Pre-cast concrete veneer system with insulation layer

• US 20060156668A1
• Filed: 12/22/2004
• Published: 07/20/2006
• Est. Priority Date: 12/22/2004
• Status: Active Grant

• Current Assignee: Paul C Nasvik
• Original Assignee: Paul C Nasvik
• Inventors: Nasvik, Paul C.
• Granted Patent: US 7,647,738 B2
• Time in Patent Office: Days
• US Class Current: 52/516
• CPC Class Codes: B32B 13/02 with fibres or particles being present as additives in the layer
• CPC Class Codes: B32B 13/04 comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a glass layer B32B17/06
• CPC Class Codes: B32B 13/045 of foam
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2419/04 Tiles for floors or walls tiles for roofs B32B2419/06
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 3/06 for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• CPC Class Codes: B32B 3/085 spaced apart pieces on the surface of a layer
• CPC Class Codes: B32B 3/263 characterised by a layer having non-uniform thickness
• CPC Class Codes: B32B 3/30 characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs apertured layer B32B3/266; layer with cavities or internal voids B32B3/26

Abstract

A multi-layered panel comprises a first layer made of concrete, a second layer made of foam and an edge perimeter region. The first layer is a thin concrete layer of near uniform thickness that is cast onto the second layer. The exterior surface of the concrete layer simulates an exterior surface of a building. The front of the foam layer has dimensions designed to accommodate the application of the concrete layer. The back of the foam layer has features that assist in mounting the panel on an exterior surface of a building. The edge perimeter region includes a system for interconnecting adjacent multi-layered panels.

Claims

1. A multi-layered panel that simulates a finish of a wall comprising:

a foam layer having a front surface that approximates a topography of the finish of the wall, a back surface for mounting on a surface of a building and an edge perimeter region; and

a concrete layer wherein the concrete layer is cast onto the front surface of the foam layer to simulate a texture and likeness of the finish of the wall.

2. The multi-layered panel of claim 1 wherein the finish of the wall is a stone pattern.

3. The multi-layered panel of claim 1 wherein the finish of the wall is a brick pattern.

4. The multi-layered panel of claim 1 wherein the finish of the wall is a log pattern.

5. The multi-layered panel of claim 1 wherein the finish of the wall is a lap siding pattern.

6. The multi-layered panel of claim 1 wherein the finish of the wall is a shingle pattern.

7. The multi-layered panel of claim 1 wherein the edge perimeter region of the foam layer comprises a system for interlocking adjoining multi-layered panels.

8. The edge perimeter region of claim 7 wherein the system for interlocking adjoining multi-layered panels comprises a tongue and groove system.

9. The edge perimeter region of claim 7 wherein the system for interlocking adjoining multi-layered panels comprises a slat system.

10. The multi-layered panel of claim 1 wherein the back surface of the foam layer comprises a system for allowing air flow between the back surface of the foam layer and the surface to which the panel will be mounted.

11. The multi-layered panel of claim 10 wherein the system for allowing air flow between the back surface of the foam layer and the surface to which the panel will be mounted comprises a series of ribs and grooves on the back surface of the foam layer.

12. The system of claim 11 wherein the grooves have a width that is wider than the ribs.

13. The system of claim 11 wherein the grooves have a width of 1.25 inches and the ribs have a width of 0.75 inches.

14. The multi-layered panel of claim 1 wherein the concrete layer is about 0.25 to about 0.375 inches thick.

15. The multi-layered panel of claim 1 wherein the concrete of the concrete layer is a fiber reinforced concrete mixture.

16. A method for making a multi-layered panel with a thin, uniformly thick concrete layer, the method comprising:

creating a mold that has the negative of a pattern;

creating a preformed foam layer that has a surface with the inverse pattern of the mold that is reduced in volume;

placing a quantity of concrete in the mold; and

inserting the preformed foam layer into the concrete filled mold.

17. The method of claim 16 wherein the concrete is a fiber reinforced mixture.

18. The method of claim 16 wherein placing a quantity of concrete in the mold comprises spraying the concrete into the pattern of the mold.

19. The method of claim 16 wherein inserting the preformed foam layer into the mold cavity comprises limiting the inserting by use of a temporary backing.

20. The method of claim 16 wherein the inserting the preformed foam layer into the mold cavity comprises clamping the preformed foam layer to the mold in order to hold the preformed foam layer in place.

21. The method of claim 16 and further comprising:

vibrating the preformed foam layer as it is inserted into the mold.

22. The method of claim 16 and further comprising:

treating the mold pattern with a coloring agent before the concrete is placed in the mold.

23. The method of claim 16 wherein the concrete is placed in the mold so that the concrete is evenly distributed along the surface of the preformed foam layer inserted into the mold.

24. The method of claim 16 and further comprising:

maintaining the preformed foam layer in contact with the concrete so that the concrete bonds to the surface of the preformed foam layer.

25. The method of claim 16 wherein the preformed foam layer is inserted into the mold so that the surface of the preformed foam layer is about 0.25 inches to about 0.375 inches from the pattern of the mold.

26. A veneer panel system comprising:

a multi-layered panel comprising a thin concrete layer and a foam layer; and

a fastener comprising;

a mounting member for mounting on a wall; and

a support member for supporting the multi-layered panel, the support member comprising;

upward facing teeth for insertion into a multi-layered panel located on the support member; and

downward facing teeth for insertion into a multi-layered panel located below the fastener.

27. The veneer panel system of claim 26 wherein the mounting member of the fastener has a hole for assisting mounting of the fastener to a wall.

28. A method for installing a multi-layered veneer panel wherein the multilayered panel comprises a foam layer and a concrete layer, the method comprising:

affixing a fastener to a surface of a wall, the fastener comprising;

a mounting member for mounting on a wall; and

a support member for supporting the multi-layered panel comprising;

upward facing teeth for insertion into a multi-layered panel located on the support member; and

downward facing teeth for insertion into a multi-layered panel located below the fastener;

placing a multi-layered panel against the wall;

sliding the multi-layered panel down the surface of the wall so that the upward facing teeth penetrate the foam layer of the multi-layered panel and the support member contacts a bottom surface of the multi-layered panel;

placing a second fastener against the wall;

sliding the second fastener down the surface of the wall so that the downward facing teeth penetrate the foam layer of the multi-layered panel and the support member contacts a top surface of the multi-layered panel; and

affixing the second fastener to the wall.