfaces of the insulative boards, with a reinforcing mesh material 7 (e.g., fiberglass or polypropylene mesh of various densities, provided from a roll of material) embedded in the basecoat before allowing the basecoat to dry over a fourth period (e.g., day four). A wet finish layer 9 (e.g., acrylic or other weather resistant coating, may or may not contain texturizing agent) is then applied over the basecoat and allowed to dry over a fifth period (e.g., day five). As noted, this installation process may take up to five days, or longer, and requires skilled implementationof multiple installation steps and / or additional labor in material clean-up and aesthetic corrective actions.

[0033] According to an exemplary aspect of the present disclosure, an EIFS arrangement may be adapted or configured to eliminate one or more conventional EIFS installation steps, for example, to reduce the time for installation and / or the amount of skilled labor required for installation.

[0034] In one such exemplary arrangement, an insulative panel for an EIFS arrangement may be provided in a pre-reinforced and coated condition, for example, to eliminate mesh and basecoat applying steps during panel installation. According to an inventive aspect of the present disclosure, an insulative panel may be provided with a central base insulation board and one or more outer peripheral edge insulation boards secured to the edges of the base insulation board. In such an arrangement, the one or more edge insulation boards may be provided with edge coating or other edge specific treatments prior to assembly with the base insulation board. For example, the one or more edge insulation boards may be provided with mesh reinforcement (“backwrapping”) and a basecoat layer prior to assembly with the base insulation board, and the assembled panel may be reinforced and coated in a single coating application (e.g., extrusion) during fabrication of the panel, thereby eliminating these steps during field installation.

[0035] FIG. 2 illustrates a rear view of an exemplary insulative panel 100 including a base insulation board 150 having first and second opposed end (e.g., horizontal top and bottom, as shown) edges 151, 152 extending between third and fourth opposed side (e.g., vertical left and right, as shown) edges 153, 154, and first, second, third, and fourth edge insulation boards 110, 120, 130, 140 secured to the edges of the base insulation board to define an outer periphery of the panel 100. The first and second end (e.g., horizontal, as shown) edge insulation boards 110, 120 have inner edges 111, 121 secured to the first and second end edges 151, 152 of the base insulation board 150, and the third and fourth side (e.g., vertical, as shown) edge insulation boards 130, 140 have inner edges 131, 141 secured to the third and fourth side edges 153, 154 of the base insulation board. In other embodiments, the insulative panel may have more or fewer than four edge insulation boards, and may, for example, have edge insulation board secured to fewer than all four edges (e.g. any one, two or three of the edges) of the base insulation board.

[0036] Many different configurations may be utilized to secure the edge insulation boards 110, 120, 130, 140 to the base insulation board 150. As one example, the insulation boards may be provided with protruding tongue and recessed groove edge configurations forinterlocking engagement of the base insulation board with the edge insulation boards. In the illustrated embodiment, the edges 151, 152, 153, 154 of the base insulation board 150 include protruding tongue portions 151a, 152a, 153a, 154a (FIGS. 3A - 3D) and the inner edges 111, 121, 131, 141 of the edge insulation boards 110, 120, 130, 140 include recesses slot or groove portions I l la, 121a, 131a, 141a (FIGS. 5A - 5B, 6A - 6B) that receive the corresponding tongue portions for interlocking engagement of the base insulation board with the edge insulation boards. In some embodiments, the tongue portions 151a, 152a, 153a, 154a and the groove portions I l la, 121a, 131a, 141a may be dimensioned for friction fit, press fit, or compressible interference fit engagement sufficient to secure the edge insulation boards 110, 120, 130, 140 to the base insulation board 150. In some embodiments, an adhesive may additionally or alternatively be provided to secure the tongue portions in the groove portions. In other embodiments (not shown), one or more of the base insulation board edges may be provided with a recessed groove portion for interlocking with a protruding tongue portion on one or more of the edge insulation boards.

[0037] In the illustrated embodiment, as shown in FIG. 2, the third and fourth edge insulation boards 130, 140 extend beyond the first and second edges 151, 152 of the base insulation board 150, for attachment to the end portions 113, 114, 123, 124 of the first and second edge insulation boards 110, 120, with end portions 133, 134, 143, 144 of the third and fourth edge insulation boards being flush with the outer edges 112, 122 of the first and second edge insulation boards to define the end edges 101, 102 of the insulative panel 100. As shown in FIG. 5A, the end portions 113, 114, 123, 124 of the first and second edge insulation boards 110, 120 may be provided with protruding tongue portions 113a, 114a, 123a, 124a received in the recessed groove portions 131a, 141a of the third and fourth edge insulation boards 130, 140 for interlocking engagement, similar to the interlocking engagement described above. In other embodiments (not shown), the first and second end edge insulation boards may extend beyond the third and fourth side edges of the base insulation board for attachment to the end portions of the third and fourth side edge insulation boards.

[0038] While the insulative panel may be configured to be attached to a building substrate using an adhesive, in some applications, a mechanical attachment may be more desirable, for example, to provide more secure attachment of the panel in a range of environments (e.g., cold weather or high moisture environments). Many different mechanical attachment configurations may be utilized. In the illustrated embodiment, as shown in FIGS. 3A - 3C, a plurality of rigid channels 160 are at least partially embedded in a rear portion 156of the base insulation board 150, extending between the third and fourth edges 153, 154 of the base insulation board. While many different types of mounting channels may be utilized, in the illustrated embodiment, as shown in FIGS. 3C and 4, the rigid channels 160 comprise hat channels having opposed L-shaped leg portions 161, 162 embedded or otherwise retained in L-shaped slots 157, 158 in the base insulation board rear portion 156 and a central bight portion 163 received in a recessed portion 159 of the base insulation board rear portion, for example, for flush alignment of the bight portion with the rear surface of the base insulation board.

[0039] In some arrangements, the rigid channels may each include an integrated hook portion for hanging engagement with a mounting rail attached to the building substrate (not shown). In other arrangements, a separate hook element may be mounted to the mounting rail to provide a hook portion for hanging engagement with the mounting rail. In the illustrated embodiment, hook elements 170 (e.g., having a J-shaped cross-section, as shown in FIGS. 14A - 14B) are fastened to the mounting channels 160 to provide a hook portion. As shown in FIG. 2, the ends of the hook elements 170 may extend beyond the ends of the mounting channels 160 and beyond third and fourth edges 153, 154 of the base insulation board 150, for example, to the outer edges 132, 142 of the third and fourth edge insulation boards 130, 140.

[0040] To provide additional rigidity or bracing of the insulative panel along its major length, the third and fourth side edge insulation boards may be provided with rigid brace members at least partially embedded in rear portions of the third and fourth edge insulation boards, extending in a direction parallel to the third and fourth side edges of the base insulation board. In the illustrated embodiment, rigid brace members 180 are at least partially embedded in the rear portions 136, 146 of the third and fourth edge insulation boards 130, 140 extending between the first and second ends 133, 134, 143, 144 of the third and fourth edge insulation boards 130, 140, in a direction parallel to the third and fourth side edges 153, 154 of the base insulation board. While many different types of brace members may be utilized (e.g. L-shaped or U-shaped in cross-section), in the illustrated embodiment, the rigid brace members 180 comprise hat channels (e.g., similar to the hat channel 160 of FIG. 4), with opposed L-shaped leg portions 181, 182 embedded or otherwise retained in a corresponding L-shaped slots 137, 147, 138, 148 in the rear portions 136, 146 of the third and fourth edge insulation boards 130, 140 and a base portion 183 received in a recessed portion 139, 149 of the third and fourth edge insulation board rear portions, for example, for flushalignment of the base portion with the rear surfaces of the third and fourth edge insulation boards.

[0041] To provide for panel edge reinforcement mesh backwrapping prior to field installation, the edge insulation boards may be provided with a sheet of reinforcing mesh extending from a front surface to a rear surface of the edge insulation board, and over the outer edge of the edge insulation board.

[0042] As shown in FIGS. 5 A and 5B, the first and second end edge insulation boards 110, 120 may each be provided with a reinforcing mesh sheet 115, 125 wrapped or otherwise applied over the front, outer edge, and rear surfaces of the edge insulation boards, with a basecoat layer 118, 128 applied over the reinforcing mesh sheet to embed and retain the reinforcing mesh sheet. As shown, the backwrapped portion of the first and second edge insulation boards 110, 120 may be provided with a recessed surface 119, 129 (e.g., about 1 / 8” recess), such that the reinforcing mesh sheet 115, 125 and basecoat layer 118, 128 provide an outer surface that is substantially flush with the non-recessed surface. The end portions 113, 114, 123, 124 of the first and second edge insulation boards 110, 120 may be provided without the basecoat layer 118, 128, for example, to facilitate post-assembly wrapping and coating of the adjoining, comer defining end portions of the edge insulation boards 110, 120, 130, 140, as described in greater detail below.

[0043] As shown in FIGS. 6A and 6B, the third and fourth side edge insulation boards 130, 140 may each be provided with a reinforcing mesh sheet 135, 145 wrapped or otherwise applied over the front, outer edge, and rear surfaces of the edge insulation boards, and over the brace member 180, with a basecoat layer 138, 148 applied over the reinforcing mesh sheet to embed and retain the reinforcing mesh sheet. As shown, the backwrapped portion of the third and fourth edge insulation boards 130, 140 may be provided with a recessed surface 139, 149 (e.g., about 1 / 8” recess), such that the reinforcing mesh sheet 135, 145 and basecoat layer 138, 148 provide an outer surface that is substantially flush with the non-recessed surface. The end portions 133, 134, 143, 144 of the third and fourth edge insulation boards 130, 140 may be provided without the basecoat layer 138, 148, for example, to facilitate postassembly wrapping and coating of the adjoining, corner defining end portions of the edge insulation boards 110, 120, 130, 140, as described in greater detail below.

[0044] FIG. 8 illustrates an exploded view of the insulative panel 100, prior to assembly of the edge insulation boards 110, 120, 130, 140 with the base insulation board 150. When the edge insulation boards 110, 120, 130, 140 are assembled with the base insulation board 150, for example, using a friction fit and / or adhesive between interlocking tongue andgroove portions, as described above, the comer portions of the insulative panel 100 may be individually wrapped and coated to provide complete embedded backwrapping around the perimeter of the insulative panel. FIG. 9 illustrates a partially exploded perspective view of a corner portion of the insulative panel 100 prepared for application of a comer covering reinforcing mesh element 109 (e.g., fiberglass mesh). As shown, the reinforcing mesh element 109 may be shaped to cover and span the adjoining end portions 124, 144 of the second (i.e., bottom, as shown) and fourth (i.e., right, as shown) edge insulation boards 120, 140, with reinforcing mesh elements similarly applied to the other three adjoining corner portions. As shown, the non-recessed portion of the side edge insulation board end portion 144 may be sanded flush with the uncoated reinforcing mesh sheet portions of the adjoining end portions 124, 144 before the reinforcing mesh element 109 is applied. A basecoat layer (e.g., a polymer modified cementitious mortar material, such as, for example, an acrylic polymer modified Type N or S mortar material, not shown) may then be applied over the mesh element 109 to embed the mesh element and provide a substantially uniform surface for application of the basecoat and finish coat to the panel front surface, as described below.

[0045] With the assembled insulation boards having a uniform coated front surface and complete backwrapping around the panel perimeter, a front panel mesh layer 105 (e.g., fiberglass mesh) may be applied to the front surface of the adjoined insulation boards, as shown in FIG. 11. The mesh layer 105 may be sized and positioned to terminate inward from the outer edges 101, 102, 103, 104 of the panel, as the edges are already provided with reinforcing mesh backwrapping. A basecoat layer 106 (e.g., a polymer modified cementitious mortar material, such as, for example, an acrylic polymer modified Type N or S mortar material) may then be applied over the mesh layer 105, for example, by extrusion of the basecoat onto the panel front surface. A finish layer 107 (e.g., a textured modified cementitious mortar material) may then be applied over the basecoat layer 106 (FIG. 12).

[0046] Once the insulative panel 100 has been assembled and coated, hook elements 170 may be fastened to the bight portions 163 of the mounting channels 160 (e.g., using mounting screws or other fasteners 179) and positioned to extend substantially to the outer side edges 103, 104 of the panel 100 (defined by the side edge insulation boards, as described above), as shown in FIG. 13. In some embodiments, mounting plates may be attached to one or more of the embedded channels and positioned to extend beyond the outer side edges of the panel to provide an additional mounting point and / or an offset between adjacent installed panels. In the illustrated embodiment, mounting plates 190 are fastened (e.g., using mounting screws or other fasteners 199) to the ends of the lowermost mounting channel 160, such thatend portions 195 of the mounting plates extend beyond the outer side edges 103, 104 of the panel to provide additional mounting points and / or offsets between adjacent installed panels. In the illustrated embodiment, the mounting plate 190 is a two-piece assembly including an elongated plate element 191 (FIGS. 15A - 15B) for attaching to the mounting channel 160, and an L-shaped plate element 192 (FIG. 16) fastened to the elongated plate element 191 and positioned to extend beyond the panel side edge. The L-shaped plate element 192 may be oriented so as to align with, but not to overlap with, an L-shaped plate element of an adjacent panel. In other embodiments (not shown), the mounting plate may be provided as a single piece component.

[0047] These attachment arrangements may be selected and configured to meet desired EIFS / ASTM performance standards, such as, for example, ASTM E2568, Standard Specification for PB Exterior Insulation and Finish Systems.

[0048] The insulative panels described herein may be formed from a variety of suitable materials, including, for example, expanded polystyrene (EPS) foam, extruded polystyrene (XPS) foam, polyurethane (PU) foam, and mineral wool. Insulative materials and panel thickness (e.g., between 1 and 12 inches) may be selected, for example, to provide a desired insulating R-value (e.g., an R-value of at least about R-4 / inch nominal for a system between 1 and 12 inches thick), and / or based on other factors (e.g., cost, weight, inflammability, impact resistance). In some embodiments the panel material may include one or more additive materials, such as, for example, graphite, silicone, glass, or other such additive materials, for example, to provide enhanced properties, such as enhanced insulation (e.g., increased R-value), increased fire resistance, etc.

[0049] While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions— such as alternative materials, structures, configurations, methods, devices and components, alternatives as to form, fit and function, and so on— may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additionalembodiments and uses within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure, however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Parameters identified as “approximate” or “about” a specified value are intended to include both the specified value, values within 5% of the specified value, and values within 10% of the specified value, unless expressly stated otherwise. Further, it is to be understood that the drawings accompanying the present disclosure may, but need not, be to scale, and therefore may be understood as teaching various ratios and proportions evident in the drawings. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention, the inventions instead being set forth in the appended claims. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.

Claims

We claim:

1. An insulative panel comprising: a base insulation board having first and second opposed edges extending between third and fourth opposed edges; a first edge insulation board having an inner edge secured to the first edge of the base insulation board and an outer edge defining a first edge of the insulative panel; a second edge insulation board having an inner edge secured to the second edge of the base insulation board and an outer edge defining a second edge of the insulative panel; a third edge insulation board having an inner edge secured to the third edge of the base insulation board and an outer edge defining a third edge of the insulative panel; a fourth edge insulation board having an inner edge secured to the fourth edge of the base insulation board and an outer edge defining a fourth edge of the insulative panel; and a coating applied to a front surface of each of the base insulation board, the first edge insulation board, the second edge insulation board, the third edge insulation board, and the fourth edge insulation board, the coating providing a uniform front surface of the insulative panel.

2. The insulative panel of claim 1, wherein each of the first, second, third, and fourth edges of the base insulation board includes one of a protruding tongue portion and a recessed groove portion, and each of the inner edges of the first, second, third, and fourth edge insulation boards includes the other of the protruding tongue portion and the recessed groove portion for interlocking with the corresponding one of the first, second, third, and fourth edges of the base insulation board.

3. The insulative panel of claim 2, wherein each of the first, second, third, and fourth edges of the base insulation board includes the protruding tongue portion and each of the inner edges of the first, second, third, and fourth edge insulation boards includes the recessed groove portion.

4. The insulative panel of any of claims 2-3, wherein the protruding tongue portions are secured with the recessed groove portions by a friction fit.

5. The insulative panel of any of claims 2-3, wherein the protruding tongue portions are secured with the recessed groove portions by an adhesive.

6. The insulative panel of any of claims 1-5, further comprising a plurality of rigid channels at least partially embedded in a rear portion of the base insulation board and extending between the third and fourth edges of the base insulation board.

7. The insulative panel of claim 6, further comprising a plurality of rigid hook portions each fastened to a corresponding one of the plurality of rigid channels.

8. The insulative panel of claim 7, wherein each of the plurality of rigid hook portions extends beyond the first and second edges of the base insulation board for alignment with the first and second edge insulation boards.

9. The insulative panel of any of claims 7-8, wherein each of the plurality of rigid hook portions has a J-shaped cross-section.

10. The insulative panel of any of claims 6-9, wherein the plurality of rigid channels comprise hat channels at least partially embedded in the rear portion of the base insulation board.

11. The insulative panel of any of claims 1-10, further comprising first and second rigid brace members at least partially embedded in rear portions of corresponding ones of the third and fourth edge insulation boards and extending parallel to the third and fourth edges of the base insulation board.

12. The insulative panel of claim 11, wherein each of the first and second rigid brace members comprises a hat channel at least partially embedded in the rear portion of the corresponding one of the third and fourth edge insulation boards.

13. The insulative panel of any of claims 1-12, wherein the third and fourth edge insulation boards extend beyond the first and second edges of the base insulation board, with the inner edges of the third and fourth insulation board being secured to corresponding firstand second ends of the first and second edge insulation boards at corresponding first, second, third, and fourth corner edge board junctions.

14. The insulative panel of claim 13, further comprising first, second, third, and fourth reinforcing mesh elements wrapped over corresponding ones of the first, second, third, and fourth comer edge board junctions.

15. The insulative panel of any of claims 1-14, wherein each of the first and second edge insulation boards includes a reinforcing mesh layer extending from the front surface to a rear surface and over the outer edge.

16. The insulative panel of claim 15, wherein each of the first and second edge insulation boards includes a basecoat layer covering a substantial portion of the reinforcing mesh layer.

17. The insulative panel of any of claims 1-16, wherein each of the third and fourth edge insulation boards includes a reinforcing mesh layer extending from the front surface to a rear surface and over the outer edge.

18. The insulative panel of claim 17, wherein each of the third and fourth edge insulation boards includes a basecoat layer covering a substantial portion of the reinforcing mesh layer.

19. The insulative panel of any of claims 1-18, wherein the coating comprises a basecoat layer adhered to the front surfaces of the base insulation board, the first edge insulation board, the second edge insulation board, the third edge insulation board, and the fourth edge insulation board.

20. The insulative panel of claim 19, further comprising a reinforcing mesh embedded in the basecoat layer.

21. The insulative panel of any of claims 19-20, wherein the coating further comprises a finish layer adhered to an outer surface of the basecoat layer.

22. A method of fabricating an insulative panel, the method comprising:providing a base insulation board having first and second opposed edges extending between third and fourth opposed edges; securing an inner edge of a first edge insulation board to the first edge of the base insulation board; securing an inner edge of a second edge insulation board to the second edge of the base insulation board; securing an inner edge of a third edge insulation board to the third edge of the base insulation board; securing an inner edge of a fourth edge insulation board to the fourth edge of the base insulation board; applying a coating to a front surface of each of the base insulation board, the first edge insulation board, the second edge insulation board, the third edge insulation board, and the fourth edge insulation board to define a uniform front surface of the insulative panel.

23. The method of claim 22, wherein securing the inner edges of each of the first, second, third, and fourth edge insulation boards to the corresponding ones of the first, second, third, and fourth edges of the base insulation board comprises interlocking protruding tongue portions and recessed groove portions of the corresponding edge insulation boards and base insulation board edges.

24. The method of claim 23, wherein each of the first, second, third, and fourth edges of the base insulation board includes the protruding tongue portion and each of the inner edges of the first, second, third, and fourth edge insulation boards includes the recessed groove portion.

25. The method of any of claims 23-24, wherein the protruding tongue portions are secured with the recessed groove portions by a friction fit.

26. The method of any of claims 23-24, wherein the protruding tongue portions are secured with the recessed groove portions by an adhesive.

27. The method of any of claims 22-25, further comprising at least partially embedding a plurality of rigid channels in a rear portion of the base insulation board and extending between the third and fourth edges of the base insulation board.

28. The method of claim 27, further comprising fastening a plurality of rigid hook portions to corresponding ones of the plurality of rigid channels.

29. The method of claim 28, wherein each of the plurality of rigid hook portions extends beyond the first and second edges of the base insulation board for alignment with the first and second edge insulation boards.

30. The method of any of claims 28-29, wherein each of the plurality of rigid hook portions has a J-shaped cross-section.

31. The method of any of claims 27-30, wherein the plurality of rigid channels comprise hat channels embedded in the rear portion of the base insulation board.

32. The method of any of claims 22-31, further comprising at least partially embedding first and second rigid brace members in rear portions of corresponding ones of the third and fourth edge insulation boards, the first and second rigid brace members extending parallel to the third and fourth edges of the base insulation board.

33. The method of claim 32, wherein each of the first and second rigid brace members comprises a hat channel at least partially embedded in the rear portion of the corresponding one of the third and fourth edge insulation boards.

34. The method of any of claims 22-33, further comprising securing the inner edges of the third and fourth insulation board to corresponding first and second ends of the first and second edge insulation boards at corresponding first, second, third, and fourth corner edge board junctions.

35. The method of claim 34, further comprising wrapping first, second, third, and fourth reinforcing mesh elements over corresponding ones of the first, second, third, and fourth corner edge board junctions.

36. The method of any of claims 22-35, wherein each of the first and second edge insulation boards includes a reinforcing mesh layer extending from the front surface to a rear surface and over the outer edge.

37. The method of claim 36, wherein each of the first and second edge insulation boards includes a basecoat layer covering a substantial portion of the reinforcing mesh layer.

38. The method of any of claims 22-37, wherein each of the third and fourth edge insulation boards includes a reinforcing mesh layer extending from the front surface to a rear surface and over the outer edge.

39. The method of claim 38, wherein each of the third and fourth edge insulation boards includes a basecoat layer covering a substantial portion of the reinforcing mesh layer.

40. The method of any of claims 22-39, wherein applying the coating to the front surface of each of the base insulation board, the first edge insulation board, the second edge insulation board, the third edge insulation board, and the fourth edge insulation board comprises adhering a basecoat layer to the front surfaces of the base insulation board, the first edge insulation board, the second edge insulation board, the third edge insulation board, and the fourth edge insulation board.

41. The method of claim 40, further comprising embedding a reinforcing mesh in the basecoat layer.

42. The method of any of claims 40-41, wherein applying the coating to the front surface of each of the base insulation board, the first edge insulation board, the second edge insulation board, the third edge insulation board, and the fourth edge insulation board further comprises adhering a finish layer to an outer surface of the basecoat layer.

43. An insulative panel comprising: a base insulation board having first and second opposed edges extending between third and fourth opposed edges;at least one edge insulation board each having an inner edge secured to a corresponding one of the first, second, third, and fourth edges of the base insulation board and an outer edge defining an outer edge of the insulative panel; and a coating applied to a front surface of each of the base insulation board and each of the at least one edge insulation boards, the coating providing a uniform front surface of the insulative panel.

44. The insulative panel of claim 43, wherein the at least one edge insulation board comprises a first edge insulation board secured to the first edge of the base insulation board.

45. The insulative panel of any of claims 43-44, wherein the at least one edge insulation board comprises a second edge insulation board secured to the second edge of the base insulation board.

46. The insulative panel of any of claims 43-45, wherein the at least one edge insulation board comprises a third edge insulation board secured to the third edge of the base insulation board.

47. The insulative panel of any of claims 43-46, wherein the at least one edge insulation board comprises a fourth edge insulation board secured to the fourth edge of the base insulation board.

48. The insulative panel of claim any of claims 43-47, wherein the inner edge of each of the at least one edge insulation board includes one of a protruding tongue portion and a recessed groove portion, and each of the corresponding edges of the base insulation board includes the other of the protruding tongue portion and the recessed groove portion for interlocking with the corresponding one of the protruding tongue portion and the recessed groove portion.

49. The insulative panel of claim any of claims 43-47, wherein the inner edge of each of the at least one edge insulation board includes a recessed groove portion, and each of the corresponding edges of the base insulation board includes a protruding tongue portion for interlocking with the corresponding recessed groove portion.

50. The insulative panel of any of claims 48-49, wherein the protruding tongue portions are secured with the recessed groove portions by a friction fit.

51. The insulative panel of any of claims 48-50, wherein the protruding tongue portions are secured with the recessed groove portions by an adhesive.

52. The insulative panel of any of claims 43-51, further comprising a plurality of rigid channels at least partially embedded in a rear portion of the base insulation board and extending between the third and fourth edges of the base insulation board.

53. The insulative panel of claim 51, further comprising a plurality of rigid hook portions each fastened to a corresponding one of the plurality of rigid channels.

54. The insulative panel of claim 53, wherein the at least one edge insulation board comprises a first edge insulation board secured to the first edge of the base insulation board and a second edge insulation board secured to the second edge of the base insulation board, wherein each of the plurality of rigid hook portions extends beyond the first and second edges of the base insulation board for alignment with the first and second edge insulation boards.

55. The insulative panel of any of claims 53-54, wherein each of the plurality of rigid hook portions has a J-shaped cross-section.

56. The insulative panel of any of claims 52-55, wherein the plurality of rigid channels comprise hat channels at least partially embedded in the rear portion of the base insulation board.

57. The insulative panel of any of claims 43-56, wherein the at least one edge insulation board comprises a third edge insulation board secured to the third edge of the base insulation board and a fourth edge insulation board secured to the fourth edge of the base insulation board, the insulative panel further comprising first and second rigid brace members at least partially embedded in rear portions of corresponding ones of the third and fourth edge insulation boards and extending parallel to the third and fourth edges of the base insulation board.

58. The insulative panel of claim 57, wherein each of the first and second rigid brace members comprises a hat channel at least partially embedded in the rear portion of the corresponding one of the third and fourth edge insulation boards.

59. The insulative panel of any of claims 43-58, wherein the at least one edge insulation board comprises a first edge insulation board secured to the first edge of the base insulation board and a second edge insulation board secured to the second edge of the base insulation board, wherein each of the first and second edge insulation boards includes a reinforcing mesh layer extending from the front surface to a rear surface and over the outer edge.

60. The insulative panel of claim 59, wherein each of the first and second edge insulation boards includes a basecoat layer covering a substantial portion of the reinforcing mesh layer.

61. The insulative panel of any of claims 1-16, wherein the at least one edge insulation board comprises a third edge insulation board secured to the third edge of the base insulation board and a fourth edge insulation board secured to the fourth edge of the base insulation board, wherein each of the third and fourth edge insulation boards includes a reinforcing mesh layer extending from the front surface to a rear surface and over the outer edge.

62. The insulative panel of claim 61, wherein each of the third and fourth edge insulation boards includes a basecoat layer covering a substantial portion of the reinforcing mesh layer.

63. The insulative panel of any of claims 43-62, wherein the coating comprises a basecoat layer adhered to the front surfaces of the base insulation board and the at least one edge insulation board.

64. The insulative panel of claim 63, further comprising a reinforcing mesh embedded in the basecoat layer.

65. The insulative panel of any of claims 63-64, wherein the coating further comprises a finish layer adhered to an outer surface of the basecoat layer.

66. The insulative panel of any of claims 43-65, wherein the at least one edge insulation board comprises a first edge insulation board secured to the first edge of the base insulationboard, a second edge insulation board secured to the second edge of the base insulation board, a third edge insulation board secured to the third edge of the base insulation board, and a fourth edge insulation board secured to the fourth edge of the base insulation board, wherein the third and fourth edge insulation boards extend beyond the first and second edges of the base insulation board, with the inner edges of the third and fourth insulation board being secured to corresponding first and second ends of the first and second edge insulation boards at corresponding first, second, third, and fourth comer edge board junctions.

67. The insulative panel of claim 66, further comprising first, second, third, and fourth reinforcing mesh elements wrapped over corresponding ones of the first, second, third, and fourth comer edge board junctions.

68. A method of fabricating an insulative panel, the method comprising: providing a base insulation board having first and second opposed edges extending between third and fourth opposed edges; securing an inner edge of at least one edge insulation board to a corresponding one of the first, second, third, and fourth edges of the base insulation board; applying a coating to a front surface of each of the base insulation board and the at least one edge insulation board to define a uniform front surface of the insulative panel.

69. The method of claim 68, wherein securing the inner edge of the at least one edge insulation board to a corresponding one of the first, second, third, and fourth edges of the base insulation board comprises securing the inner edge of a first edge insulation board to the first edge of the base insulation board.

70. The method of any of claims 68-69, wherein securing the inner edge of the at least one edge insulation board to a corresponding one of the first, second, third, and fourth edges of the base insulation board comprises securing the inner edge of a second edge insulation board to the second edge of the base insulation board.

71. The method of any of claims 68-70, wherein securing the inner edge of the at least one edge insulation board to a corresponding one of the first, second, third, and fourth edges of the base insulation board comprises securing the inner edge of a third edge insulation board to the third edge of the base insulation board.

72. The method of any of claims 68-71, wherein securing the inner edges of each of the at least one edge insulation board to the corresponding one of the first, second, third, and fourth edges of the base insulation board comprises interlocking protruding tongue portions and recessed groove portions of the corresponding edge insulation boards and base insulation board edges.

73. The method of any of claims 68-72, wherein the inner edge of each of the at least one edge insulation board includes a recessed groove portion, and each of the corresponding edges of the base insulation board includes a protruding tongue portion for interlocking with the corresponding recessed groove portion.

74. The method of any of claims 72-73, wherein the protruding tongue portions are secured with the recessed groove portions by a friction fit.

75. The method of any of claims 72-74, wherein the protruding tongue portions are secured with the recessed groove portions by an adhesive.

76. The method of any of claims 68-75, wherein securing the inner edge of the at least one edge insulation board to a corresponding one of the first, second, third, and fourth edges of the base insulation board comprises securing the inner edge of a third edge insulation board to the third edge of the base insulation board and securing the inner edge of a fourth edge insulation board to the fourth edge of the base insulation board, the method further comprising at least partially embedding a plurality of rigid channels in a rear portion of the base insulation board and extending between the third and fourth edges of the base insulation board.

77. The method of claim 76, further comprising fastening a plurality of rigid hook portions to corresponding ones of the plurality of rigid channels.

78. The method of claim 77, wherein securing the inner edge of the at least one edge insulation board to a corresponding one of the first, second, third, and fourth edges of the base insulation board comprises securing the inner edge of a first edge insulation board to the first edge of the base insulation board and securing the inner edge of a second edge insulationboard to the second edge of the base insulation board, wherein each of the plurality of rigid hook portions extends beyond the first and second edges of the base insulation board for alignment with the first and second edge insulation boards.

79. The method of any of claims 77-78, wherein each of the plurality of rigid hook portions has a J-shaped cross-section.

80. The method of any of claims 76-79, wherein the plurality of rigid channels comprise hat channels embedded in the rear portion of the base insulation board.

81. The method of any of claims 68-80, wherein securing the inner edge of the at least one edge insulation board to a corresponding one of the first, second, third, and fourth edges of the base insulation board comprises securing the inner edge of a third edge insulation board to the third edge of the base insulation board and securing the inner edge of a fourth edge insulation board to the fourth edge of the base insulation board, the method further comprising at least partially embedding first and second rigid brace members in rear portions of corresponding ones of the third and fourth edge insulation boards, the first and second rigid brace members extending parallel to the third and fourth edges of the base insulation board.

82. The method of claim 81, wherein each of the first and second rigid brace members comprises a hat channel at least partially embedded in the rear portion of the corresponding one of the third and fourth edge insulation boards.

83. The method of any of claims 68-82, wherein securing the inner edge of the at least one edge insulation board to a corresponding one of the first, second, third, and fourth edges of the base insulation board comprises securing the inner edge of a first edge insulation board to the first edge of the base insulation board and securing the inner edge of a second edge insulation board to the second edge of the base insulation board, wherein each of the first and second edge insulation boards includes a reinforcing mesh layer extending from the front surface to a rear surface and over the outer edge.

84. The method of claim 83, wherein each of the first and second edge insulation boards includes a basecoat layer covering a substantial portion of the reinforcing mesh layer.

85. The method of any of claims 68-84, wherein securing the inner edge of the at least one edge insulation board to a corresponding one of the first, second, third, and fourth edges of the base insulation board comprises securing the inner edge of a third edge insulation board to the third edge of the base insulation board and securing the inner edge of a fourth edge insulation board to the fourth edge of the base insulation board, wherein each of the third and fourth edge insulation boards includes a reinforcing mesh layer extending from the front surface to a rear surface and over the outer edge.

86. The method of claim 85, wherein each of the third and fourth edge insulation boards includes a basecoat layer covering a substantial portion of the reinforcing mesh layer.

87. The method of any of claims 68-86, wherein applying the coating to the front surface of each of the base insulation board and the at least one edge insulation board comprises adhering a basecoat layer to the front surfaces of the base insulation board and the at least one edge insulation board.

88. The method of claim 87, further comprising embedding a reinforcing mesh in the basecoat layer.

89. The method of any of claims 87-88, wherein applying the coating to the front surface of each of the base insulation board and the at least one edge insulation board comprises adhering a finish layer to an outer surface of the basecoat layer.

90. The method of any of claims 68-89, wherein securing the inner edge of the at least one edge insulation board to a corresponding one of the first, second, third, and fourth edges of the base insulation board comprises securing the inner edge of a first edge insulation board to the first edge of the base insulation board, securing the inner edge of a second edge insulation board to the second edge of the base insulation board, securing the inner edge of a third edge insulation board to the third edge of the base insulation board, and securing the inner edge of a fourth edge insulation board to the fourth edge of the base insulation board, further comprising securing the inner edges of the third and fourth insulation board to corresponding first and second ends of the first and second edge insulation boards at corresponding first, second, third, and fourth corner edge board junctions.

91. The method of claim 90, further comprising wrapping first, second, third, and fourth reinforcing mesh elements over corresponding ones of the first, second, third, and fourth corner edge board junctions.

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