Lightweight, weather-resistant, barriers, methods and structures using the same

Abstract

Insulated building products, methods and structure using those products are disclosed. The embodiments described include building materials having a core of encapsulated polystyrene (EPS) which is completely coated with a polymer. The polymer coating provides protection and structural integrity to the foam such that virtually indestructible structures can made of EPS foam that can form barriers for use in crowd control, cordoning off areas, creating corrals for lines at events, etc. Moreover, additional embodiments are provided in which additional structural integrity is provided by affixing one or more rigid materials to the EPS foam prior to coating. The results, as disclosed, are light-weight, portable building structures that can be made into lightweight, easily deployable and easily storable barriers.

What is claimed is: 
     
         1 . A lightweight barrier comprising:
 a core of at least one piece of expanded polystyrene foam, the core comprising:
 first and second vertical support portions having space therebetween; and 
 an upper barricade portion from which the first and second portions extend; and 
   a polymer coating that encapsulates the core.   
     
     
         2 . The lightweight barrier of  claim 1 , wherein the first and second vertical support portions are substantially parallel to each other. 
     
     
         3 . The lightweight barrier of  claim 1 , wherein:
 the first vertical support portion is formed intrinsically with a first attachment portion, and the first attachment portion is formed intrinsically with the upper barricade portion; and   the second vertical support portion is formed intrinsically with a second attachment portion, and the second attachment portion is formed intrinsically with the upper barricade portion, the first and second attachment portions being aligned on substantially the same, but opposing angle to each other such that the space between the first and second attachment portions narrows going from the vertical support portions to the upper barricade portion.   
     
     
         4 . The lightweight barrier of  claim 3 , wherein the region of the upper barricade portion farthest from the vertical support portions is contoured such that it is capable of fitting within the space therebetween the first and second vertical portions of an additional lightweight barrier. 
     
     
         5 . The lightweight barrier of  claim 4 , wherein the lightweight barrier and the additional lightweight barrier are substantially identical to each other. 
     
     
         6 . The lightweight barrier of  claim 1 , wherein the core is formed from a unitary piece of expanded polystyrene foam. 
     
     
         7 . The lightweight barrier of  claim 1 , wherein is formed from first and second substantially identical pieces of expanded polystyrene foam, each identical piece of expended polystyrene foam comprising a vertical support portion, and attachment portion, and an upper barricade portion, the first and second substantially identical pieces being arranged such that the upper barrier portions can be affixed to each other in a manner to create the space therebetween the first and second vertical support portions. 
     
     
         8 . The lightweight barrier of  claim 7 , wherein the first and second substantially identical pieces are affixed to each other using a permanent adhesive prior to the core being encapsulated with the polymer coating. 
     
     
         9 . The lightweight barrier of  claim 8 , wherein at least a portion of the barricade portion is coated with reflective material. 
     
     
         10 . The lightweight barrier of  claim 9 , wherein the reflective material comprises a plurality of stripes that are affixed to the upper barricade portion. 
     
     
         11 . The lightweight barrier of  claim 10 , wherein the plurality of stripes alternate between a first color and a second color.