Concrete panel construction
A concrete panel system comprising a plurality of concrete panels arranged in side-by-side fashion on a substantially vertical supporting wall, each of the panels comprising a rectangular body having a front surface and a rear surface and beveled side edges, the side edges each forming an angle of between eighty-five and ninety degrees with the rear surface, and a concave caulking groove lying between and connecting each of the beveled side edges with the front face, the side edges of adjacent panels forming a V-joint between the adjacent panels, a flexible sealant material in a portion of the caulking grooves of adjacent panels and a portion of the V-joint for providing a seal between adjacent panels, and a hanger element embedded in the rear of the panels for securing the panels to the supporting wall.
This application is a continuation-in-part of U.S. application Ser. No. 08/603,243, filed Feb. 20, 1996 now abandoned.
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 INVENTIONThin 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 INVENTIONCladding 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 INVENTIONThe 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 hoarding, 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 adjustable chamber equal in volume to a panel.
Another object of the invention is to provide a molding method which utilizes lateral shock vibration, jarring air bubbles free instantly and allowing them to travel away from what will be the panel face virtually eliminating all surface air voids.
Another object of the invention is to provide a tilting stretch wrap bundler which greatly reduces shipping breakage.
Another object of this invention is to provide concrete panels which can be complimented with a comprehensive line of concrete architectural component that are produced with the same method as described above resulting in a dramatic new look that simulates European architecture at a great cost saving.
It is another feature of this invention to easily obtain a number of different surface profiles that will offer an unlimited choice of design alternatives.
It is another object of the invention to provide panels which have a glossy concrete surface that is resistant to any surface dirt entrapment. The glossy surface is achieved by high gloss plastic molds.
It is another object of the invention to obtain better quality control by providing panels which are prefabricated under controlled conditions dissimilar to other masonry cladding systems like stucco, artificial stone, brick and real stone.
BRIEF SUMMARY OF THE INVENTIONAccordingly, the invention relates to a method of producing a concrete building panel of the type including a thin concrete body and metal hangers embedded in the body for mounting the panel, said method comprising the steps of:
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- (a) placing hangers for the panel on a form;
- (b) loading a transfer dispenser with sufficient concrete to fill the form;
- (c) placing the transfer dispenser over the form, to release the concrete into the form; and
- (d) applying shock vibration to the form to release air bubbles and settle the concrete in the form.
The invention also relates to an apparatus for producing a concrete building panel of the type including a thin, concrete body and metal hangers embedded in the body for mounting the panel, said apparatus comprising:
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- (a) thin plastic form means defining a cavity including bottom wall means, side wall means and an open top for receiving concrete;
- (b) hanger positioning cavity means on said side wall means for supporting said metal hangers in the open top of the form;
- (c) transfer dispenser means for receiving and dispensing a predetermined volume of concrete into said form means; and
- (d) vibrator means for applying shock vibration to said form to eliminate air pockets in the concrete.
The invention also relates to an improved concrete building panel which comprises a thin concrete body having metal hangers embedded in the rear of the body for mounting the panel, and a decorative front face. The front face may be textured, smooth, colored or otherwise finished to provide a decorative appearance according to the design tastes of the designer or owner.
The front and the rear faces of the body are substantially parallel, and the sides of the panel comprise a beveled edge which adjoins the rear face at an angle slightly less than ninety degrees, and extends toward the front face. A caulking ledge or groove extends around the periphery of the panel and joins the beveled edge and the front face. The caulking ledge or groove is a concave recessed groove which will receive a caulking material for sealing the space between adjacent panels.
The adjacent panels will be in contact with each other at the back edge of the panels, but because of the slight bevel, the adjacent panels do not contact each other at the front face. In this manner, any expansion of the panels will cause compression cracking or crushing of the panel only at the rear of the panel, and only in a localized area. The caulking material, such as a urethane caulk, will seal the space between the panels and prevent intrusion of moisture.
As noted above, a silica sand may then be applied over the caulking if desired, to alter the aesthetic appearance of the structure.
The invention will be described, by way of example only, reference being had to the accompanying drawings in which:
FIG. 15(a) is a partially sectional perspective view of the form referencing the formation of the caulking grooves;
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A shock vibrator 50 with hydraulic motor 52 is also mounted to the frame 48. Lateral vibrating shock action is produced by an eccentric wheel 53 and transferred to the vibrating table 45 through the shock vibrator connector arm 51. This lateral shock action of approximately 200 shocks per minute jars air bubbles free from the form cavity bottom 36 instantly and allows them to travel to the surface or the back of the panel 7. As part of this invention it was discovered that rotary vibrating action at high RPM's, e.g. 10000 RPM and the lateral shock action is extremely effective in a speedy air bubble elimination.
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Panels 1 are loaded against the retention forks 81 on the turntable 83. The stacking guides 82 aid in achieving an orderly bundle. The device is now placed in its level position by simply pulling it forward. The stretch wrap 90 is started as best shown in FIG. 28. The knee switch 85 activates the motor 84 and turns the turntable 83.
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While this invention has been described as having certain preferred features and embodiments, it will be understood that it is capable of still further variation and modification with out departing from the spirit of the invention, and this application is intended to cover any and all variations and modifications of the invention as may be apparent from the foregoing description and claims, and as may be within the spirit of the invention and the scope of the appended claims.
Claims
1. A concrete panel system comprising a plurality of concrete panels arranged in side-by-side fashion on a substantially vertical supporting wall, each of said panels comprising in turn;
- a rectangular body having a front surface and a rear surface and beveled side edges, said side edges forming an angle of between eighty-five and ninety degrees with said rear surface;
- a caulking groove connecting each of said beveled side edges with said front face, the side edges of adjacent panels forming a V-joint therebetween, and,
- a flexible sealant material in a portion of said caulking grooves of adjacent panels and a portion of said V-joint for providing a seal between adjacent panels,
- and wherein said V-joint widens from said rear surface toward said front surface
- and wherein the apex of said V-joint lies in the plane of said rear surface upon installation of said panels.
2. A concrete panel system as in claim 1 and wherein said panels include hanger means for securing said panels to said supporting wall.
3. A concrete panel system as in claim 2 and wherein said-hanger means includes a hanger embedded in said panels and projecting from said rear surface.
4. A concrete panel system as in claim 1 and including a coating on the exposed surface of said sealant material for protecting said sealant material from LTV UV light.
5. A concrete panel system as in claim 4 and wherein said coating comprises a silica sand.
6. A concrete panel system comprising a plurality of concrete panels arranged in side-by-side fashion on a substantially vertical supporting wall, each of said panels comprising in turn;
- a rectangular body having a front surface and a rear surface and beveled side edges, said side edges forming an angle of between eighty-five and ninety degrees with said rear surface;
- a caulking groove connecting each of said beveled side edges with said front face, the side edges of adjacent panels forming a V-joint therebetween, and,
- a flexible sealant material in a portion of said caulking grooves of adjacent panels and a portion of said V-joint for providing a seal between adjacent panels,
- and wherein said side edges of each panel are in contact with the side edges of each adjacent panel at a crush zone formed in the panel for absorbing thermal expansion of said panels after installation.
7. A concrete panel system as in claim 6 and wherein the apex of said V-joint lies in the plane of said rear surface upon installation of said panels.
8. A concrete panel system as in claim 7 and wherein said panels include hanger means embedded in said panels and projecting from said rear surface for securing said panels to said supporting wall.
9. A concrete panel system comprising a plurality of concrete panels arranged in side-by-side fashion on a substantially vertical supporting wall, each of said panels in turn comprising;
- a rectangular body having a front surface and a rear surface and beveled side edges, said side edges forming an angle of between eighty-five and ninety degrees with said rear surface;
- a caulking groove connecting each of said beveled side edges with said front face, the side edges of adjacent panels forming a V-joint between the adjacent panels;
- a flexible sealant material in portions of said caulking grooves of adjacent panels and a portion of said V-joint for providing a seal between adjacent panels, and,
- hanger means embedded in said panels for securing said panels to said supporting wall and, a coating on the exposed surface of said sealant material for protecting said sealant material from UV light.
10. A concrete panel system comprising a plurality of concrete panels arranged in side-by-side fashion on a substantially vertical supporting wall, each said panel having:
- a rectangular panel body having a front surface and a rear surface and beveled side edges, such that the side edges of adjacent panels form a V-joint therebetween, said V-joint having its apex at the rear surfaces of the panels upon installation of the panels;
- a caulking groove connecting each beveled side edge with said front surface; and
- a flexible sealant material in portions of the caulking grooves of adjacent panels and said V-joints, for providing a seal between adjacent panels.
11. A concrete panel system as in claim 10 wherein each panel includes hanger means for securing the panel to the supporting wall.
12. A concrete panel system as in claim 11 wherein the hanger means comprises a hanger embedded in the panel and projecting from the rear surface thereof.
13. A concrete panel system as in claim 10, further including a coating on the exposed surface of the sealant material, for protecting the sealant material from ultraviolet light.
14. A concrete panel system as in claim 13 wherein the coating comprises a silica sand.
15. A concrete panel system as in claim 10 wherein the side edges of the panels are in contact with corresponding side edges of adjacent panels at crush zones formed in the panels at the apex of the V-joint, for absorbing thermal expansion of the panels after installation.
16. A concrete panel system comprising a plurality of concrete panels arranged in side-by-side fashion on a substantially vertical supporting wall, each said panel having: and wherein the side edges of the panels are in contact with corresponding side edges of adjacent panels at crush zones formed in the panels at the apex of the V-joint, for absorbing thermal expansion of the panels after installation.
- a rectangular panel body having a front surface and a rear surface and beveled side edges, such that the side edges of adjacent panels form a V-joint therebetween, said V-joint having its apex at the rear surfaces of the panels upon installation of the panels;
- a hanger embedded in the panel and projecting from the rear surface thereof, for securing the panel to the supporting wall;
- a caulking groove connecting each beveled side edge with said front surface;
- a flexible sealant material in portions of the caulking grooves of adjacent panels and said V-joints, for providing a seal between adjacent panels; and
- a coating on the exposed surface of the sealant material, for protecting the sealant material from ultraviolet light, said coating comprising a silica sand;
Type: Grant
Filed: Jun 11, 2002
Date of Patent: May 9, 2006
Assignee: Stonetile (Canada) Ltd. (Calgary)
Inventor: Peter A. Kuelker (Calgary)
Primary Examiner: Carl D. Friedman
Assistant Examiner: Brian E. Glessner
Attorney: Miller Thomson LLP
Application Number: 10/166,190
International Classification: E04B 2/28 (20060101);