Static structures (e.g. – buildings) – Sheetlike element assembled parallel to existing wall,... – Assembled with fastening device
Reexamination Certificate
2000-03-07
2001-07-03
Kent, Christopher T. (Department: 3635)
Static structures (e.g., buildings)
Sheetlike element assembled parallel to existing wall,...
Assembled with fastening device
C052S384000, C052S385000, C052S508000, C052S511000
Reexamination Certificate
active
06253515
ABSTRACT:
This invention relates to an improved building panel, as well as a method and apparatus for producing the building panels, and in particular to concrete building panels for exterior use on buildings. This new cladding system is a radical departure from any commonly used systems.
FIELD OF THE INVENTION
Thin panels of the type produced in accordance with the present invention are used to simulate natural stones. Because the panels are relatively thin, the cost of producing a simulated stone finish is substantially less expensive than when using artificial or real stones. Panels of the type described herein are typically produced in separate molds which is both time consuming and expensive.
BACKGROUND OF THE INVENTION
Cladding systems such as stucco, brick, stone and artificial stone veneer are typically manufactured off-site and installed on a building using mortars which are prepared on the building site. Such systems often encounter a great number of potential problems related to the particular systems. For example, the quality of the mortar materials is often impaired due to the fact that monitoring of accurate formulas on the building site is difficult. Moreover, variations in weather and temperature can affect the mortars significantly.
The installation of typical masonry products is often hindered by weather conditions, such as rain and freezing conditions which usually force a work stoppage unless measures are taken to shield the work area.
The quality of these materials is further impaired due to the fact that typically these mortar materials are allowed to air dry without attempting to seal these cementitious products for proper curing. Sealing during curing greatly improves cementitious products thus making them denser and reducing a condition known as efflorescing, a process that allows calcium to migrate from the material and deposit on the surface. Efflorescence is extremely difficult to prevent in presently known masonry cladding installation systems.
Typically with presently known masonry cladding systems it is necessary to provide mixing equipment on job sites for preparing the cementitious mortar products that are required for installation.
In the case of stucco it becomes necessary to carry out the installation in three or four steps such as: wire installation, first layer of stucco (scratch coat) second layer (float coat) and top layer (finish coat). Often with stucco or artificial stone, an inferior cladding system is achieved due to the fact that no venting space is provided in behind the cladding.
Brick and stone cladding systems are generally very heavy, and special consideration must be given, especially in the areas of the foundation and over window and door openings, to supporting this weight.
Generally speaking all existing masonry cladding systems are plagued with cracking problems. It is virtually impossible to prevent this condition. Furthermore, all existing masonry cladding systems require unsightly expansion joints, both laterally and vertically. Concealing these joints is virtually impossible.
It is also difficult to maintain a uniform minimum thickness with presently known masonry cladding systems.
Presently known artificial stone cladding systems require surface preparation such as a stucco base coat. This adds greatly to their expense.
Finally, known masonry cladding systems are prone to dirt entrapment.
As is evident from the above discussion of the prior art, what is needed is a cladding system where these above mentioned conditions are eliminated or at least minimized.
OBJECTS OF THE INVENTION
The object of the present invention is to solve the above mentioned problems by providing a relatively simple, efficient method and apparatus for producing concrete panels.
An object of the present invention is to provide a panel with a peripheral shoulder that, with an adjoining panel forms, a channel that is most conducive for receiving caulking.
Another object of the invention is that a V-groove between panels is formed that offers a maximum surface for caulking adhesion.
Another object of the invention is to eliminate the need for unsightly expansion joints.
Another object of this invention is to provide concrete panels having beveled side edges which provide a limited crush zone that absorbs thermal expansion without damage to the panel itself.
Another feature of this invention is that each panel has a molded center mark. This feature greatly assists in centering the panels during installation. This mark is located in the side shoulder and becomes covered by the flexible grout.
Another object of this invention is to provide a masonry product which can be installed without mortars, glues, nails, or additional brackets.
Another feature of the invention is that each panel has two cast-in-place hangers that provide several advantages.
A feature of the hanger allows the panel to be simply screwed to a wall.
Another feature of the hanger is that it provides a vent or draining space behind the panel preventing any water from ever contacting the building itself.
Another feature of the hanger is that a kink in the end of the nails prevent pull out and that the point of the nails prevent surface spotting that are normally caused by minor temperature differences of metal and curing concrete.
Another feature of this invention is that the plural leg sets of the hangers have spring action and are shaped in such a way that concrete break out during installation is avoided, and that proper panel tension is provided and that adequate strength against cyclonic conditions exists.
It is another feature of the hangers that four syphoning bridges are provided on each hanger. These bridges help to prevent of concrete from traveling into the hanger positioning cavities.
Another feature of the hanger is that the center section can be cut away and when horizontally screwed to the wall it can be used as a stabilizing bracket for a single hangered smaller panel.
Another object of the invention is that an unusually thin but relatively rigid thermoformed plastic form is used to greatly reduce mold costs.
Another feature of the form is that hanger positioning cavities are built in allowing the hangers to remain accurately positioned during vibration.
It is a feature of this invention that the forms feature releasing strips, back-up panels, stacking strips and a thin membrane that prevents thermal cracking. These thin fragile forms can be stacked in an unusually small space and support in excess of one ton of loading capacity.
It is a feature of this invention that a multi-layered form stack can be demolded or removed from the mold simultaneously by lifting and pivoting the complete stack
180
degrees. The mold releasing strips gently push on the edges of the form thus releasing all the panels and allowing them to rest on the bottom of the back-up panel, ready for bundling and shipping.
Another object of the invention is to provide a masonry product that can be installed during freezing temperatures without the need for hording, which is the practice of building a temporary enclosure of canvas, plastic, etc. around the work area to keep out weather, and to enable heating of the work area within the enclosure.
Another object of this invention is to provide panels which are compact and can be installed with great speed.
Another object of the invention is to provide an improved “mortar” which is crack resistant. This is achieved through the use of urethane caulking that is then coated with silica sand, giving the caulking an aesthetically pleasing mortar appearance. This silica sand coating now greatly improves the resistance to ultraviolet radiation damage of the urethane caulking. An additional coating of dolomite dust avoids the caulking becoming soiled from airborne dust particles.
Another feature of the invention is the bottom and top “J” channels have perforations to allow the vent space to function and also retain the bottom of the bottom panel and the top of the top panel.
Another feature of the invention is a dispensing apparatus with lateral rollers and tracks and an
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