Abstract: A method and apparatus for making an rigid foam insulating panel is disclosed. The panel includes an rigid foam sheet with a plurality of grooves or recesses in which reinforcing strips are placed. Both sides of the sub-assembly are covered with a reinforcing sheet made of plastic, paper, foil, or a combination thereof. These reinforcing sheets are bonded to the surface of the rigid foam sheet and provide structural support to the sheet, as well as retaining the reinforcing strips in place. They also provide a vapor barrier on both sides of the sheet to prevent the migration of moisture through the sheet toward the wall covering, which will typically be attached to the side of the sheet in which the reinforcing strips are inserted.

Abstract: An insulated wall system includes a concrete wall, either cast or built up with blocks, to which is attached several insulated panels, each of the insulated panels having reinforcing strips placed in recesses of the panel that extend the length of the panel. A reinforcing layer is provided on the outer surface of the panels that extends across the top of the recess and across the top of the reinforcing strips. This layer provides a vapor barrier, and is sealed between the fasteners and the reinforcing strips when the panels are attached to the concrete wall. The wall system is constructed by making the concrete wall, then attaching each of the insulated panels to the wall by fasteners that penetrate the reinforcing strips and are embedded in the wall. The wall system may also include another outer layer of wallboard that is mounted to the reinforcing strips, but preferably not to the wall itself.