Static structures (e.g. – buildings) – Processes – Fabrication of member – module – etc.
Reexamination Certificate
2000-07-25
2001-06-05
Friedman, Carl D. (Department: 3635)
Static structures (e.g., buildings)
Processes
Fabrication of member, module, etc.
C052S742100, C052S742140, C052S797100, C052S309120, C052S783100, C264S256000, C264S255000
Reexamination Certificate
active
06240701
ABSTRACT:
FIELD OF THE INVENTION
The following invention relates to a method and apparatus for forming a building panel. The invention also relates to a building panel.
Lightweight concrete building panels are known. Such panels are produced in a raw, unfinished condition for installation. After being installed into a building under construction, the panels are rendered or otherwise coated to provide an acceptable surface finish. This process requires the labour of a skilled renderer in applying the rendered finish with a trowel. Furthermore, the strength of such known lightweight concrete panels is not high.
OBJECT OF THE INVENTION
It is an object of the present invention to overcome or substantially ameliorate at least one of the above disadvantages and/or more generally to provide an improved building panel and a method and apparatus for forming a building panel.
DISCLOSURE OF THE INVENTION
There is disclosed herein a method of forming a building panel or panels, the method including:
applying a flowable, settable coating material to respective surfaces of at least two baffles,
placing the baffles in a substantially parallel, spaced interrelationship,
at least substantially filling the space between the two baffles with a settable core material prior to setting of the coating material, and
allowing the core material and coating material to set.
Preferably, the baffles are located with respect to one another prior to filling the space with core material.
Alternatively, the baffles can be moved together after filling the space with core material but prior to setting of the core material and coating material.
Preferably, the baffles are moved apart and/or separately removed after setting of the core material and coating material so as to release the formed panel(s).
Preferably, the method further provides n+1 baffles in a parallel spaced interrelationship, between which n panels are formed where n equals any integer greater than or equal to 1.
Preferably, after the baffles are moved apart, the panels are removed in a direction substantially parallel to the plane of the baffles by application of force thereto.
Preferably, the baffles are located within a mould box or supporting frame.
Preferably, the baffles are moved toward one another by means of hydraulic clamping cylinders.
There is further disclosed herein an apparatus for use in forming a building panel in accordance with the above disclosed method, the apparatus including:
a mould box or supporting frame into which said coated baffles are receivable,
means to locate said coated baffles in association with one another so as to define a minimum space therebetween, and
means to apply a settable core material between each of said baffles.
Preferably, the apparatus further includes a means to apply a coating material to both sides of at least some of said baffles prior to applying said settable core material between each of said baffles.
Preferably, each baffle is substantially hollow, having a pair of spaced apart side sheets.
Preferably, each baffle has air inlet means by which air can be injected to the space between the sheets so as to outwardly expand the same under pressure to assist in releasing the set panels from the baffles.
Alternatively, each baffle is solid. Plywood is a suitable material for a solid baffle. The plywood can be plastics coated. As a further alternative, the baffles can be a composite of plywood, nylon, PVC and steel.
Preferably, the baffles have extraction engagement holes to which an extraction device can be anchored for the purpose of applying force to the set panels for removal.
Preferably, said mould box or supporting frame is formed upon a mobile structure.
Preferably, the mobile structure has one or more posts to which clamping cylinders are affixed, said clamping cylinders being associated with side walls of the mould box or supporting frame.
Preferably, the side walls of the mould box or supporting frame act as end baffles.
There is further disclosed herein a plant for forming building panels, the plant including:
means for applying a flowable, settable coating material to respective surfaces of at least two baffles,
means for placing the baffles in a substantially planar, spaced interrelationship,
means for substantially filling the space between the two baffles with a settable core material prior to setting of the coating material, and
means for conveying the individual panel throughout the plant for the purpose of cleaning and coating the same with said settable coating material and for arranging the coated baffles in said substantially parallel, spaced interrelationship.
Preferably, the plant also includes means for conveying a mould box or supporting frame into which and from which the baffles are inserted and removed and means for transferring the mould box from a first, baffle removal position to a second baffle insertion position, between which positions the mould box or supporting frame is rotated.
Preferably, the means for substantially filling the space between the two baffles with a settable core material includes a hopper from which there extends one or more filling tubes, the hopper being mounted upon a frame and being pivotable about a horizontal axis, the hopper being adapted to be raised and lowered such that the filling tubes enter and are withdrawn from a space between adjacent baffles while core material is being delivered thereto by said filling tubes.
Preferably, means are provided to oscillate the hopper horizontally, during vertical withdrawal of the tubes and delivery of the core material.
There is further disclosed herein a building panel formed by the above disclosed method or by use of the above disclosed apparatus or as produced by the above disclosed plant.
There is further disclosed herein a building panel including a core having been set from a settable core material and a coating on either side thereof, the coating on either side having been set from a settable coating material concurrently with setting of said core material.
REFERENCES:
patent: 3809516 (1974-05-01), Komaki
patent: 4191521 (1980-03-01), Muldery et al.
patent: 4409768 (1983-10-01), Boden
patent: 5209968 (1993-05-01), Sweeney
Moses Paul Russell
Munn Robert Lawrence
Story Robert
Boral Resources (NSW) Pty Limited
Friedman Carl D.
McDonnell & Boehnen Hulbert & Berghoff
Nguyen Chi Q
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