IPC분류정보
국가/구분 |
United States(US) Patent
등록
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국제특허분류(IPC7판) |
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출원번호 |
US-0838436
(2004-05-04)
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등록번호 |
US-7395999
(2008-07-08)
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발명자
/ 주소 |
|
출원인 / 주소 |
|
대리인 / 주소 |
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인용정보 |
피인용 횟수 :
22 인용 특허 :
37 |
초록
▼
A method and apparatus for manufacturing reinforced wall panels and reinforced roof panels and using the pre-manufactured reinforced wall and roof panels in the construction of a building structure at a building site. The reinforced wall and roof panels are molded using a molding medium consisting o
A method and apparatus for manufacturing reinforced wall panels and reinforced roof panels and using the pre-manufactured reinforced wall and roof panels in the construction of a building structure at a building site. The reinforced wall and roof panels are molded using a molding medium consisting of two part polyurethane which is mixed with Portland cement. Reinforcing members and exterior weather resistant materials are placed within a mold and the mold is filled with the molding medium by injection or by pouring. The filled mold is then placed within a press to ensure against expansion by internal pressure caused by curing of the molding medium, thus ensuring dimensional accuracy of the finished panel. After hardening of the molding medium, the mold is removed from the press, opened and the finished panel is removed from the mold and is stored until the molding medium has completely cured. The reinforcing members and weather resistant material constitute integral components of the building panel structure.
대표청구항
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I claim: 1. A method for forming a building structure, comprising: placing a mold for a reinforced building panel on a generally horizontally oriented bottom press wall member of a press mechanism having relatively moveable generally horizontally oriented top and bottom press wall members, said mol
I claim: 1. A method for forming a building structure, comprising: placing a mold for a reinforced building panel on a generally horizontally oriented bottom press wall member of a press mechanism having relatively moveable generally horizontally oriented top and bottom press wall members, said mold having top and bottom generally horizontally oriented mold walls defining a rectangular mold cavity and being configured to mold interior and exterior surfaces of said reinforced building panel, said mold having mold edge members configured for molding top bottom and side edges of said reinforced building panel, said top generally horizontally oriented mold wall being removable from said mold; with said top generally horizontally oriented mold wall removed from said mold locating panel reinforcing members and external weather resistant members within said mold cavity; introducing a two-part polyurethane and Portland cement molding medium into said mold cavity in a substantially liquid state, the molding medium establishing intimate contact with said mold walls said panel reinforcing members and said external weather resistant members; closing said mold by assembling said top generally horizontally oriented mold wall to said mold; moving a said top and bottom press wall members toward one another and establishing compressive engagement with said top and bottom mold walls and securing said mold walls against movement during curing of the molding medium to define a hardened and dimensionally stable building panel structure for use as a wall panel or roof panel of a building; after desired hardening of said molding medium causing separating movement of said at least one of said top and bottom press wall members and releasing said compressive engagement of said mold walls; opening the mold by removing said top mold wall member from said mold and removing the hardened, dimensionally stable building panel from the mold cavity; fixing a panel mounting member to outside edge portions of a building foundation at a construction site; and assembling a plurality of said reinforced building panels in side by side relation and with bottom portions thereof located within said panel mounting member and forming walls of a building structure having external weather resistant surfaces defined by said external weather resistant members. 2. The method of claim 1, wherein said panel reinforcing members are wall stud members and at least one structural mesh panel, said method comprising: locating a plurality of wall stud members and at least one structural mesh panel within said mold; and upon said introducing a two-part polyurethane and Portland cement molding medium into said mold cavity, causing intimate contact of said molding medium with said wall stud members and said at least one structural mesh panel. 3. The method of claim 1, wherein said top and bottom mold walls are configured to defines internal and external wall surfaces of said reinforced building panels and said mold edge members are configured to define side, top and bottom edges of said reinforced building panels and said panel reinforcing members are metal wall stud members and at least one metal structural mesh panel, said at least one metal structural mesh panel being positioned in slightly spaced and parallel relation with at least one of said internal and external mold walls, said method comprising: locating a plurality of metal wall stud members and at least one metal structural mesh panel within said mold; and upon said introducing a two-part polyurethane and Portland cement molding medium into said mold cavity, causing intimate contact of said molding medium with said metal wall stud members said top and bottom mold walls and said at least one structural mesh panel. 4. The method of claim 1, wherein said generally horizontally oriented top and bottom mold walls are configured to define internal and external surface configurations of said building panel walls and said mold edge members are configured to define configurations of side, top and bottom reinforced building panel edges and said panel reinforcing members are metal wall stud members of substantially C-shaped cross-sectional configuration defined by substantially parallel stud flanges each being integral with respective sides of a central stud web having a plurality of web apertures defined therein, said panel reinforcing members also being at least one metal structural mesh panel, said at least one metal structural mesh panel being positioned in slightly spaced and parallel relation with at least one of said internal and external mold walls, said method comprising: locating a plurality of metal wall stud members and at least one metal structural mesh panel within said mold cavity and being supported by said bottom mold wall with said parallel stud flanges substantially parallel with said top and bottom mold walls and with said central stud web being oriented in transverse relation with said top and bottom mold walls; and upon said introducing a two-part polyurethane and Portland cement molding medium into said mold cavity, causing intimate contact of said molding medium with said stud flanges and central stud web of said metal wall stud members and with said molding medium extending through said plurality of web apertures and said at least one structural mesh panel. 5. The method of claim 1, said reinforced building panels comprising reinforced wall panels having interior and exterior panel surfaces and side edges defining tongue and groove panel edge joint connectors and top and bottom edges, said method comprising: providing a building foundation; mounting a bottom wall panel mounting member to said building foundation, said bottom wall panel mounting member having a horizontally oriented web and an upstanding flange; positioning reinforced building panels as wall panels with interior and external wall surfaces thereof oriented substantially vertically and with said bottom edges of said reinforced wall panels positioned above said horizontally oriented web and with said interior and exterior panel surfaces oriented in substantially parallel relation with said upstanding flange of said bottom wall panel mounting member and with said tongue and groove panel edge joint connectors of said reinforced wall panels in engagement and forming the walls of a building structure; and fixing said bottom edges of said reinforced wall panels to said bottom wall panel mounting member. 6. The method of claim 5, comprising: prior to said fixing step, positioning a bottom wall mounting and panel alignment channel on said wall panel mounting member, said wall mounting channel member being of C-shaped cross-sectional configuration having a central web and spaced channel flanges facing upwardly and defining a panel mounting channel receiving said bottom edges of said reinforced wall panels therein; said fixing step extending fastener members through at least one of said spaced channel flanges and fixing said bottom edges of said reinforced wall panels both to said bottom wall mounting and panel alignment channel and said wall panel mounting member; and positioning a wall panel alignment cap in assembly with said top edges of said reinforced wall panels, said wall panel alignment cap being a channel member of C-shaped cross-section and having a central web and spaced substantially parallel depending channel flanges and extending fasteners through at least one of said depending channel flanges and securing said wall panel alignment cap to said top edges of said reinforced wall panels. 7. The method of claim 5, wherein said reinforced building panels also comprise reinforced roof panels having side edges defining tongue and groove panel joint connectors and having top and bottom edges, said reinforced roof panels having external weather resistant roofing material integral therewith and having at least a bottom portion and one side portion extending beyond said reinforced roof panel, said method comprising: anchoring a roof framework to said reinforced wall panels; and fixing reinforced roof panels to said roof framework in side by side and end to end relation with said exterior roofing material of said reinforced roof panels overlapping at least one side and at least a top edge of adjacent reinforced roof panels and defining a drip edge extending beyond the lower edge of the lowermost reinforced roof panel. 8. The method of claim 5 comprising: prior to said introducing said two-part polyurethane and Portland cement molding medium into said mold, positioning at least one roof anchor at least partially within said mold and with a portion of said at least one roof anchor engaging within an aperture of said wall stud and with a portion of said at least one roof anchor projecting from said mold; after positioning of said reinforced wall panels assembling a roof framework to said wall panels with said at least one roof anchor projecting through a portion of said roof framework; and anchoring a roof framework to said reinforced wall panels with said at least one roof anchor; and fixing reinforced roof panels to said roof framework with said exterior roofing material of said reinforced roof panels overlapping at least one side and at least the top edge of adjacent reinforced roof panels and defining a drip edge extending beyond the lower edge of the lowermost reinforced roof panel. 9. The method of claim 7, wherein said reinforced building panels comprise reinforced wall panels composed of two-part molded polyurethane and Portland cement molding medium and having panel reinforcing members embedded therein, said reinforced wall panels having roof anchor members being at least partially embedded therein and being mechanically interconnected with said panel reinforcing members and projecting upwardly from said reinforced wall panels, said method comprising: extending said roof anchor members through said roof framework by lowering roof framework onto said reinforced wall panels; and attaching retainer elements to said roof anchor members and securing said roof framework to said reinforced wall panels. 10. The method of claim 1, comprising: after introducing said two-part polyurethane and Portland cement molding medium into said mold, locating said mold between said horizontally oriented and relatively moveable top and bottom press wall members and with said mold being supported by said bottom press wall member having relatively moveable press walls being moveable to a mold confining position and a mold release position; confining said mold within said press with said relatively moveable press walls and preventing movement of said mold walls by any molding medium pressure caused by expansion of said molding medium during hardening thereof; after hardening of said molding medium moving said relatively moveable press walls to said mold release positions and removing said mold from said press; and opening said mold and extracting said reinforced building panel therefrom. 11. The method of claim 1, wherein said reinforced building panel is a reinforced roof panel and said panel reinforcing members are metal mesh members and sheets of metal roofing material are integrally molded with said reinforced roof panel and have internal and external sheet surfaces; said method comprising: locating said metal mesh members within said mold; positioning at least one sheet of metal roofing material within said mold with said internal sheet surface facing within said mold and with said external sheet surface being supported by said bottom mold wall; and introducing said two-part polyurethane and Portland cement molding medium within said mold in intimate contact with said metal mesh members and in intimate contact with said internal sheet surface of said sheet of metal roofing material; positioning the filled mold within a press having substantially horizontally oriented top and bottom press plate members and causing relative movement of said top and bottom press plate members toward one another and applying compression to said filled mold and restraining any molding medium expansion during curing of said molding medium to a hardened solid state; after desired hardening of said molding medium causing relative separating movement of said top and bottom press plate members to positions releasing compression of said mold: removing said mold from said press; and opening said mold and extracting said reinforced roof panel from said mold. 12. The method of claim 1, wherein said reinforced building panel is a reinforced door panel defining a door opening and said panel reinforcing members are metal wall stud members, metal mesh members and metal door frame members, said method comprising: with said top generally horizontally oriented wall of said mold removed from said mold locating said metal wall stud members, mesh members and metal door frame members within said mold; introducing said two-part polyurethane and Portland cement molding medium within said mold in intimate contact with said metal wall stud members, metal mesh members and metal door frame members and filling said mold; securing said top generally horizontally oriented wall of said mold in assembly with said mold and closing said mold; positioning the filled and closed mold within a press having relatively moveable generally horizontally oriented top and bottom press walls and moving said top and bottom press walls to compression positions engaging said filled and closed mold and restraining mold wall movement by said molding medium during curing expansion within said mold during curing of said molding medium from a substantially liquid state to a solid state; removing said mold from between said top and bottom press walls of said press; and opening said mold by removing said top mold wall from said mold and extracting said reinforced door panel from said mold. 13. The method of claim 1, comprising: after removing said reinforced door panel from said mold preparing interior and exterior surface finishes of said reinforced door panel. 14. The method of claim 1, wherein said reinforced building panel is a reinforced window panel defining a window opening and said panel reinforcing members are metal wall stud members, metal mesh members and metal window frame members, said method comprising: with said top generally horizontally oriented mold wall removed from said mold locating said metal wall stud members, metal mesh members and metal window frame members and exterior weather resistant members within said mold cavity; introducing said two-part polyurethane and Portland cement molding medium within said mold cavity and in intimate contact with said wall stud members metal mesh members and metal window frame members and in intimate contact with said exterior weather resistant material and filling said mold; closing the filled mold by assembling said top mold wall to said mold; moving the filled and closed mold within a press having relatively moveable top and bottom press walls and establishing force transmitting engagement of said top and bottom mold walls with said top and bottom press walls and restraining expansion of said mold by any curing expansion said molding medium during curing of said molding medium from a substantially liquid state to a solid state; removing said mold from said press; and opening said mold by removing said top mold wall from said mold and extracting said reinforced window panel from said mold. 15. A method for forming a building structure, comprising: locating a mold for a reinforced building panel at a mold filling site, said mold having substantially horizontally oriented top and bottom mold walls configured for molding interior and exterior surfaces of a reinforced building panel and having mold top bottom and side edge members configured for molding top bottom and side edges of the reinforced building panel and defining a generally rectangular mold cavity, said top mold wall being removable from said mold for opening said mold; with said top generally horizontally oriented mold wall removed from said mold locating panel reinforcing members and external weather resistant members within said mold cavity; introducing a two-part polyurethane and Portland cement molding medium into said mold cavity in a substantially liquid state, the molding medium establishing intimate contact with said top and bottom mold walls said panel reinforcing members and said external weather resistant members; closing said mold by assembling said top generally horizontally oriented mold wall to said mold; moving said filled and closed mold laterally into an open mold press having relatively moveable top and bottom generally horizontally oriented press wall members; closing said mold press by moving said relatively moveable top and bottom generally horizontally oriented press wall members toward one another and into compressive engagement with said top and bottom mold walls and applying sufficient compression to restrain said top and bottom mold walls against being moved or deformed by the pressure of any expansion of said molding medium during hardening thereof; after curing of said molding medium to a hardened state opening said mold press by causing relative movement of said top and bottom mold wall members away from one another; moving said mold laterally from between said top and bottom press wall members; opening said mold by removing said top mold wall from said mold; removing the hardened reinforced building panel from said mold cavity; securing a U-shaped panel mounting channel to outer edge portions of a building foundation; positioning a plurality of said reinforced building panels in side by side relation with bottom portions located within said panel mounting channel; positioning a U-shaped panel alignment channel on upper end portions of said plurality of said reinforced building panels; mounting a roof framework on said U-shaped panel alignment channel; and mounting a plurality of reinforced roof panels on said roof framework. 16. The method for forming a building structure of claim 15, comprising: prior to step of introducing a two-part polyurethane and Portland cement molding medium into said mold cavity, selectively locating within said mold cavity metal mesh material wall stud members, window frame members door frame members and exterior weather resistant panel members for molding of reinforced building panel members in the form of wall panels, window panels, door panels or roof panels. 17. The method for forming a building structure of claim 15 wherein said panel reinforcing members are wall stud members and at least one structural mesh panel, said method comprising: locating a plurality of wall stud members and at least one structural mesh panel within said mold; and upon said introducing a two-part polyurethane and Portland cement molding medium into said mold cavity, causing intimate contact of said molding medium with said wall stud members and said at least one structural mesh panel. 18. The method of claim 15, wherein said top and bottom mold walls are configured to define internal and external panel wall surfaces of said reinforced building panels and said mold edge members are configured to define side, top and bottom edges of said reinforced building panels and said panel reinforcing members are metal wall stud members and at least one metal structural mesh panel, said at least one metal structural mesh panel being positioned in slightly spaced and parallel relation with at least one of said internal and external mold walls, said method comprising: locating a plurality of metal wall stud members and at least one metal structural mesh panel within said mold cavity; and upon said introducing a two-part polyurethane and Portland cement molding medium into said mold cavity, causing intimate contact of said molding medium with said metal wall stud members said top and bottom mold walls and said at least one structural mesh panel. 19. The method of claim 15, wherein said generally horizontally oriented top and bottom mold walls are configured to define internal and external surface configurations of said building panel walls and said mold edge members are configured to define configurations of side, top and bottom reinforced building panel edges and said panel reinforcing members are metal wall stud members of substantially C-shaped cross-sectional configuration defined by substantially parallel stud flanges each being integral with respective sides of a central stud web having a plurality of web apertures defined therein, said panel reinforcing members also being at least one metal structural mesh panel, said at least one metal structural mesh panel being positioned in slightly spaced and parallel relation with at least one of said internal and external mold walls, said method comprising: locating a plurality of metal wall stud members and at least one metal structural mesh panel within said mold cavity and being supported by said bottom mold wall with said parallel stud flanges substantially parallel with said top and bottom mold walls and with said central stud web being oriented in transverse relation with said top and bottom mold walls; and upon said introducing a two-part polyurethane and Portland cement molding medium into said mold cavity, causing intimate contact of said molding medium with said stud flanges and central stud web of said metal wall stud members and with said molding medium extending through said plurality of web apertures and said at least one structural mesh panel. 20. The method of claim 15, comprising: prior to said fixing step, positioning a bottom wall mounting and panel alignment channel on said wall panel mounting member, said wall mounting channel member being of C-shaped cross-sectional configuration having a central web and spaced channel flanges facing upwardly and defining a panel mounting channel receiving said bottom edges of said reinforced wall panels therein; said fixing step extending fastener members through at least one of said spaced channel flanges and fixing said bottom edges of said reinforced wall panels both to said bottom wall mounting and panel alignment channel and said wall panel mounting member; positioning a wall panel alignment cap in assembly with said top edges of said reinforced wall panels, said wall panel alignment cap being a channel member of C-shaped cross-section and having a central web and spaced substantially parallel depending channel flanges and extending fasteners through at least one of said depending channel flanges and securing said wall panel alignment cap to said top edges of said reinforced wall panels, said reinforced building panels also comprise reinforced roof panels having side edges defining tongue and groove panel joint connectors and having top and bottom edges, said reinforced roof panels having external weather resistant roofing material integral therewith and having at least a bottom portion and one side portion extending beyond said reinforced roof panel, said method comprising: anchoring a roof framework to said reinforced wall panels; and fixing reinforced roof panels to said roof framework in side by side and end to end relation with said exterior roofing material of said reinforced roof panels overlapping at least one side and at least a top edge of adjacent reinforced roof panels and defining a drip edge extending beyond the lower edge of the lowermost reinforced roof panel.
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