Prefabricated composite wall panel and method and apparatus for manufacture and installation thereof
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
E04B-001/00
E04F-013/08
E04C-001/00
E04C-002/54
출원번호
US-0459156
(2009-06-26)
등록번호
US-8353144
(2013-01-15)
발명자
/ 주소
Bolin, Joel W.
출원인 / 주소
Bolin, Joel W.
인용정보
피인용 횟수 :
1인용 특허 :
4
초록▼
A prefabricated composite wall panel has a desired exterior finish defined by thin finish elements of brick, stone or any other suitable material and is adapted for mounting to the wall structure of a building framework by screws or other suitable fasteners. During panel manufacture thin wall finish
A prefabricated composite wall panel has a desired exterior finish defined by thin finish elements of brick, stone or any other suitable material and is adapted for mounting to the wall structure of a building framework by screws or other suitable fasteners. During panel manufacture thin wall finish elements are positioned at predetermined sites within the mold and aligned by alignment members in a pattern defining grout spaces. A grout placement screed having multiple holes arranged in a desired mortar pattern is positioned on the thin finish elements and pulverulent grout is deposited through the holes of the screed and into spaces between the finish elements. After removal of the screed the pulverulent grout is compacted and a liquid uncured polymeric mixture is applied as a contiguous substrate to the back surface of the panel and serves to retain the masonry elements and grout in place and to provide a moisture and air barrier that minimizes the potential for leakage or wicking of water or air infiltration through assembled panels of a wall structure. Finished panels having empty filler element spaces at side edges thereof are fixed to a wall or wall framework of a building with straight edges in abutment and filler elements are positioned to cover joints between the panels.
대표청구항▼
1. A composite construction panel for mounting to the framework or other part of a building, comprising: a substantially contiguous substrate of polymeric material defining a moisture and air barrier of said composite construction panel and defining interior and exterior surfaces;a plurality of pane
1. A composite construction panel for mounting to the framework or other part of a building, comprising: a substantially contiguous substrate of polymeric material defining a moisture and air barrier of said composite construction panel and defining interior and exterior surfaces;a plurality of panel finish elements connected to said exterior surface of said substantially contiguous substrate of polymeric material and being disposed in spaced relation with one another to define grout spaces therebetween, wherein said substantially contiguous substrate of polymeric material bonds with said plurality of panel finish elements;a pulverulent grout material at least partially filling said grout spaces and being embedded in a matrix of said substantially contiguous substrate of polymeric material within said grout spaces; andan interior sheathing substrate connected to said interior surface of said substantially contiguous substrate of polymeric material and defining an interior surface of said composite wall construction panel. 2. The composite construction panel of claim 1, wherein said plurality of panel finish elements are thin masonry elements having the height and width of conventional bricks and having a depth less than the depth of conventional bricks. 3. The composite wall construction panel of claim 1, comprising: said panel finish elements having a defined height and width; andside portions of said composite wall construction panel defining empty finish element spaces being of said defined height and having a width less than said defined width. 4. The composite construction panel of claim 1: wherein said substantially contiguous substrate of polymeric material bonds said panel finish elements and said interior sheathing together,wherein at least a portion of said pulverulent grout particulate is being visible within said grout spaces between said finish elements. 5. The composite construction panel of claim 1, wherein said substantially contiguous substrate of polymeric material is a polymeric material having a thermal insulating characteristic, defining an air and moisture infiltration barrier within said composite construction panel and having an adhesive characteristic integrating said plurality of panel finish elements to said exterior surface thereof and integrating said pulverulent grout material within said grout spaces, said polymeric material integrating said interior sheathing substrate with said composite construction panel. 6. The construction panel of claim 1, wherein the substantially contiguous substrate of polymeric material is a bonding agent that bonds the plurality of panel finish elements with the interior sheathing substrate, wherein the plurality of panel finish elements and the interior sheathing substrate are physically and chemically bonded together by the substantially contiguous substrate of polymeric material. 7. A method for manufacturing a composite wall construction panel intended for mounting to the structural framework members of a building, comprising: positioning a multiplicity of panel finish elements outer face down and in spaced relation on a support with grout spaces being defined between said panel finish elements;distributing pulverulent grout material within said grout spaces;applying a substantially contiguous substrate of uncured polymeric material onto said panel finish elements and onto said pulverulent grout material within said grout spaces;positioning an interior panel substrate within said substantially contiguous substrate of uncured polymeric material; andsubjecting said multiplicity of panel finish elements and said substantially contiguous substrate of uncured polymeric material to mechanical compression during curing of said polymeric material and adhering said multiplicity of panel finish elements and said pulverulent grout material in integral relation forming said composite construction panel. 8. The method of claim 7, comprising after said applying a substantially contiguous substrate and before said subjecting said uncured polymeric material to mechanical compression, positioning a sheathing panel onto said substantially contiguous substrate of uncured polymeric material, said mechanical compression at least partially embedding said sheathing panel within said polymeric substrate and bonding said sheathing panel to said substantially contiguous substrate of polymeric material. 9. The method of claim 7, wherein said support being a mold base having a mold receptacle defining a bottom wall and mold side surfaces, said method comprising: said positioning step being location of said multiplicity of panel finish elements oriented outer faces down on said bottom wall in spaced relation with one another and in spaced relation with said mold side surfaces; andafter said step of distributing pulverulent grout material within said grout spaces said applying step being mixing and depositing said substantially contiguous substrate of uncured polymeric material onto said multiplicity of panel finish elements, onto pulverulent grout material within said grout spaces between said multiplicity of panel finish elements and in spaces between said multiplicity of panel finish elements and said side surfaces of said mold receptacle, causing said polymeric substrate to form a generally rectangular surround of said composite construction panel having substantially straight panel edges. 10. The method of claim 9 wherein said polymeric material is a polymeric foam material and a mold cover of said mold defines a panel recess releasably retaining an interior sheathing substrate therein, said method comprising: following said applying a substantially contiguous substrate of uncured polymeric foam material and before curing of said polymeric material, moving said mold cover into closing engagement with said mold and positioning said interior sheathing substrate in engagement with said uncured polymeric foam substrate;applying a compressive force to said mold cover causing said interior sheathing substrate to become at least partially embedded within said uncured polymeric foam material, said compressive force causing said uncured polymeric foam material to substantially completely fill said mold, restrain polymeric foam expansion during curing, and enhance the density of said polymeric foam material; andfollowing curing of said polymeric foam substrate to a dimensionally stabilized state, removing said mold cover from said mold and removing said composite construction panel from said mold. 11. The method of claim 9, comprising: positioning a masonry alignment jig within said mold receptacle, said masonry alignment jig defining a plurality of masonry element sites and having masonry element alignment members;providing a plurality of thin masonry elements each having a front face and a back face and having edge surfaces;positioning one of said plurality of thin masonry elements front face down at each of said masonry element sites, said thin masonry elements each being aligned by said masonry element alignment members and establishing a masonry pattern for said composite wall panel and defining grout spaces between said masonry elements;after said depositing pulverulent grout material within said grout spaces and applying a substrate of mixed uncured polymeric foam material onto said plurality of thin masonry elements and said pulverulent grout material, assembling said mold cover to said mold base;applying compressive force to said polymeric foam substrate forcing a portion of said polymeric foam substrate into said grout spaces and into intimate engagement with said plurality of thin masonry elements and into intimate engagement with said pulverulent grout material and maintaining application of said compressive force until curing of said polymeric foam substrate has occurred; andafter curing of said polymeric foam material to a dimensionally stable state, removing said composite construction panel from said mold. 12. The method of claim 11, wherein said step of applying compressive force to said polymeric foam substrate comprising: positioning in force transmitting engagement with said uncured polymeric foam substrate a sheathing panel being releasably received within a mold cover; andapplying a force to said mold cover urging said sheathing panel against said uncured polymeric foam substrate with sufficient force to deform said polymeric substrate within said mold and at least partially embed said sheathing panel within said polymeric substrate and establish intimate bonding engagement of said polymeric substrate with said plurality of thin finish elements and in bonding engagement with pulverulent grout material within said grout spaces. 13. The method of claim 11, comprising: prior to the method step of applying the substrate of mixed uncured polymeric foam material, locating a screed member in covering relation with said thin finish elements, said screed member having a plurality of grout deposit holes located in registry with said grout spaces between said thin finish elements;depositing said pulverulent grout material through said grout deposit holes of said screed member and into said grout spaces; andafter completing said depositing of said pulverulent grout material in said grout spaces, removing said screed member. 14. The method of claim 13, comprising after removal of said screed member, compressing a resilient panel against said thin finish elements with sufficient force causing said resilient panel to enter said grout spaces and achieve compression of said pulverulent grout material within said grout spaces. 15. The method of claim 7 wherein said plurality of thin finish elements are of rectangular configuration, each defining four corners, and said finish element alignment members are alignment pins within said mold receptacle positioned for orienting engagement with the four corners of said thin finish elements, said method comprising: prior to said step of applying said substrate, positioning each of said plurality of thin finish elements with alignment pins having aligning relation with edge surfaces of said thin masonry elements adjacent to each of the four corners thereof, said alignment pins retaining said thin finish elements against lateral movement from said masonry element sites. 16. The method of claim 7, wherein said applying compressive force comprises: positioning said mold and mold cover on a support member of a press;moving a platen member of the press against said mold cover with sufficient force to deform said uncured polymeric material against said thin finish elements and within said grout spaces and against said pulverulent grout material; andmaintaining said application of compressive force for a sufficient time for curing of said polymeric material. 17. A method for assembling pre-manufactured composite construction panels to the framework of a building structure, wherein said pre-manufactured composite construction panels have substantially straight side edges and define a plurality of finish element sites, said composite construction panels having a substantially contiguous polymer substrate and having a plurality of thin finish elements fixed to said finish element sites and having pulverulent grout material retained in grout spaces between the finish elements by said substantially contiguous polymeric substrate, said composite construction panels further having a plurality of empty finish element sites on the side portions of said composite construction panels, said method comprising: mounting composite construction panels to the wall framework of a building with fasteners and with said substantially straight side edges in abutting relation and defining panel joints between adjacent composite construction panels;after mounting the composite wall panels to the framework, securing thin filler finish elements to each of said empty finish element sites and with grout spaces between said thin filler finish element with one another at least some of the thin finish filler elements bridging and covering said panel joints;applying caulking material within said grout spaces between said thin filler finish elements, said caulking material initially having a tacky state and curing to a more hardened stabilized state; andwhile said caulking material is tacky, applying pulverulent grout material to said caulking material for retention within said grout spaces by said caulking material. 18. The method of claim 17, wherein said external thin finish filler elements being in the form of filler panels having assembled groups of external thin assembled to a filler substrate with grout spaces therebetween, said method comprising: securing said filler panels within said empty finish element spaces of adjacent composite construction panels, said filler panels bridging joints established by abutting side edges of installed composite construction panels;applying caulking material within grout spaces between said thin finish elements; andapplying pulverulent grout material to said caulking material. 19. The method of claim 17, wherein said composite construction panels having edges defining spline slots and receiving spline members engaging within spline slots of adjacent composite construction panels for ensuring precise panel edge alignment when said composite construction panels are installed in edge to edge abutting relation on a building, said method comprising: fixing a composite construction panel to a building;positioning at least one spline member within a spline slot of said fixed composite construction panel; andpositioning another composite construction panel on said building and moving it laterally into edge to edge abutting relation relative to the fixed composite construction panel and causing said spline slot thereof to receive at least one said spline member of said fixed composite construction panel and define a spline oriented and sealed joint between adjacent composite construction panels; andapplying sealant material to said spline oriented and sealed joint. 20. A construction panel for mounting to the framework or other part of a building, comprising: a substrate of polymeric material having an interior surface and an exterior surface;an exterior finish element in contact with the exterior surface of the substrate of polymeric material, wherein the substrate of polymeric material directly bonds with the exterior finish element; anda sheathing substrate in contact with the interior surface of the substrate of polymeric material, wherein the substrate of polymeric material directly bonds with the sheathing substrate. 21. The construction panel of claim 20, wherein the exterior finish element and the sheathing substrate are physically bonded together by the substrate of polymeric material, wherein the substrate of polymeric material is a bonding agent that bonds the exterior finish element and the interior sheathing substrate. 22. The construction panel of claim 20, further comprising: a particulate material, wherein the particulate material is bound by the substrate of polymeric material, wherein the particulate material is bound on the exterior surface of the substrate of polymeric material. 23. The construction panel of claim 20, further comprising: a composite of particulate material embedded in a matrix of the substrate of polymeric material. 24. The construction panel of claim 20, wherein the exterior finish element comprises a plurality of exterior finish elements having spaces therebetween. 25. The construction panel of claim 24, further comprising: a composite of the particulate material embedded in a matrix of the substrate of polymeric material, wherein the composite is contained in the spaces between the plurality of exterior finish elements.
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이 특허에 인용된 특허 (4)
Smith, Brian, Composite building panel and method of making composite building panel.
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