Architectural Building Material

Abstract

An architectural material comprising a bulk polymeric foam material which includes additional structural support which provides increased strength and durability at the front surface of the architectural material. The architectural material includes a mesh material which is disposed near the front surface of the architectural material. The architectural material may additionally include a barrier layer which further protects the surface of the architectural material.

1 . An architectural material comprising:
 a bulk polymeric foam material; and   a mesh material disposed within said polymeric material at a position between the midpoint and the front surface of said architectural material.   
     
     
         2 . The architectural material according to  claim 1 , wherein said mesh material is disposed proximate to the front surface of said architectural material. 
     
     
         3 . The architectural material according to  claim 1 , wherein said mesh material is disposed within 3 cm from the front surface of said architectural material. 
     
     
         4 . The architectural material according to  claim 1 , wherein said mesh material is disposed within 2 cm from the front surface of said architectural material. 
     
     
         5 . The architectural material according to  claim 1 , wherein said mesh material is disposed within 1 cm from the front surface of said architectural material. 
     
     
         6 . The architectural material according to  claim 1  further comprising a barrier layer. 
     
     
         7 . The architectural material according to  claim 6 , wherein said barrier layer is formed from a gel-based precursor material, a liquid based precursor material, or a powder based precursor material. 
     
     
         8 . The architectural material according to  claim 6 , wherein said mesh material is at least partially disposed within said barrier layer. 
     
     
         9 . The architectural material according to  claim 1 , wherein said polymeric foam material is polyurethane free rise foam. 
     
     
         10 . The architectural material according to  claim 9 , wherein said polyurethane free rise foam has a density in the range of 2 pounds per cubic feet to about 25 pounds per cubic feet. 
     
     
         11 . The architectural material according to  claim 9 , wherein said polyurethane free rise foam has a density in the range of 8 pounds per cubic feet to about 14 pounds per cubic feet. 
     
     
         12 . The architectural material according to  claim 1 , wherein said mesh material comprises metal, composite material, polymer material, fiberglass, or any combination thereof. 
     
     
         13 . The architectural material according to  claim 1 , wherein said mesh material comprises a polymer coated fiberglass material. 
     
     
         14 . The architectural material according to  claim 1 , wherein said architectural material further comprises a topcoat layer. 
     
     
         15 . A method for forming an architectural material comprising the steps of:
 1) applying a barrier precursor material to the inner surface of the cavity of a mold;   2) placing a mesh material in said mold proximate to the inner surface of the cavity of the mold;   3) dispensing a polymeric foam precursor material into the cavity of said mold;   4) sealing said mold;   5) placing said mold into a press;   6) removing said architectural material from said mold.   
     
     
         16 . The method according to  claim 1  further comprising the step of:
 7) applying a topcoat layer to said architectural material.   
     
     
         17 . A method for forming an architectural material comprising the steps of:
 1) placing a mesh material in a mold proximate to the inner surface of the cavity of said mold;   2) dispensing a polymeric foam precursor material into the cavity of said mold;   3) sealing said mold;   4) placing said mold into a press;   5) removing said architectural material from said mold.   
     
     
         18 . The method according to  claim 1  further comprising the step of:
 6) applying a topcoat layer to said architectural material.