U.S. patent application number 10/024600 was filed with the patent office on 2002-08-08 for faux stone concrete panel and method for making same.
Invention is credited to Stott, Gale.
Application Number | 20020106504 10/024600 |
Document ID | / |
Family ID | 24056090 |
Filed Date | 2002-08-08 |
United States Patent
Application |
20020106504 |
Kind Code |
A1 |
Stott, Gale |
August 8, 2002 |
Faux stone concrete panel and method for making same
Abstract
A wall or panel has a thin concrete layer with a cross-sectional
contour having protrusions and indentations forming other objects,
such as stone work, brick or wood. A reinforcement layer may be
affixed to the concrete layer to provide tensile strength and
impact resistance to the concrete layer. A foam layer is affixed to
the reinforcement layer to further reinforce the concrete layer,
and so that the wall or panel is light weight. A second concrete
layer or a rigid backing layer may be disposed opposite the
concrete layer so that the foam is disposed therebetween. A method
for forming the wall or panel includes spraying the concrete onto a
mold surface which has indentations and protrusions for forming the
other objects. The reinforcement layer is sprayed onto the cured
concrete layer. The mold is closed and foam is introduced into the
mold.
Inventors: |
Stott, Gale; (Salt Lake
City, UT) |
Correspondence
Address: |
Garron M. Hobson
THORPE, NORTH & WESTERN, L.L.P.
P.O. Box 1219
Sandy
UT
84091-1219
US
|
Family ID: |
24056090 |
Appl. No.: |
10/024600 |
Filed: |
December 17, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10024600 |
Dec 17, 2001 |
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09516554 |
Mar 1, 2000 |
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6355193 |
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Current U.S.
Class: |
428/315.9 ;
156/245; 264/255; 264/309; 264/46.4; 264/46.5; 264/46.6; 264/46.7;
428/304.4; 428/315.7 |
Current CPC
Class: |
B28B 11/042 20130101;
B28B 7/0073 20130101; Y10T 428/24998 20150401; Y10T 428/249979
20150401; Y10T 428/249953 20150401 |
Class at
Publication: |
428/315.9 ;
264/46.4; 264/46.5; 264/46.6; 264/46.7; 264/255; 264/309; 156/245;
428/304.4; 428/315.7 |
International
Class: |
B29C 044/06; B29C
044/12 |
Claims
What is claimed is:
1. A panel comprising: a) a concrete layer having interior and
exterior surfaces, and a cross-sectional contour which (i) projects
outwardly to form macro projections in the exterior surface and
macro indentations in the interior surface, and (ii) projects
inwardly to form macro indentations in the exterior surface and
macro projections in the interior surface; and b) a foam layer,
coupled to the interior surface of the concrete layer, having
protrusions mating with the indentations in the interior surface of
the concrete layer.
2. A panel in accordance with claim 1, wherein the projections and
indentations are sized and shaped to appear as another object.
3. A panel in accordance with claim 1, wherein the projections and
indentations are sized and shaped to appear as another object
selected from the group consisting of: rock, stone work, brick, and
wood.
4. A panel in accordance with claim 1, wherein the concrete layer
has a substantially constant thickness at the projections and
indentations.
5. A panel in accordance with claim 1, further comprising: a rigid
backing layer, spaced-apart from the concrete layer, having an
interior surface opposing the interior surface of the concrete
layer; and wherein the foam layer is disposed between the concrete
layer and hacking layer.
6. A panel in accordance with claim 1, wherein the concrete layer
includes a first concrete layer, and further comprising: a) a
second concrete layer, spaced-apart from and opposite the first
concrete layer, having interior and exterior surfaces, and a
cross-sectional contour which (i) projects outwardly to form macro
projections in the exterior surface and macro indentations in the
interior surface, and (ii) projects inwardly to form macro
indentations in the exterior surface and macro projections in the
interior surface; and wherein the foam layer is coupled to the
interior surface of both of the first and second concrete layers,
and has protrusions mating with the indentations in the interior
surface of both of the first and second concrete layers.
7. A panel in accordance with claim 1, further comprising: a
reinforcement layer, disposed between the concrete layer and foam
layer, and directly affixed to the concrete layer, configured to
provide impact resistance and tensile strength the concrete
layer.
8. A panel in accordance with claim 7, wherein the reinforcement
layer includes an elastomer material.
9. A panel in accordance with claim 7, wherein the reinforcement
layer includes a urethane material.
10. A panel in accordance with claim 7, wherein the reinforcement
layer includes a high density foam, and the foam layer includes a
low density foam.
11. A panel in accordance with claim 7, wherein the reinforcement
layer includes a high density foam of between approximately 10-20
lbs, and the foam layer includes a low density foam of between
approximately 2-5 lbs.
12. A panel in accordance with claim 7, wherein the reinforcement
layer includes fiber reinforcement.
13. A panel in accordance with claim 1, wherein the concrete layer
has a thickness less than approximately 0.5 inches.
14. A panel in accordance with claim 1, further comprising a
plurality of voids formed in the foam layer and sized and shaped to
reduce sound.
15. A panel in accordance with claim 1, wherein the concrete layer
and foam layer are configured to enable being affixed to an
exterior wall of a building.
16. A panel in accordance with claim 1, configured to be usable in
a free-standing fencing structure.
17. A panel comprising: a) a concrete layer; b) a elastomer layer,
affixed to the concrete layer; c) a rigid backing layer,
spaced-apart from the elastomer layer; and d) a foam layer,
disposed between and affixed to the elastomer layer and backing
layer.
18. A panel in accordance with claim 17, wherein the concrete layer
has an exterior surface with protrusions and indentations, and an
interior surface with indentations corresponding to the protrusions
in the exterior surface, and protrusions corresponding to
indentations in the exterior surface, the concrete layer having a
substantially constant thickness at the projections and
indentations; and wherein the elastomer layer has an interior
surface with indentations and protrusions corresponding to
respective indentations and protrusions of the interior surface of
the concrete layer, the elastomer layer having a substantially
constant thickness at the projections and indentations.
19. A panel in accordance with claim 17, wherein the protrusions
and indentations of the exterior surface of the concrete layer are
sized and shaped to appear as another object selected from the
group consisting of: rock, stone work, brick, and wood.
20. The device of claim 17, wherein the concrete layer includes a
first concrete layer, and the rigid backing layer includes a second
concrete layer having an exterior surface with protrusions and
indentations, and an interior surface with indentations
corresponding to the protrusions in the exterior surface, and
protrusions corresponding to indentations in the exterior surface,
the second concrete layer having a substantially constant thickness
at the projections and indentations, and a second elastomer layer
including an interior surface with indentations and protrusions
corresponding to respective indentations and protrusions of the
interior surface of the second concrete layer, the elastomer layer
having a substantially constant thickness at the projections and
indentations.
21. A panel in accordance with claim 17, wherein the reinforcement
layer includes a urethane material.
22. A panel in accordance with claim 17, wherein the elastomer
layer includes fiber reinforcement.
23. A panel in accordance with claim 17, wherein the concrete layer
has a thickness less than approximately 0.5 inches.
24. A panel in accordance with claim 17, configured to enable being
affixed to a wall of a building.
25. A panel in accordance with claim 17, configured to be usable in
a free-standing fencing structure.
26. A method for forming a panel, comprising the steps of: a)
providing a mold having an inner mold surface with macro
indentations and macro protrusions; b) applying a wet mixture of
concrete material to the inner mold surface of the mold to form a
concrete layer including a cross-sectional contour corresponding to
the indentations and protrusions of the inner mold surface; c)
curing the concrete material until dry; d) introducing foam into
the mold to form a foam layer secured to the cement layer with the
foam having protrusions mating with the concrete layer; and e)
removing the secured concrete and foam layers from the mold.
27. A method in accordance with claim 26, wherein the step of
providing the mold further includes providing a mold with
indentations and protrusions sized and shaped to create another
object selected from the group consisting of: rock, stone work,
brick, and wood.
28. A method in accordance with claim 26, wherein the step of
applying the wet mixture of concrete mixture further includes
applying the wet mixture of concrete material in a substantially
constant thickness at the projections and indentations.
29. A method in accordance with claim 26, further comprising the
step of placing a rigid backing layer spaced-apart from the mold
surface prior to introducing the foam into the mold.
30. A method in accordance with claim 26, further comprising the
step of applying a rigid backing layer to the foam layer.
31. A method in accordance with claim 26, further comprising the
steps of: a) applying a layer of reinforcement material to the
concrete layer prior to introducing the foam to form a
reinforcement layer; and b) wherein the step of introducing the
foam further includes introducing the foam into the mold to form a
foam layer secured to the reinforcement layer.
32. A method in accordance with claim 26, further comprising the
steps of: a) applying a layer of elastomer material to the concrete
layer prior to introducing the foam to form an elastomer layer; and
b) wherein the step of introducing the foam further includes
introducing the foam into the mold to form a foam layer secured to
the elastomer layer.
33. A method in accordance with claim 26, further comprising the
steps of: a) applying a layer of high density foam to the concrete
layer prior to introducing the foam to form a reinforcement layer;
and b) wherein the step of introducing the foam further includes
introducing a low density of foam into the mold to form a low
density foam layer secured to the reinforcement layer.
34. A method in accordance with claim 26, wherein the step of
applying a wet mixture of concrete material further includes
applying the wet mixture of concrete material in a layer having a
thickness less than approximately 0.5 inches.
35. A method in accordance with claim 26, wherein the step of
providing the mold further includes providing the mold in a
vertical orientation.
36. A method in accordance with claim 26, wherein the step of
applying a wet mixture of cement material further includes spraying
the wet mixture of cement material onto the inner mold surface.
37. A method in accordance with claim 26, wherein the step of
introducing foam into the mold further includes introducing an
expandable foam into the mold which expands to fill the
indentations in the inner mold surface.
38. A method in accordance with claim 26, wherein the step of
providing a mold further includes providing a mold with a second
mold surface opposing the inner mold surface; and wherein the step
of introducing foam into the mold further includes introducing an
expandable foam between the concrete layer and second mold
surface.
39. A method in accordance with claim 26, wherein the step of
providing a mold further includes providing a mold with a second
mold surface pivotally coupled to the inner mold surface such that
the inner mold surface and second mold surface pivot between an
open position and a closed position in which the mold surfaces
oppose one another; and further including the steps of: opening the
mold prior to applying the wet mixture of cement material; and
closing the mold prior to introducing the foam.
40. A method in accordance with claim 26, wherein the step of
providing the mold further includes providing a mold with a second
mold surface having indentations and protrusions; and wherein
applying the wet mixture of concrete material further includes
applying a wet mixture of concrete to both the inner mold surface
to form a first cement layer and the second mold surface to form a
second cement layer; and wherein introducing the foam into the mold
further includes introducing the foam between the first and second
foam layers to form a foam layer secured to both concrete
layers.
41. A method in accordance with claim 26, further comprising the
step of: moving the mold with a transfer system through a plurality
of different stations for applying the concrete mixture, curing the
concrete mixture, and introducing the foam.
42. A method for forming a panel, comprising the steps of: a)
providing a mold having an inner mold surface with macro
indentations and macro protrusions; b) applying a wet mixture of
concrete material to the inner mold surface of the mold to form a
concrete layer; c) curing the concrete material until dry; d)
applying a layer of reinforcement material to the cured concrete
layer to form a reinforcement layer; e) introducing foam into the
mold to form a foam layer secured to the reinforcement layer; and
f) removing the secured concrete, reinforcement and foam layers
from the mold.
43. A method in accordance with claim 42, wherein applying the wet
mixture of concrete further includes applying the wet mixture of
concrete in a substantially constant thickness at the indentations
and protrusions; and wherein applying the reinforcement material
further includes applying the reinforcement material in a
substantially constant thickness at the indentations and
protrusions.
44. A method in accordance with claim 42, wherein the step of
providing the mold further includes providing a mold with
indentations and protrusions sized and shaped to create another
object selected from the group consisting of: rock, stone work,
brick, and wood.
45. A method in accordance with claim 42, further comprising the
step of placing a rigid backing layer spaced-apart from the mold
surface prior to introducing the foam into the mold.
46. A method in accordance with claim 42, further comprising the
step of applying a rigid backing layer to the foam layer.
47. A method in accordance with claim 42, wherein applying the
reinforcement material further includes applying a layer of
elastomer material to the cement layer to form an elastomer
layer.
48. A method in accordance with claim 42, wherein the step of
applying the wet mixture of concrete material further includes
applying the wet mixture of concrete material in a layer having a
thickness less than approximately 0.5 inches.
49. A method in accordance with claim 42, wherein the step of
applying the wet mixture of cement material further includes
spraying the wet mixture of cement material onto the inner mold
surface.
50. A method in accordance with claim 42, wherein the step of
applying the reinforcement material further includes spraying the
reinforcement material onto the cured cement layer.
51. A method in accordance with claim 42, wherein the step of
introducing foam into the mold further includes introducing an
expandable foam into the mold which expands to fill the
indentations in the inner mold surface.
52. A method in accordance with claim 42, wherein the step of
providing a mold further includes providing a mold with a second
mold surface opposing the inner mold surface; and wherein the step
of introducing foam into the mold further includes introducing an
expandable foam between the concrete layer and second mold
surface.
53. A method in accordance with claim 42, wherein the step of
providing a mold further includes providing a mold with a second
mold surface pivotally coupled to the inner mold surface such that
the inner mold surface and second mold surface pivot between an
open position and a closed position in which the mold surfaces
oppose one another; and further including the steps of: opening the
mold prior to applying the wet mixture of concrete material; and
closing the mold prior to introducing the foam.
54. A method in accordance with claim 42, wherein the step of
providing the mold further includes providing a mold with a second
mold surface having indentations and protrusions; and wherein
applying the wet mixture of cement material further includes
applying a wet mixture of cement to both the inner mold surface to
form a first concrete layer and the second mold surface to form a
second concrete layer; and wherein introducing the foam into the
mold further includes introducing the foam between the first and
second concrete layers to form a foam layer secured to both
concrete layers.
Description
BACKGROUND OF THE INVENTION
[0001] 1. The Field of the Invention
[0002] The present invention relates generally to a light-weight
concrete panel or wall which appears as another building material,
such as stone work, brick, wood or the like. More particularly, the
present invention relates to a panel or wall having a thin concrete
face layer with a molded contour or otherwise shaped to appear as
stone work or the like, a reinforcing elastomer layer, and an inner
foam layer.
[0003] 2. The Background Art
[0004] Traditional walls have been constructed from individual
stones, rocks, blocks, or bricks assembled together into the shape
of a wall and held together with mortar. One problem with
traditional walls of this type is they are typically expensive and
time-consuming to construct. Another problem is their great
weight.
[0005] Prior attempts have been made to simulate such stone work or
brick walls using less expensive materials and less labor-intensive
methods. One such attempt involves constructing a wall from
concrete. The concrete may be molded to the shape of bricks or
otherwise textured to appear as brick. For example, concrete
sidewalks have been provided with textured surfaces by stamping a
stone shape into the concrete before it hardens.
[0006] Another such example includes manually texturing the
concrete before it cures. One problem with using concrete is that
concrete tends to have a substantially smooth texture, unlike
natural stone or brick. Another disadvantage with such concrete
walls is that solid concrete is also extremely heavy.
[0007] Another attempt at providing such a textured or shaped
surface includes veneering, in which actual or simulated stone or
brick is adhered to a conventional concrete wall. One disadvantage
with veneering is the expense, time and care involved in providing
the veneer.
[0008] Another attempt simply involves making panels from plastic
which has been molded. One disadvantage with such plastic panels is
that they often do not provide a realistic appearance.
[0009] In addition, attempts have been made to reduce the weight of
concrete, load bearing building elements. Such attempts include the
addition of fillers into concrete. Another technique involves
bonding a plurality of laminations, including adhering a
lightweight laminate to the concrete laminate. Such techniques
typically involve a foam block onto which a concrete mixture is
applied or onto which a concrete laminate is adhered. One
disadvantage with these techniques is that the foam block must be
pre-shaped. Another disadvantage is that the building elements have
thick concrete layers, and thus are heavy.
SUMMARY OF THE INVENTION
[0010] It has been recognized that it would be advantageous to
develop a wall or panel which has the appearance of natural stone
work, rock, brick, wood, or the like, which is lightweight and
durable. The invention provides a wall or panel with a thin
concrete layer to reduce the weight of the wall or panel. The
concrete layer has interior and exterior surfaces, and a
cross-sectional contour. The contour projects outwardly to form
macro projections in the exterior surface, and macro indentations
in the interior surface. The contour also projects inwardly to form
macro indentations in the exterior surface, and macro projections
in the interior surface. The contour, or projections and
indentations, may form natural objects, such as stone work, brick,
wood, and the like. In a more detailed aspect of the invention, the
concrete layer has a substantially constant thickness at the
projections and indentations. In another more detailed aspect of
the invention, the concrete layer is less than approximately 0.5
inches thick to reduce weight.
[0011] A foam layer is coupled to the interior surface of the
concrete layer, and has protrusions mating with the indentations in
the interior surface of the concrete layer. The foam layer provides
reinforcement to the thin concrete layer and reduces the weight of
the wall or panel. The foam layer may have fiber reinforcement.
[0012] In accordance with one aspect of the present invention, the
wall or panel may have a thin elastomer layer affixed to the
concrete layer to reinforce the concrete layer, and to provide
tensile strength and impact resistance. In a more detailed aspect
of the invention, the reinforcement layer may include an elastomer
layer, such as a urethane layer. Alternatively, the reinforcement
layer may include a high density foam, and the foam layer may
include a low density foam. The reinforcement layer may include
fiber reinforcement.
[0013] In accordance with another aspect of the present invention,
the wall or panel may have a rigid backing layer spaced-apart from
the elastomer layer, with the foam layer disposed between, and
affixed to, the elastomer layer and backing layer to further
reinforce the concrete layer and making the wall or panel
lightweight.
[0014] The rigid backing layer may be a second concrete layer
spaced-apart from and opposite the first concrete layer. The second
concrete layer may have a similar cross-sectional contour.
[0015] The wall or panel may be configured to be free-standing
fencing structures. Alternatively, the wall or panel may be
configured as a facade to be affixed to an exterior wall of a
building.
[0016] A method for making the wall or panel includes providing a
mold having an inner mold surface with macro indentations and macro
protrusions. A wet mixture of concrete material is applied to the
inner mold surface of the mold to form a concrete layer with a
cross-sectional contour corresponding to the indentations and
protrusions of the inner mold surface. Preferably, the concrete
material is sprayed onto the inner mold surface. Preferably, the
wet mixture of concrete material is applied in a substantially
constant thickness at the projections and indentations. The
concrete material is cured until dry.
[0017] Foam is introduced into the mold to form a foam layer
secured to the cement layer with the foam having protrusions mating
with the concrete layer. The mold provides support to the concrete
layer as the foam expands. The secured concrete and foam layers are
removed from the mold.
[0018] In accordance with one aspect of the method of the present
invention, the layer of reinforcement material is applied to the
concrete layer prior to introducing the foam to form a
reinforcement layer. Preferably, the reinforcement layer is sprayed
onto the cured concrete layer.
[0019] In accordance with another aspect of the method of the
present invention, the rigid backing layer is spaced-apart from the
mold surface prior to introducing the foam into the mold.
Alternatively, the rigid backing layer may be applied to the foam
layer.
[0020] In accordance with another aspect of the method of the
present invention, the mold may be disposed in a vertical
orientation, either throughout the process, or just before the foam
is introduced into the mold. Thus, the wall or panel is vertically
oriented to facilitate handling and conserve space.
[0021] Additional features and advantages of the invention will be
set forth in the detailed description which follows, taken in
conjunction with the accompanying drawing, which together
illustrate by way of example, the features of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1a is a perspective view, partially in section, of a
wall or panel in accordance with the present invention;
[0023] FIG. 1b is a more detailed, partial cross-sectional view of
the wall or panel shown in FIG. 1a;
[0024] FIG. 2a is a partial perspective view, partially in section,
of another wall or panel in accordance with the present
invention;
[0025] FIG. 2b is a more detailed, partial cross-sectional view of
the wall or panel shown in FIG. 2a;
[0026] FIG. 3 is a partial cross-sectional view of another wall or
panel in accordance with the present invention;
[0027] FIG. 4 is a partial cross-sectional view of another wall or
panel in accordance with the present invention;
[0028] FIG. 5 is a partial cross-sectional view of another wall or
panel in accordance with the present invention;
[0029] FIG. 6 is a perspective view of an embodiment of a mold in
accordance with the present invention, shown in an open
configuration;
[0030] FIG. 7 is a perspective view of the mold of FIG. 6 shown in
an closed configuration;
[0031] FIG. 8 is a perspective view of another embodiment of a mold
in accordance with the present invention, shown in an open
configuration;
[0032] FIG. 9 is a perspective view of the mold of FIG. 8 shown in
an closed configuration;
[0033] FIGS. 10a-10b are schematic views of a method in accordance
with the present invention; and
[0034] FIG. 11 is a schematic view of a method in accordance with
the present invention.
DETAILED DESCRIPTION
[0035] For the purposes of promoting an understanding of the
principles of the invention, reference will now be made to the
exemplary embodiments illustrated in the drawings, and specific
language will be used to describe the same. It will nevertheless be
understood that no limitation of the scope of the invention is
thereby intended. Any alterations and further modifications of the
inventive features illustrated herein, and any additional
applications of the principles of the invention as illustrated
herein, which would occur to one skilled in the relevant art and
having possession of this disclosure, are to be considered within
the scope of the invention.
[0036] As illustrated in the Figures, walls or panels in accordance
with the present invention are shown which are configured to appear
as other objects or natural objects, including for example, stone
work, rock, brick, or wood, and the like, and which are lightweight
and durable. As used herein, the terms "wall" and "panel" are used
broadly to refer to walls or panels which may be used in building
construction systems as facades, and walls used in fence
systems.
[0037] Referring to FIGS. 1a and 1b, a wall or panel indicated
generally at 10 in accordance with the present invention is shown
configured as a wall in a fencing system. Thus, the wall or panel
is oriented in a vertical orientation and configured to be free
standing. The wall or panel 10 includes at least one thin concrete
layer, such as first thin concrete layer 14. The concrete layer 14
has an exterior surface 18 which faces outwardly to be seen, and an
opposite interior surface 22 which faces inwardly.
[0038] The concrete layer 14 advantageously has a cross-sectional
contour which projects outwardly to form projections 26 in the
exterior surface 18, and indentations 30 in the interior surface
22. In addition, the cross-sectional contour projects inwardly to
form indentations 34 in the exterior surface 18 and projections 38
in the interior surface 22. Thus, the exterior surface 18 includes
projections 26 and indentations 34, while the interior surface 22
includes indentations 30 which correspond to the protrusions 26 in
the exterior surface 18, and protrusions 38 which correspond to
indentations 34 in the exterior surface 18.
[0039] The projections and indentations are "macro-projections" and
"macro-indentations," respectively, meaning they are sized to
produce an architectural effect which is visible from a distance,
as opposed to surface or material irregularities. The projections
26 and indentations 34 of the exterior surface 18, and thus the
cross-sectional contour, are sized and shaped to appear as other
objects, or natural objects, including for example, rocks, stone
work, brick, wood or the like.
[0040] The concrete layer 14 has a thickness t which is
substantially constant throughout the portion of the concrete layer
14 including the projections and indentations. It is of course
understood that the thickness of the concrete layer 14 may vary at
the indentations and protrusions, or throughout the cross sectional
contour, especially at areas of curvature. By a "substantially
constant thickness," it is meant that the inner surface 22 of the
concrete layer 14 follows the outer surface 18 as the outer surface
18 projects inwardly and outwardly, as opposed to remaining
straight. Thus, the concrete layer 14 will cure substantially
evenly as discussed in greater detail below. The thickness t of the
concrete layer 14 is preferably less than one inch, more preferably
less than one-half inch, and most preferably less than one-eighth
inch, to reduce the weight of the concrete layer.
[0041] The concrete layer 14 may be formed of a concrete mix which
provides a cementitious or textured surface to appear as real stone
work or brick. It will be appreciated that concrete itself has a
relatively smooth surface. Thus, the concrete mix preferably
includes sand to provide strength to the concrete, and to provide a
rougher surface texture. In addition, the concrete mix may include
a plasticizer to keep the mixture as dry as possible. In addition,
the concrete mix may include a polymer to add flexibility. In
addition, the concrete mix may include an accelerator for faster
curing. Furthermore, a coloring may be applied to the exterior
surface 18 of the concrete layer 14 to further provide the desired
appearance as stone work, brick, etc. For example, a stone like
coloring may be added to the protrusions 28 in the exterior surface
18, while the indentations 34 in the exterior surface 18 retain the
natural coloring of the concrete mix. In addition, color or pigment
may be added directly to the concrete mixture.
[0042] The concrete layer 14 advantageously is thin to reduce
weight of the wall or panel 10. In addition, the concrete layer 14,
or concrete mixture, preferably and advantageously is free of fiber
reinforcement. Concrete is often reinforced with glass fiber, which
must be a special alkaline resistant glass fiber, which is very
expensive. Thus, a substantial cost reduction is realized without
using the more expensive glass fiber reinforced concrete. It is of
course understood that the concrete layer may be fiber
reinforced.
[0043] The panel 10 may also have a second concrete layer 42
opposite and spaced-apart from the first concrete layer 14. The
second concrete layer 42 may be similar to the first concrete layer
14, and includes a cross sectional contour with indentations and
protrusions configured to appear as stone work, brick, etc.
[0044] The wall or panel 10 advantageously has a reinforcement
layer 46 adjacent and affixed to the concrete layer 14. The
reinforcement layer 46 preferably is an elastomer layer, but may
also be a foam layer, such as a high density foam, as discussed in
greater detail below. The reinforcement or elastomer layer 46
advantageously provides tensile strength and impact resistance to
the concrete layer 14. As stated above, the concrete layer 14 is as
thin as possible to save weight, and may lack fiber reinforcement
to reduce cost. Thus, the elastomer layer 46 strengthens the thin
concrete layer 14, and provides tensile strength and impact
resistance to the concrete layer 14. The elastomer layer 46
preferably has a thickness between 60 and 225 mils depending on the
strength required. In addition, the elastomer layer 46 may be
reinforced with fiberglass. A less expensive fiberglass may be used
in the elastomer because it does not need to be alkaline
resistant.
[0045] The elastomer layer 46 has an exterior surface 50 which is
directly affixed to the interior surface 22 of the concrete layer
14. Thus, the exterior surface 50 of the elastomer layer 46 has
protrusions and indentations which match the respective
indentations and protrusions of the inner surface 22 of the
concrete layer 14. The elastomer layer 46 also has an interior
surface 54. The interior surface 54 of the elastomer layer 46 also
has indentations which correspond to protrusions in the exterior
surface 50, and protrusions which correspond to indentations in the
exterior surface 50. Thus, the elastomer layer 46 has a
cross-sectional contour which matches or mates with the
cross-sectional contour of the concrete layer 14. In addition, the
elastomer layer 46 has a thickness which is substantially
consistent at the protrusions and indentations.
[0046] The elastomer layer 46 preferably is a sprayable urethane,
as discussed in greater detail below. The elastomer layer 46 or
reinforcement layer alternatively may be epoxy or fiberglass
polyester. In addition, the elastomer layer 46 may be reinforced
with chopped fiberglass. Again, a less expensive fiberglass may be
used in the elastomer because it does not need to be alkaline
resistant. The concrete layer 14 protects the reinforcement layer
46 from the sun, because the reinforcement layer 46 may not be UV
stable, such as with some elastomers.
[0047] In addition, the wall or panel 10 may include a second
elastomer layer 58 affixed to the second concrete layer 42, which
is similar to the first elastomer layer 46.
[0048] The wall or panel 10 advantageously also has a foam layer 62
disposed between the concrete layers 14 and 42, and the elastomer
layers 46 and 58. The foam layer 62 is coupled or attached to the
interior surfaces 54 of the elastomer layers 46 and 58. The foam
layer 62 advantageously has protrusions 66 which extend outwardly
to mate with the indentations in the interior surface 54 of the
elastomer layer 46, and may also extend into the indentations 30 in
the inner surface 22 of the concrete layer 14. Thus, the foam layer
62 has a thickness which varies at the protrusions and
indentations, such that the wall or panel 10 is substantially
solid. The concrete and elastomer layers 14 and 46 may be flexible
by themselves. Thus, the foam layer 62 advantageously is
lightweight and provides further reinforcement and stiffness to the
elastomer and concrete layers 46 and 14.
[0049] The foam layer 62 may be a MDI poly-ether, polyester, or
polyether blend. The foam layer 62 may also be a poly-urea
elastomer or polyurethane. The foam layer 62 preferably is low
density, or has a density of two to five pounds. Alternatively, the
foam layer 62 may have a density between two and thirty pounds. In
addition, the foam layer 62 may be fiber reinforced. A less
expensive fiberglass may be used in the foam because it does not
need to be alkaline resistant.
[0050] The foam layer 62 advantageously provides a filler between
the concrete layers 14 and 42 to prevent unwanted voids or spaces,
particularly near the concrete layer 14, which may weaken the
concrete layer. In addition, the foam layer 62 advantageously bonds
the opposite concrete layers 14 and 42 together. Furthermore, the
foam layer 62 provides thermal and sound insulation to the wall or
panel 10.
[0051] As shown in FIG. 1a, the wall or panel 10 is configured for
use as a wall of a fencing system. The wall 10 may have a perimeter
border 70 or raised portion to frame and enclose the protrusions 26
and indentations 34 configured to appear as stone work, brick, etc.
The border 70 may include a base 72 configured to appear as a
foundation, a top 74 configured to appear as a cap, and sides 76
configured to appear as vertical support columns. The border 70 may
be configured to appear as concrete, as shown, or may also have
indentations and protrusions to appear as stone work, brick, etc.
The border 70 may be constructed as the rest of the wall 10, and be
formed of the thin concrete layer 14, the elastomer reinforcement
layer 46, and the foam layer 62. Thus, an entire segment of the
wall system may be formed of the wall 10 to be light weight and
durable.
[0052] Referring to FIGS. 2a and 2b, an alternative embodiment of a
wall or panel, indicated generally at 100, includes the thin
concrete layer 14, and thin elastomer layer 46, as described above.
In addition, the wall or panel 100 includes a rigid backing layer
104 spaced-apart from the concrete and elastomer layers 14 and 46.
The rigid backing layer 104 has an exterior surface 108, and an
interior surface 112 opposing an interior surface 54 of the
elastomer layer 46. A foam layer 116 is disposed between the rigid
backing layer 104 and the elastomer layer 46 or concrete layer 14.
As described above, the foam layer 116 includes protrusions 120
which extend into the indentations of the elastomer layer 46 and
concrete layer 14. The rigid backing layer 104 may be a straight or
flat layer, such as a rigid panel of fiberboard, or the like,
adhered to the foam. Alternatively, the rigid backing layer 104 may
be a flat concrete layer or an elastomer layer.
[0053] The rigid backing layer 104 may be used in applications in
which only a single side of the wall or panel 100 will be seen. For
example, the rigid backing layer 104 may be utilized to affix the
wall or panel 100 to the exterior of a building to form a facade.
Again, the thin concrete layer 14 allows the wall or panel 100 to
be light-weight, and thus more easily positioned, handled, secured,
etc. In addition, the backing layer 104 protects the foam layer
116.
[0054] As shown in FIG. 2a, the wall or panel 100 may be configured
as a free standing fence, or may be configured as a building panel
for being affixed to a building. In either case, the outer surface
18 of the concrete layer 14 may have a continuous surface of
protrusions 26 and indentations 34 extending over the entire
surface area of the outer surface 18 of the concrete layer 14.
Thus, several walls or panels 100 may be positioned adjacent one
another to form a continuous surface.
[0055] As stated above, the reinforcement layer 46 preferably is an
elastomer layer, and most preferably a urethane layer.
Alternatively, as indicated above, the reinforcement layer 46 may
be a layer of high density foam, such as 10 to 20 pound density,
while the foam layer 62 is a low density foam layer, for example,
two to five pound density.
[0056] Referring to FIG. 3, an alternative embodiment of a wall or
panel 200 is shown with the concrete layer 14 and a rigid backing
layer 104 (not shown in FIG. 3) as described above. A foam layer
204 is disposed between the concrete layer 14 and the rigid backing
layer 104. Thus, the foam layer 204 directly attaches to the inner
surface 22 of the concrete layer 14. As described above, the foam
layer 204 has a varying thickness such that the foam layer 204 has
projections 208 which extend into the indentations 30 in the inner
surface 22 of the concrete layer 14. The foam layer 204 preferably
is a high density foam for greater durability and strength, but may
be a low density foam depending on the application. Thus, the high
density foam layer 204 acts as both the reinforcement layer and the
filler.
[0057] The wall or panel 200 may be configured to be attached to
the exterior of a building as a facade. In such case, the wall or
panel 200 preferably is relatively thin, and thus the foam layer
204 preferably is a thin, high density foam. The foam layer 204 may
have a thickness less than a few inches.
[0058] Referring to FIG. 4, an alternative embodiment of a wall or
panel, indicated generally at 300, has a thin concrete layer 14, a
thin elastomer layer 46, and a rigid backing layer 104 as described
above. In addition, the wall or panel 300 has a layer of rigid,
high density foam 304 adjacent and affixed to the elastomer layer
406, and a layer of low density foam 308 disposed between the rigid
backing layer 104 and the layer of high density foam 304. The layer
of high density foam 304 provides additional rigidity and stiffness
to the wall or panel 300, while the low density foam 308 reduces
the weight of the wall or panel 300.
[0059] Referring to FIG. 5, an alternative embodiment of a wall or
panel, indicated generally at 400, is shown with increased sound
reduction, or noise insulation properties. The wall or panel 400
may be similar to any of the walls or panels described hereto, and
thus has at least a thin concrete layer 14, and a foam layer 404.
As described above, the various walls or panels preferably have a
solid interior, or at least lack inadvertent voids, particularly
near the concrete layer 14, which may result in weak or damaged
portions. The foam layer 404 includes a plurality of voids 408 or
cavities formed in the foam layer 404 to improve the sound
dampening qualities of the wall or panel 400. The cavities 408 are
macro-voids, or sized to reduce sound, as opposed to the smaller
voids inherent in the cell structure of the foam.
[0060] It will of course be understood that any of the walls or
panels described above may have double faces or be two-sided, such
as the wall or panel 10 shown in FIG. 1, with both faces being
configured to appear as stone work, brick, etc. It is also
understood that any of the wall or panel members described above
may have a single face which is shaped and configured to appear as
stone work, brick, etc., and an opposite face which is configured
to be attached to another object, or simply to remain plain, such
as walls and panels 100, 200, 300, and 400, shown in FIGS. 2-5.
Thus, the second concrete layer 42 in FIG. 1 may be replaced with a
rigid backing layer. Likewise, the rigid backing layers 104 in
FIGS. 2-5 may be replaced with a second concrete layer which is
configured to appear as stone work, brick or the like.
[0061] In addition, the various walls or panels described above may
be configured to be attached to other objects or other walls or
panels. For example, the sides of the walls or panels may be
configured with tongue and groove type interconnections, with a
first panel having a tongue, and a second panel having a groove,
such that the tongue of the first panel may be inserted into the
groove of an adjacent second panel to facilitate securing adjacent
panels. Such tongue and groove type interconnections may be formed
integrally with the walls and panels. As another example, the
panels may have inserts for interconnecting the panels to one
another, or other objects.
[0062] In addition, the various walls or panels described above may
contain other structural members to reinforce the panels or
facilitate attachment of the panels to other objects, such as the
exterior of a building. For example, elongated metal bars may be
disposed in the foam layer to provide additional structural
rigidity to large panels.
[0063] The walls or panels of the present invention advantageously
are light weight and durable. Thus, the walls or panels may be
easily manufactured at a facility, easily transported, and easily
arranged at a building site.
[0064] The present invention also involves a method for making the
walls or panels. Referring to FIG. 6, a mold, indicated generally
at 500, is shown for forming the panels or walls of the present
invention. The mold 500 preferably has first and second mold halves
504 and 508. The mold 500, and thus the mold halves 504 and 508,
may be oriented vertically in order to save space. The mold halves
504 and 508 preferably are pivotally coupled along one side, such
that the mold halves 504 and 508 may be pivoted with respect to one
another between an open position as shown in FIG. 6 and a closed
position as shown in FIG. 7.
[0065] The first mold half 504 includes an inner mold surface 512
which includes macro-indentations 516 and macro-protrusions 520.
The indentations and protrusions 516 and 520 are configured to
produce the protrusions 26 and indentations 34 in the concrete
layer 14. Similarly, the second mold half 508 may include a second
mold surface 524 which may also have indentations and protrusions.
It is of course understood that both mold surfaces 512 and 524 will
have indentations and protrusions to form a dual sided wall or
panel 10 as shown in FIG. 1. Alternatively, only the first mold
surface 512 may have indentations and protrusions if the mold is to
be used to produce a wall or panel with a single shaped face.
[0066] As shown in FIG. 6, the mold 500 may be opened so that both
mold surfaces 512 and 524 are easily accessible. Color or pigment
may be applied to the indentations 516 in the mold surface 512. The
color or pigments correspond to the desired color of the stone or
brick. Alternatively, color or pigment may be added directly to the
concrete mixture of the concrete layer 14.
[0067] Referring to FIGS. 8 and 9 another mold 550 is shown for
forming the walls or panels of the present invention. The mold 550
preferably has first and second mold halves 554 and 558. The mold
halves 554 and 558 preferably are pivotally coupled to each other
or the ground at their bottom sides, so that the mold halves 554
and 558, may be oriented horizontally in the open position, as
shown in FIG. 8, and vertically in the closed position, as shown in
FIG. 9.
[0068] Similar to the mold 500 shown in FIGS. 6 and 7, the first
mold half 554 of mold 550 includes the inner mold surface 512 which
includes macro-indentations 516 and macro-protrusions 520.
Similarly, the second mold half 558 may include the second mold
surface 524 which may also have indentations and protrusions. As
shown in FIG. 8, the mold 550 may be opened so that both mold
surfaces 512 and 524 are easily accessible.
[0069] Referring to FIG. 10a, a mold, such as molds 500 (FIG. 6) or
550 (FIG. 8) is provided with at least the mold surface 510.
Preferably, the mold is initially open into an open configuration,
as shown in FIG. 6 or 8. Referring to FIG. 10b, a wet mixture of
concrete material is applied to at least the first mold surface 512
to form the first concrete layer 14. In addition, the wet mixture
of concrete material may also be applied to the second mold surface
524 to produce the second concrete surface 42 for a double sided
wall or panel. The concrete preferably is sprayed, indicated by
arrow 580, onto the mold surface 512 with a sprayer in a thin layer
preferably between one-eighth of an inch to one-half of an inch or
more. As stated above, the concrete material preferably is applied
as thinly as possibly to reduce weight. In addition, the concrete
material preferably is free of glass reinforcement to reduce the
cost associated with alkali resistant fiberglass. Alternatively,
the concrete material may be reinforced with alkali resistant
fiberglass.
[0070] In addition, the concrete material preferably is applied to
the mold surface 512 in a consistent or uniform thickness at the
indentations and protrusions 516 and 520. As stated above,
variations in thickness may occur as a result of overlapping spray
patterns, or at changes in curvature in the mold surface 512. But
wide variations in concrete thickness preferably are avoided by
refraining from filling the indentations 516 in the mold surface
512 with the concrete material.
[0071] The concrete material is then allowed to cure or harden into
the concrete layers 14 and 42. The concrete material cures more
evenly due to the constant thickness of the concrete layer 14.
[0072] Referring to FIG. 10c, a reinforcement material, such as an
elastomer material, is applied to the cured concrete layer 14 (and
42) to form the reinforcement layer 46 (and 58). The elastomer
material or reinforcement material preferably is sprayed onto the
concrete layers 14 and 42, indicated by arrow 584. In the case of
an elastomer material, the elastomer material sets up almost
immediately as it is applied to the concrete layers 14 and 42. As
stated above, the elastomer material preferably is applied in a
thin layer of between 60 to 225 mils, depending on the strength
required. As stated above, the concrete layers 14 and 42 preferably
are thin to reduce weight and lack glass reinforcement to reduce
cost. Thus, the elastomer layers 46 and 58 advantageously provide
tensile strength and impact resistance to the concrete layers 14
and 42. In addition, the elastomer material bonds to the concrete
layers as it is applied.
[0073] The elastomer material may include fiber reinforcement. It
will be appreciated that glass fiber reinforcement for the
elastomer is much less expensive than the special alkali resistant
glass fiber required when mixed with concrete.
[0074] Referring to FIGS. 7 and 9, the mold halves 504 and 508, or
554 and 558, are pivoted to the closed position, such that the mold
halves are spaced-apart from one another, and a gap or space 528
formed between the concrete layers 14 and 42 and elastomer layers
46 and 58. Referring to FIG. 1d, foam is then introduced into the
mold 500 (FIG. 7) or 550 (FIG. 9), or the space 528 between the
mold halves 504 and 508 (FIG. 7), or 554 and 558 (FIG. 9), as
indicated by arrow 588. Preferably, the foam is an expandable foam
which expands to fill the space 528 between the concrete layers 14
and 42 and elastomer layers 46 and 58. As the foam material
expands, it creates the protrusions 66 which extend into the
indentations 30 in the concrete layer 14. The foam stiffens the
panel and further reinforces the concrete layers 14 and 42. The
foam preferably is a low density foam between two and five pounds
to be lightweight. In addition, glass reinforcement may be added to
the foam. Again, it will be appreciated that glass reinforcement
for foam is much less expensive than a special alkali resistant
glass reinforcement required for concrete.
[0075] The mold 500 or 550 may then be opened and the resulting
panel, or combined concrete layers 14 and 42, elastomer layers 46
and 58, and foam layer 62, removed.
[0076] It will be noted that the mold 500 preferably is oriented
vertically in order to save space and facilitate handling, thus
reducing the need for large equipment to lift and handle heavy
molds. In addition, the vertically oriented molds which pivot open
allow workers easy access to the interior of the molds.
Alternatively, the mold 550 is preferably oriented horizontally
while the concrete is applied to prevent the concrete from running,
but vertically while the foam is injected. In addition, the
vertically oriented molds 500 and 550 result in vertically oriented
walls or panels, again saving space.
[0077] The method and molds described above also may also be used
to manufacture a single sided panel. The concrete and elastomer
materials are applied to a single sided mold, as described above.
The second mold surface 524 may be flat, or may not have the
indentations and protrusions to form stone work, brick, or the like
as in the first mold surface 512. Thus, when the mold is closed, a
gap or space is formed between the mold halves or between the
elastomer layer 46 and the second mold surface 524. Thus, the foam
material is introduced into the mold and expands between the
elastomer layer 46 and the second mold surface 524. The resulting
panel may be removed and a rigid backing layer 104, such as plywood
or the like, may be adhered to the exposed foam surface.
Alternatively, an elastomer material or the like may be added to
the exposed foam layer, forming the rigid backing layer.
[0078] The concrete and elastomer layers 14 and 46 by themselves
are relatively flexible. Therefore, the molds 500 and 550, or mold
halves 504 and 508, 554 and 558, provide rigidity to the concrete
and elastomer layers 14 and 46 as the foam material expands.
[0079] Alternatively, the rigid backing material 104, such as a
plywood sheet, may be placed in the mold adjacent the second mold
surface 524 such that the foam material is introduced between the
elastomer layer 46 and the rigid backing layer 104 so that the foam
bonds to the rigid backing layer 104 in the mold itself.
[0080] Alternatively, a concrete material may be applied in a flat
layer to the second surface 524 of the mold, and foam introduced so
that the resulting wall or panel has a rigid backing layer 104 of
concrete formed in the foam material.
[0081] Alternatively, the reinforcement layer may be formed by
applying a high density foam material directly to the interior
surface 22 of the concrete layer 14 and then introducing a
lightweight foam material into the mold.
[0082] It is of course understood that the molds may have a single
mold half. In addition, the rigid backing layer 104, such as a
plywood layer, may be utilized as the second mold half.
[0083] Referring to FIG. 11, a plurality of molds 600 may be
disposed on a transfer system 604, such as a moving conveyor, etc.,
and moved through a plurality of stations, indicated by arrow 608.
At a first station 612, the concrete mixture may be applied 580 to
the mold 600. The mold 600 is then moved to a curing station 616
where the concrete mixture is cured. The curing station 616 may be
on the transfer system 604, or the molds may be removed from the
transfer system 604 to a separate curing station 620. The mold 600
may then be moved to a reinforcing station 624 where a
reinforcement material, such as the elastomer material, is applied
584 to the concrete layer 14. The mold 600 is then moved to a foam
and/or backing layer station 628 where the foam material is applied
to the concrete and/or reinforcement layers 14 and 46, and the
backing layer 104 is applied. The foam material may be applied, and
then the backing layer 104 may be positioned by a press 632 as
shown. The foam and backing layer 104 may be applied at the same
station 628, as shown, or at different stations. In addition, the
walls or panels may be removed from the mold 600 at a different
station. Alternatively, the mold 600 may be moved directly from the
curing station 616 or 620 to the foam and/or backing layer station
628. The transfer system 604 and plurality of molds 600 facilitate
manufacturing larger quantities of walls or panels, and speeds
manufacturing.
[0084] It is to be understood that the above-described arrangements
are only illustrative of the application of the principles of the
present invention. Numerous modifications and alternative
arrangements may be devised by those skilled in the art without
departing from the spirit and scope of the present invention and
the appended claims are intended to cover such modifications and
arrangements. Thus, while the present invention has been shown in
the drawings and fully described above with particularity and
detail in connection with what is presently deemed to be the most
practical and preferred embodiment(s) of the invention, it will be
apparent to those of ordinary skill in the art that numerous
modifications, including, but not limited to, variations in size,
materials, shape, form, function and manner of operation, assembly
and use may be made, without departing from the principles and
concepts of the invention as set forth in the claims.
* * * * *