Foam panels for wall construction

• US 5,966,885 A
• Filed: 12/01/1997
• Issued: 10/19/1999
• Est. Priority Date: 12/01/1997
• Status: Expired due to Term

• Current Assignee: Paul J. Chatelain
• Original Assignee: Paul J. Chatelain
• Inventors: Chatelain, Paul J.
• Primary Examiner(s): STEPHAN, BETH A
• Application Number:
  US08/980,570
• Time in Patent Office: 687 Days
• Field of Search: 52/309.4, 52/309.7, 52/309.12, 52/309.17, 52/800.1, 52/800.12, 52/745.09, 256/31, 256/73, 256/24, 256/19
• US Class Current: 52/309.4
• CPC Class Codes: E04C 2/22 reinforced E04C2/205 takes precedence

Abstract

A panel for use in the construction of walls. The panel is preferably about 2'"'"' high and 10'"'"' long with a thickness of approximately 4". An upper pair of grooves is formed longitudinally near the top and another pair formed longitudinally near the bottom. A metal C-shaped reinforcing member is held by these grooves over the top and bottom of the rectangular panel to reinforce the same. Preferably the top and bottom are slightly beveled so that when one panel is placed with its top adjacent the bottom of a superior panel, a slight depression is formed which may be readily filled with a grout to provide a smooth upper surface. The panel is particularly useful in conjunction with spaced fence posts which have grooves to permit the panel to be slid in between two adjacent posts. After grouting, the entire fence or wall may be stuccoed to give it a smooth and attractive appearance.

Claims

1. A panel for use in the construction of walls comprising:

a generally rectangular panel having a top, a bottom, a first end, a second end, a first face and a second face, said panel having a height and a length with said length substantially longer than its height, said panel being fabricated from a polymeric foam;

an upper pair of grooves formed in the first and second faces of said panel parallel to and near said top;

a lower pair of grooves in the first and second faces of said panel parallel to and near said bottom; and

a pair of generally C-shaped reinforcing channels, each channel having a face adjacent one of said top and bottom, one of said channels being adjacent said top of said panel and the other of said channels being adjacent said bottom of said panel, a pair of generally flat sides on each channel extending from the face adjacent said first and second faces, and a pair of inwardly depending portions on each of said channels at ends of each generally flat side, said inwardly depending portions positioned in said grooves of said panel and said channels being fabricated from a rigid material, the panel and channels forming a rigid assembly and wherein said first and second faces of said panel are beveled longitudinally to form beveled faces along said panel at the top and bottom of said panel and said beveled faces extend past said grooves.

2. The panel of claim 1 wherein said beveled faces are at an angle of from about two to about ten degrees with respect to said first and second faces.

3. The panel of claim 2 wherein said bevel is at an angle of about five degrees.

4. The panel of claim 1 further including at least one reinforced coating on the first and second faces.

5. The panel of claim 4 wherein said reinforced coating extends to about the top, the bottom, the first end and the second end.

6. The panel of claim 4 wherein said reinforced coating includes a mesh made of fibers.

7. The panel of claim 4 wherein said at least one reinforced coating comprises a cement based coating with polymer.

8. The panel of claim 1 wherein said pair of generally C-shaped reinforcing channels are fabricated from a ferrous metal.

9. The panel of claim 8 wherein said channels are fabricated from galvanized sheet metal.

10. The panel of claim 9 wherein said galvanized sheet metal is about 25 gauge thick.

11. A process for building a hard and flat surfaced paneled fence utilizing a plurality of vertical adjacent fence posts, a plurality of elongated rectangular panels, each panel having a reinforced top and bottom and a beveled portion along at least one of said top and bottom, a first end and a second end and a length, and said fence posts having spaces between the adjacent posts about equal to said length, said fence having a fence height and each of said panels having a height which is about an even fraction of the height of the fence, said process comprising:

affixing a first end of the first of said panels to a first of said posts and affixing the second end of said first of said panels to a second of said posts which is adjacent said first post, said first panel having a beveled portion facing upwardly;

affixing a first end of the second panel to said first post and affixing the second end of said second panel to said second post, said second panel having a beveled portion facing downwardly and adjacent said beveled portion of said second panel adjacent said beveled portion of said first panel thereby forming a shallow trough below a plane of a first face of said first panel and a first face of said second panel; and

filling said shallow trough with a grouting material so that said grouting material has an outer face which is aligned with the first faces of said first and second panels thereby forming a hard and flat face made up of said first and second panels.

12. The process for building the smooth-surfaced paneled fence of claim 11 wherein said affixing steps further comprise sliding one of said panels into a pair of opposing channels held by the first and second posts.

13. The process for building the smooth-surfaced paneled fence of claim 11 further including the step of covering said panels and posts with stucco.