Prefabricated, prefinished reinforced panels for building exterior and interior surfaces and method of manufacture

• US 20030200711A1
• Filed: 04/24/2003
• Published: 10/30/2003
• Est. Priority Date: 04/25/2002
• Status: Active Grant

• Current Assignee: Michael R. Sullivan, Richard E. Peterson
• Original Assignee: Michael R. Sullivan, Richard E. Peterson
• Inventors: Peterson, Richard E., Sullivan, Michael R.
• Granted Patent: US 8,006,448 B2
• Time in Patent Office: Days
• US Class Current: 52/268
• CPC Class Codes: B28B 13/0215 Feeding the moulding material in measured quantities from a container or silo
• CPC Class Codes: B28B 7/0029 Moulds or moulding surfaces not covered by B28B7/0058 - B28B7/36 and B28B7/40 - B28B7/465, e.g. moulds assembled from several parts
• CPC Class Codes: B28B 7/0064 Moulds characterised by special surfaces for producing a desired surface of a moulded article, e.g. profiled or polished moulding surfaces B28B7/36 takes precedence; producing decorative effects B44C; designs of stone surfaces B44F
• CPC Class Codes: B28B 7/02 Moulds with adjustable parts specially for modifying at will the dimensions or form of the moulded article
• CPC Class Codes: B32B 3/266 characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: E04C 2/06 reinforced
• CPC Class Codes: E04F 13/08 composed of a plurality of similar covering or lining elements, E04F13/072 takes precedence; borders, skirtings E04F19/02; of webs or fabrics E04F13/002; fixing strips E04F19/06; separate provisional spacers between adjacent tiles E04F21/0092; implements or means for setting tiles E04F21/18
• CPC Class Codes: E04F 13/0837 extending completely through the covering elements

Abstract

A building panel for attachment to exterior and interior building surfaces, the panel including a casting layer having at least one imbedded reinforcing layer, at least one attachment means extending through the casting layer and imbedded reinforcing layer for attachment to a building frame, and a finishing layer adjacent to the casting layer, the finishing layer being positioned to cover a first end of the at least one attachment means.

Claims

1. A building panel for attachment to exterior and interior building surfaces, the panel comprising:

a casting layer having at least one imbedded reinforcing layer;

at least one attachment means extending through the casting layer and imbedded reinforcing layer for attachment to a building frame; and

a finishing layer adjacent to the casting layer, the finishing layer being positioned to cover a first end of the at least one attachment means.

2. The building panel of claim 1, wherein the reinforcing layer is an expanded mesh material.

3. The building panel of claim 2, wherein the expanded mesh material is steel.

4. The building panel of claim 1, wherein the attachment means comprises a first washer on a first side of one of the at least one reinforcing layers, a second washer on a second side of one of the at least one reinforcing layers, and a securing member extending through a first reinforcing layer and secured to the first and second washers.

5. The building panel of claim 4, further including a second reinforcing layer, wherein the securing member extends through the first and second reinforcing layers.

6. The building panel of claim 4, wherein the securing member is a steel sleeve.

7. The building panel of claim 1, wherein the casting layer comprises a cement-based material including an additive.

8. The building panel of claim 1, wherein the at least one attachment means includes an opening that is sized to accept a corresponding fastener for securing the building panel to a building structure.

9. The building panel of claim 1, wherein the finish layer has a textured outer surface.

10. The building panel of claim 1, wherein the finish layer has a patterned outer surface.

11. The building panel of claim 1, wherein the casting layer has a textured outer surface.

12. A resusable mold system for the manufacturing of building panels having a casting layer having at least one imbedded reinforcing layer, at least one attachment means extending through the casting layer and imbedded reinforcing layer for attachment to a building frame, and a finishing layer adjacent to the casting layer, the finishing layer being positioned to cover a first end of the at least one attachment means;

the mold system comprising;

a frame; and

at least one mold module positioned within the frame, wherein the mold module is configured to receive a reinforcing layer and a casting material for the casting layer.

13. The mold system of claim 12, further comprising a plurality of mold modules positioned within the frame in a stacking configuration.

14. The mold system of claim 12, wherein the frame rests on a supporting, movable member.

15. The mold system of claim 14, wherein the supporting, movable member is a pallet.

16. The mold system of claim 12, wherein at least one of the mold modules comprises at least one separator for subdividing the mold module into at least two sections.

17. The mold system of claim 12, wherein at least one of the mold modules comprises at least one insert for embossing a pattern into at least one of the sides of the building panel.

18. The mold system of claim 12, wherein the frame further includes at least one vibrating mechanism for vibrating the frame to reduce air bubble and voids in the casting layer of the building panel.