U.S. patent application number 12/866623 was filed with the patent office on 2011-10-06 for prefabricated wall panel with interlocking structure.
Invention is credited to James Belt, Wayne Buoni, David C. Hines, William Smith, Joy Stickel, Martin Tusim, Donn Vermilion, David Wolf.
Application Number | 20110239578 12/866623 |
Document ID | / |
Family ID | 40602438 |
Filed Date | 2011-10-06 |
United States Patent
Application |
20110239578 |
Kind Code |
A1 |
Wolf; David ; et
al. |
October 6, 2011 |
PREFABRICATED WALL PANEL WITH INTERLOCKING STRUCTURE
Abstract
A prefabricated wall panel (10) has a precast body (12)
including at least one decorative design element (14). In addition,
the wall panel includes a mounting element (16) having a first end
(18) embedded in the precast body and a second end (20) projecting
from the precast body. A interlocking structure (36,40) is provided
along at least two opposing edges of the wall panel to insure
proper alignment and interconnection when two or more wall panels
are installed together on a support substrate.
Inventors: |
Wolf; David; (Newark,
OH) ; Belt; James; (Utica, OH) ; Smith;
William; (Pataskala, OH) ; Vermilion; Donn;
(Newark, OH) ; Buoni; Wayne; (New Albany, OH)
; Stickel; Joy; (Columbus, OH) ; Tusim;
Martin; (Reynoldsburg, OH) ; Hines; David C.;
(Swanton, OH) |
Family ID: |
40602438 |
Appl. No.: |
12/866623 |
Filed: |
February 6, 2009 |
PCT Filed: |
February 6, 2009 |
PCT NO: |
PCT/US09/33405 |
371 Date: |
June 10, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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12026876 |
Feb 6, 2008 |
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12866623 |
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Current U.S.
Class: |
52/588.1 ;
52/578 |
Current CPC
Class: |
E04F 13/147 20130101;
B29L 2031/10 20130101; B29C 39/18 20130101; E04F 13/0894 20130101;
B29C 39/36 20130101; E04F 13/0873 20130101; B29D 99/001 20130101;
E04F 15/02038 20130101 |
Class at
Publication: |
52/588.1 ;
52/578 |
International
Class: |
E04C 2/38 20060101
E04C002/38; E04C 2/30 20060101 E04C002/30 |
Claims
1. A prefabricated wall panel, comprising: a precast body including
at least one decorative design element; a mounting element
including a first end embedded in said precast body and a second
end projecting from said precast body; and an interlocking
structure provided along at least two opposing edges of said
prefabricated wall panel to insure proper alignment and
interconnection when at least two of said prefabricated wall panels
are positioned together to complete a wall.
2. The wall panel of claim 1, further including at least one
protrusion in said second end and at least one keying hole in said
first end of said mounting element.
3. The wall panel of claim 2, wherein said protrusion has an
interior diameter of between approximately 0 and approximately 7.6
centimeters.
4. The wall panel of claim 3, wherein said protrusion has a depth
of between approximately 0.30 and approximately 0.6
centimeters.
5. The wall panel of claim 4, further including at least one weep
hole in said mounting element.
6. The wall panel of claim 5, wherein said first end of said
mounting element extends in a first plane and said second end of
said mounting element extends in a second plane wherein said second
plane is substantially parallel to said first plane.
7. The wall panel of claim 6, wherein said mounting element further
includes a transition section that connects said first end to said
second end and transitions between said first and second
planes.
8. The wall panel of claim 7, wherein said mounting element is made
from a material selected from wood, concrete, cellulose fiberboard,
polymer material, composite material, metal, plastic, reinforced
plastic, thermoplastic, fiber composite, reinforced wood, steel,
corrosion-resistant steel, aluminum, stainless, steel, zinc,
copper, and combinations thereof.
9. The wall panel of claim 8, wherein said mounting element is
formed as a solid sheet, as a mesh or as a combination thereof.
10. The wall panel of claim 1, wherein said precast body is made
from a material selected from a group consisting of concrete, fiber
reinforced concrete, gypsum, fiber reinforced gypsum, polymer
modified gypsum, other cementitious materials and mixtures
thereof.
11. The wall panel of claim 10, wherein said precast body includes
reinforcing fibers selected from a group of fibers consisting of
glass fibers, carbon fibers, mineral fibers, natural fibers,
polymer fibers, E-glass fibers, AR-glass fibers and mixtures
thereof.
12. The wall panel of claim 1, wherein said interlocking structure
comprises a cooperating tongue and groove arrangement.
13. The wall panel of claim 1, wherein said interlocking structure
includes alternating tongues and grooves staggered in two rows.
14. The wall panel of claim 1, wherein said interlocking structure
comprises a cooperating hook and slot arrangement.
15. The wall panel of claim 1, wherein said interlocking structure
comprises edge grooves and an interconnecting pin received in said
grooves.
16. The wall panel of claim 1, wherein said interlocking structure
is provided along at least two opposing edges of said precast
body.
17. The wall panel of claim 16, wherein said interlocking structure
comprises a cooperating tongue and groove arrangement.
18. The wall panel of claim 16, wherein said interlocking structure
includes alternating tongues and grooves staggered in two rows.
19. The wall panel of claim 16, wherein said interlocking structure
comprises a cooperating hook and slot arrangement.
20. The wall panel of claim 16, wherein said interlocking structure
comprises edge grooves and an interconnecting pin received in said
grooves.
21. A wall panel system, comprising: a prefabricated wall panel; a
starter strip; and a trim element; said wall panel system being
characterized by said prefabricated wall panel including; a precast
body including at least one decorative design element; a mounting
element including a first end embedded in said precast body and a
second end projecting from said precast body; and an interlocking
structure provided along at least two opposing edges of said
prefabricated wall panel to insure proper alignment and
interconnection when at least two of said prefabricated wall panels
are positioned together to complete a wall.
22. The wall panel system of claim 21, wherein said starter strip
includes a securing leg and a channel.
23. The wall panel system of claim 22, wherein said trim element
includes a substantially J-shaped body including a mounting leg, a
covering leg and a wall panel holding channel.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present invention claims priority to U.S. patent
application Ser. No. 12/026,876 filed on 6 Feb. 2008 and entitled
"Prefabricated Wall Panel with Tongue and Groove Construction", the
entirety of which is incorporated by reference herein.
BACKGROUND
[0002] Prefabricated or cast veneer wall panels have been developed
as a quick and efficient way to provide a masonry appearance for a
building while simplifying construction and lowering construction
cost. The design elements of prefabricated wall panels typically
simulate brick, stone, tile and other masonry building components
or materials commonly used in the construction of buildings.
Examples of prefabricated wall panels are disclosed in U.S. Pat.
Nos. 3,142,938 to Eberhardt, No. 4,669,238 to Kellis et al,
5,379,561 to Saito and 5,673,529 to Treister et al, in published
U.S. Patent Application Ser. No. 2007/0137128 to Viau et al and in
Co-pending patent application Ser. No. 11/647,751 owned by the
Assignee of the present invention.
[0003] Prefabricated wall panels are typically made from reinforced
construction materials such as fiberglass reinforced concrete.
Prefabricated wall panels made from such reinforced materials are
resistant to damage to handling during packaging, shipping and
installation. However, further improvements in durability to
decrease loss due to breakage are still desired. The present
invention relates to a prefabricated wall panel incorporating a
mounting element to enhance durability and provide significantly
improved handling characteristics as well as tongue and groove
construction to simplify installation.
SUMMARY
[0004] In accordance with the embodiments of the present invention
improved prefabricated wall panels are provided. The prefabricated
wall panel comprises a precast body including at least one
decorative design element and a mounting element including a first
end embedded in the precast body and a second end projecting from
the precast body. An interlocking structure is provided along at
least two opposing edges of the prefabricated wall panel to ensure
proper alignment and interconnection when at least two of the
prefabricated wall panels are positioned together to complete a
wall.
[0005] In accordance with one possible embodiment of the present
invention, the interlocking structure comprises a cooperating
tongue and groove arrangement.
[0006] In accordance with yet another possible embodiment of the
present invention, the interlocking structure includes alternating
tongues staggered in two rows.
[0007] In accordance with yet another possible embodiment of the
present invention, the interlocking structure comprises a
cooperating hook and slot arrangement.
[0008] In still another possible embodiment of the present
invention, the interlocking structure comprises edge grooves and an
interconnecting pin received in those grooves to hold the adjacent
wall panels in proper position. In any of these possible
embodiments, the interlocking structure is provided along at least
two opposing edges of the precast body.
[0009] In accordance with yet another aspect of the present
invention, a wall panel system is provided comprising a
prefabricated wall panel, a starter strip and a trim element.
[0010] In the following description there is shown and described
several different embodiments of the invention, simply by way of
illustration of some of the modes best suited to carry out the
invention. As it will be realized, the invention is capable of
other different embodiments and its several details are capable of
modification in various, obvious aspects all without departing from
the invention. Accordingly, the drawings and descriptions will be
regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The accompanying drawings incorporated herein and forming a
part of the specification, illustrate several aspects of the
present invention and together with the description serve to
explain certain principles of the invention. In the drawings:
[0012] FIG. 1 is a front perspective view of a prefabricated
wall;
[0013] FIG. 2 is a cross-sectional view of the prefabricated wall
panel illustrated in FIG. 1;
[0014] FIG. 3 is a partially schematical and cross sectional view
illustrating the mounting of two wall panels, one above the other,
along a support substrate such as a wall stud;
[0015] FIGS. 4A-4D are fragmentary front elevational views of four
different mounting elements used in the prefabricated wall panel of
the present invention;
[0016] FIGS. 5A-5G are schematical sectional views illustrating
several different embodiments of the wall panel of the present
invention;
[0017] FIG. 6 is a cross sectional view of the mold in which the
wall panel of FIGS. 1 and 2 are formed;
[0018] FIG. 7A is a perspective view of an alternative embodiment
of a wall panel incorporating an interlocking structure comprising
alternating tongues staggered in two rows;
[0019] FIG. 7B is an end elevational view showing the
interconnection of two wall panels of the type illustrated in FIG.
7A;
[0020] FIG. 8 is an end elevational view showing another
alternative embodiment of wall panel incorporating a cooperating
tongue and groove arrangement wherein the entire tongue and groove
arrangement is formed in the precast body of the wall panel;
[0021] FIG. 9 is an end elevational view of yet another embodiment
incorporating two cooperating grooves and a separate pin or biscuit
as the interlocking structure;
[0022] FIG. 10 is an end elevational view of yet one more
alternative embodiment incorporating cooperating hooks and slots as
the interlocking structure;
[0023] FIGS. 11A and 11B are respective end elevational and front
elevational views of a starter strip that forms a part of the
present wall panel system;
[0024] FIGS. 12A and 12B are respective end elevational views of
the hinged trim element that forms another part of the present wall
panel system.
[0025] FIG. 13 is a schematical illustration of two panels
overlying a starter strip against a framed wall of a building;
[0026] FIG. 14 is a schematical view illustrating a trim element
provided between a panel and a window or wall; and
[0027] FIG. 15 is a schematical view illustrating a trim element
provided between a panel and a fascia or soffit of a building.
DETAILED DESCRIPTION
[0028] Reference is now made to FIG. 1 illustrating a prefabricated
wall panel 10. Such a wall panel 10 may be used as a wall cladding
for a building. Further applications include but are not limited to
the construction of a fireplace surround or an outdoor living
component such as a decorative wall or grill surround.
[0029] The prefabricated wall panel 10 comprises a precast body 12
including at least one decorative design element 14. As illustrated
the design element 14 comprises two rows of overlapping brick with
four brick in each row. It should be appreciated that substantially
any other masonry material known in the art may be simulated
including bricks of different sizes, stones of the same or
different sizes and shapes, tiles of different sizes and shapes and
the like.
[0030] The precast body 12 is made from a cast material such as
concrete, reinforced concrete, gypsum, fiber reinforced gypsum,
polymer modified gypsum, reinforced cementitious material and
mixtures thereof. Typically the cast material reinforcement
comprises fibers selected from glass fibers, carbon fibers, mineral
fibers, natural fibers, polymer fibers and mixtures thereof. Where
glass fibers are used they may be of the E-glass or AR-glass type
which exhibits some alkali resistance.
[0031] As best illustrated in FIGS. 1 and 2, the prefabricated wall
panel 10 also includes a mounting element, generally designated by
reference numeral 16. The mounting element 16 may be made from any
suitable a material including, but not limited to, wood, concrete,
cellulose fiber board, polymer material, composite material, metal,
plastic, reinforced plastic, thermoplastic, fiber composite,
reinforced wood, steel, corrosion-resistant steel, aluminum,
stainless steel, zinc, copper and combinations thereof. The
corrosion-resistant steel may take any number of forms including,
but not limited to, galvanized, galvanneal, Gavalume.TM. brand, tin
coating, chromium coating, nickel coating, phosphorous coating,
magnesium coating, copper coating, zinc coating, weathering steels
(i.e., alloys of steel with small additions of copper, aluminum,
nickel and/or phosphorous), polymer coatings and paint.
[0032] Polymer materials useful for the making of the mounting
element 16 include various thermoplastic and thermoset resins
including but not limited to polyolefins, polyesters,
polyvinylchloride, polypropylene, polyethylene, polyamide, epoxy,
vinyl ester, acrylic, polystyrene, ABS, melamine and mixtures
thereof. Composite materials used to make the mounting element 16
may include a reinforcing material and a matrix binder. Appropriate
reinforcing materials useful in the present invention include but
are not limited to glass fibers, natural fibers, mineral fibers,
basalt fibers, carbon fibers, kenaf fibers, jute fibers, hemp
fibers, E-glass fibers, C-glass fibers, R-glass fibers, S-glass
fibers, ECR-glass fibers, AR-glass fibers and mixtures thereof. It
should be appreciated that substantially any type of glass fiber
may be used for reinforcement fibers. Glass fibers appropriate for
use in the present invention may be loose chopped strand or glass
mat and include those available under the trademark ADVANTEX.
Matrix binder materials useful for this purpose include but are not
limited to polyolefins, polyesters, polyvinylchloride,
polypropylene, polyethylene, polyamide, epoxy, vinyl ester and
mixtures thereof.
[0033] As best illustrated in FIG. 2, the mounting element 16
includes a first end 18 that is embedded in the precast body 12 and
a second end 20 that projects from the precast body. This may be
accomplished by positioning the mounting element 16 so that the
first end 18 projects into the mold cavity in which the body 12 is
cast. After positioning the mounting element 16, the cast material
is sprayed, injected or otherwise added to the mold. The cast
material of the body 12 covers the front and the rear major faces
of the first end 18 of the mounting element 16. When set, the body
12 securely holds the mounting element 16 in position. In some
embodiments, the first end 18 includes a series of spaced keying
holes 17. These holes 17 fill with the cast material and ensure
that the mounting element 16 is firmly seated and secured in the
cast body 12 once the material sets.
[0034] As illustrated in FIGS. 1 and 2, the second end 20 of the
mounting element 16 projects upwardly from the top edge of the
precast body 12. In the illustrated embodiment, the mounting
element 16 includes a transition section 22 connecting the first
end 18 with the second end 20. In one embodiment, the transition
section 22 forms an included angle of between 0.degree. and about
180.degree.. In another embodiment, as illustrated in FIG. 2, the
transition section 22 forms an included angle of between about
130.degree. and about 140.degree. or about 135.degree. with the
first end 18.
[0035] As further illustrated in FIGS. 1, 2 and 3 the second end 20
of the mounting element 16 may include a series of protrusions 21.
The protrusion 21 may take the form of dimples, slots, ribs or any
other structure that provides a set back means and can receive a
nail or fastener. In the illustrated embodiment, the protrusion 21
is a dimple. The dimples 21 project away from the front face 28 of
the wall panel 10. The dimples 21 function to provide an air space
A between the wall panel 10 and the sheathing S or other building
substrate to which the wall panel 10 is fastened. The wall panel 10
is fastened or secured to the sheathing S by means of fasteners
such as nails or screws F that are received and pass through the
recessed apertures 23 provided along the second end 20 of the
mounting element 16.
[0036] In some examples, each dimple 21 has an interior diameter of
between approximately 0 and approximately 7.6 centimeters. In other
examples, each dimple 21 has an interior diameter of between about
2.5 and about 7.6 centimeters. In yet other examples, each dimple
21 has an interior diameter of between about 2 to about 5
centimeters. In further examples, each dimple 21 has an interior
diameter of between about 1.0 and about 1.6 centimeters.
[0037] Each dimple also has any suitable depth. For example, each
dimple 21 may have a depth of between approximately 0.30 and
approximately 0.60 centimeters. The aperture 23 in each dimple 21
may have any suitable dimensions. For example, the aperture 23 may
have a diameter of about 0.3175 centimeters. Further, the aperture
23 may be concentrically received in the bottom of the dimple 21.
In some examples, the diameter of the dimple 21 allows the head of
a fastener, such as a roofing nail, to fit inside the dimple where
it will not interfere with the mounting of the next panel. The
aperture 23 ensures the centering of the nail in the dimple. The
bottom wall of the dimple 21 may also be slightly curved as
illustrated. The size and shape of the dimple 21 ensures that the
dimple does not collapse or become embedded in the underlying
sheathing during installation of the wall panel 10. In this way
good ventilation is provided between the wall panel and the
underlying sheathing to which it is mounted as discussed in detail
below.
[0038] In order to complete a wall, it is generally necessary to
vertically and horizontally stack a series of prefabricated wall
panels 10. In some examples, each additional row of wall panels 10
is offset with respect to the previous row by the staggered ends 34
(see FIG. 1) provided on the panels. As each succeeding wall panel
10 in each succeeding row is added (see FIGS. 2 and 3), an
interlocking structure in the form of a tongue and groove
arrangement ensures proper placement and greatly simplifies
installation. In other examples, the panels may have a square,
rectangular, or other suitable shape with no staggered ends.
[0039] More specifically, each wall panel 10 includes a groove 36
formed between the precast body 12 and the front face of the second
end 20 of the mounting element 16. The groove 36 is provided in or
along the first or top edge 38 of the precast body 12. In the
illustrated embodiment, a cooperating tongue 40 is formed by the
second or bottom edge of the precast body 12. In alternative
embodiments, the tongue 40 could be formed by a metal backer or
other similar structure. During installation, the tongue 40 on one
wall panel 10 is precisely sized and shaped to be received in the
cooperating groove 36 on the underlying wall panel 10. This
interconnection ensures proper registration between wall panels 10
during installation. Further, the tongue and groove connection
between the wall panels 10 functions to support the wall panel
being added in proper position until fasteners F can be positioned
in the support substrate S through the recessed apertures 21 to
hold the panel in place. If desired, grout is then provided in the
grout areas 32 between the design elements 14 on all of the wall
panels 10 in order to complete the installation. Weep holes 25 are
provided at spaced locations in the second end 18 of the mounting
element 16 adjacent the transition section 22. These weep holes 25
allow water to drain from the groove 36. In the illustrated
embodiment, a weep hole 25 is provided at the center of each design
element 14. In another embodiment, the weep hole 25 may not be at
the center of each design element 14.
[0040] As best illustrated in FIGS. 4A-4D, the mounting element 16
may take a number of forms. As illustrated in FIGS. 1, 2, 3 and 4A,
the first end 18 and second end 20 may both be made from a solid
piece of material. Alternatively, as illustrated in FIG. 4B, the
two ends 18, 20 may both be made from a mesh material (i.e. any
perforated material), such as, galvanized steel, aluminum and/or
copper. In this embodiment, no weep holes 25 or recessed apertures
21 are provided. It should be appreciated, however, that weep holes
25 and recessed apertures 21 may be provided if desired. As yet
another alternative, FIG. 4C illustrates an embodiment wherein the
first end 18 is made from a mesh material and the second end 20 is
made from a solid material. In contrast, FIG. 4D illustrates an
embodiment where the first end 18 is made from a solid material and
the second end 20 is made from a mesh material.
[0041] The use of mesh material instead of solid material serves a
number of advantages. Good strength is obtained yet less material
is used thereby reducing costs of production. Where the first end
18 is made of mesh material, the interlocking of the mounting
element 16 in the precast body 12 is enhanced. This is because the
cast material is received in and passes through each of the
openings in the mesh to provide a most secure interconnection.
[0042] Alternative embodiments for the wall panel 10 are
illustrated in FIGS. 5A-5G. In FIG. 5A, the first end 18 of the
mounting element 16 is long enough to extend nearly to the end of
the tongue 40. This provides added strength to the precast body 12.
In this embodiment, the first end 18 of the mounting element 16 is
made from solid material including a few spaced keying holes 17 for
receiving cast material. In the embodiment illustrated in FIG. 5B,
the first end 18 is made from mesh material.
[0043] FIG. 5C illustrates a wall panel 10 incorporating a mounting
element 16 with a second end 20 constructed from mesh material and
an extended first end 18 constructed from solid material but
incorporating several keying holes 17. FIG. 5D illustrates yet
another alternative embodiment wherein the entire mounting element
16 is made from mesh material including the first end 18. In FIGS.
5C and 5D, the mounting element 16 is illustrated as being formed
from a double layer of mesh material. This provides added strength
to the mounting element 16.
[0044] FIGS. 5E-5G illustrates additional alternative embodiments.
In FIG. 5E, the mounting element 16 is made from two separate
pieces. It will be understood that it could be made of three, four
or more pieces if desired. The first piece 16a of the mounting
element includes a first end 18 embedded in the precast body 12 and
extending in a first plane P.sub.1, a second end 20 projecting from
the precast body 12 and extending in a second plane P.sub.2 and a
transition section 22 connecting the first and second ends 18 and
20. As further illustrated, the first end may include a keying hole
17 that receives the cast material to ensure that the first piece
of the mounting element 16a is securely held in position by the
precast body. The second end 20 includes at least one dimple or
other aperture 21 as described above. In addition, the transition
section 22 includes a slot 70.
[0045] As further illustrated in FIG. 5E, a second mounting element
16b forms a tab 72 projecting from a second edge of the precast
body 12. The second piece of the mounting element 16b, like the
first piece of the mounting element 16a, may include a keying hole
17 to receive cast material and ensure it is securely held in the
precast body 12. As illustrated, the slot 70 and the tab 72 both
extend in a third plane P.sub.3 between the first and second planes
P.sub.1, P.sub.2. Accordingly, a second wall panel 10 may be added
to a first wall panel 10 previously secured to a substrate by
aligning and inserting the tabs 72 on the second wall panel into
the slots 70 on the first wall panel. Thus, the slots and tabs
70,72 function like the tongue and grooves 40,36 on the embodiments
in FIGS. 1 and 2 to align and secure wall panels 10 together.
[0046] FIG. 5F shows yet another alternative embodiment of the slot
and tab 70,72 construction. In this embodiment the mounting element
16 is a single piece incorporating a series of keying holes 17 to
allow it to be firmly secured in the precast body 12. This single
piece mounting element 16 provides additional strength to the
precast body 12.
[0047] In the additional embodiment illustrated in FIG. 5G, a
single piece mounting element 16 is again illustrated incorporating
the slot 70 and groove 72 connection system. Unlike the embodiment
illustrated in FIG. 5F, in the embodiment illustrated in FIG. 5G, a
portion 74 of the mounting element 16 embedded in the precast body
12 is made from a mesh material.
[0048] A mold 50 for forming a wall panel 10 is illustrated in FIG.
6. The mold 50 comprises a mold body 52 formed from an elastomeric
material such as silicone, urethane, polyurethane, and/or latex.
The mold body 52 includes a mounting element support surface 54, a
mold cavity 56 and a dimensional flap 58 overlying a portion of the
mold cavity that forms the tongue 40. Sufficient casting material
may be added to the mold 50 above a lowermost surface 39 of the
dimensional flap 58 to insure the groove 36 is formed to proper
shape. More specifically, the mounting element support surface 54
is provided along a first edge 60 of the mold cavity 56 while the
dimensional flap 58 is provided along a second opposite edge 62 of
the mold cavity.
[0049] The wall panel 10 is produced by positioning a mounting
element 16 onto the support surface 54 with the first end 18
extending into the mold cavity 56 and the second end 20 extending
from the mold cavity. Casting material may be added to the mold
cavity 56 before and/or after positioning the mounting element 16
onto the support surface 54. This may be done by injecting,
spraying or any other means known in the art. During this step, the
first end 18 of the mounting element 16 is embedded in the casting
material.
[0050] The method also includes the step of forming the tongue 40
in the mold cavity 56 from casting material captured under the
dimensional flap 58. Still further, the method includes forming the
groove 36 in the mold 50 between the precast body 12 and the second
end 20 of the mounting element 16. After allowing the cast material
to set, the wall panel 10 is removed from the mold 50. This may be
done by stretching the mold body 52 to free the tongue 40 from
under the dimensional flap 58, It will be understood that the
method and mold may be modified to produce the alternate
embodiments illustrated in FIGS. 5A-5G, 7A, 7B and 8-10.
[0051] Alternative interlocking structures are illustrated in FIGS.
7A, 713, 8, 9 and 10. In all of these embodiments, the mounting
element is identified by reference numeral 16, the precast body is
identified by reference numeral 12 and the design element is
identified by reference numeral 14. The mounting elements 16
illustrated do not include dimples 21 as described above and
illustrated in FIGS. 2 and 3. In the embodiment illustrated in
FIGS. 7A and 7B, each wall panel 100 includes alternating tongues
staggered in two rows across the top and bottom edges 106, 108 of
the wall panel. When two panels 100 are vertically stacked as
illustrated in FIG. 7B, the two rows of tongues 102 on each panel
mate to lock the bottom of the top panel into the top of the bottom
panel. This keeps the panels 100 in proper alignment and position,
preventing the bottom of any upper panel from lapping the top of
any lower panel. It should also be understood that more than two
rows of tongues and corresponding grooves may be provided.
[0052] FIG. 8 illustrates yet another alternative embodiment of
wall panel 200 wherein the upper edge 202 includes a groove 204 and
the bottom edge 206 includes a cooperating tongue 208. In this
embodiment, the groove 204 and tongue 208 are both fully formed in
the precast body 210 of the wall panel 200. FIG. 8 shows how two
wall panels 200 are interconnected using the cooperating groove 204
and tongue 208 to locate, align and support the panels in position
when constructing a wall.
[0053] Reference is now made to FIG. 9 illustrating yet another
embodiment of wall panel 300 wherein the upper and lower edges 302,
304 of the wall panel each include a groove 306. A separate pin or
biscuit 308 having a cross sectional area adapted to be received in
the aligned grooves 306 of the upper and lower edges 302, 304
completes the inner connection of these two wall panels 300.
[0054] FIG. 10 illustrates yet another embodiment of wall panel 400
of the present invention. In this embodiment the top edge or margin
402 includes a slot 404 while the bottom edge or margin 406
includes a cooperating hook 408. When the two wall panels 400 are
interconnected, the hook 408 of one panel 402 is received in the
slot 404 of the other panel in order to locate, align and support
the wall panels 400 in position when forming a wall.
[0055] It will be understood that the side of the wall panels
discussed herein may contain any suitable interlocking structures.
For example, the sides may have discontinuous tongue and groove
portions that cooperate with tongue and groove portions on adjacent
panels.
[0056] In accordance with yet another aspect of the present
invention, a wall panel system is provided. The wall panel system
includes a prefabricated wall panel 10, 100, 200, 300 or 400 as
illustrated in, for example, FIGS. 1, 7A, 8, 9 and 10, a starter
strip 500 as illustrated in FIGS. 11A and 11B and a trim element
600 as illustrated in FIGS. 12A and 12B. The starter strip 500
includes a securing leg 502, a support shelf 504, a channel 506
between the securing leg and the support shelf and a stabilizing
lug 508. Weep holes 507 are provided at spaced locations along the
bottom of the channel 506. Spaced apertures 510 are provided in the
securing leg 502. These apertures 510 receive fasteners (not shown)
for securing the starter strip 500 to an underlying substrate or
support such as the sheathing of a building. When properly mounted
to the sheathing, the face 512 of the securing lug 502 abuts the
sheathing as does the end 514 of the stabilizing lug 508. Once the
starter strip 500 is properly anchored to the sheathing, a wall
panel 10, 100, 200, 300, 400 is positioned against the face 516 of
the securing lug with the lower most edge of the wall panel
received and held in the channel 506. In one possible embodiment
the support shelf 504 underlies and supports the design elements 14
of the wall panel 10.
[0057] The trim element 600 includes a substantially j-shaped body
602 including a mounting leg 604 and a covering leg 606. The
covering leg 606 includes a first portion 608 connected to the
mounting leg 604 and a second portion 610 connected to the first
portion 608 by an optional hinge 612. This allows the second
portion 610 of the covering leg 606 to be moved out of the way
during installation of wall panels. It will be understood that the
body 602 may have any other suitable shape. It will be further
understood that the covering leg 606 may be made to be flexible in
any suitable manner at any suitable location to allow an installer
to more easily fit a panel into the trim element.
[0058] In use, the trim element 600 is connected to a substrate
such as wall sheathing by positioning the face 614 of the mounting
leg 604 against the sheathing and securing the trim element in
position by means of fasteners (not shown) received in spaced
apertures 616 provided in the mounting leg 604. The wall panel 10,
100, 200, 300, 400 is then positioned against the face 618 of the
mounting leg 604 and the second portion 610 of the covering leg 606
is pivoted about the optional hinge 612 from the position
illustrated in FIG. 12B into the position illustrated in FIG. 12A.
This hinged movement of the second portion 610 serves to form a
wall panel holding channel 620 about the end of the wall panel 10,
100, 200, 300, 400 so as to provide an aesthetically pleasing
surface. As illustrated, one or more drain holes 622 may be
provided in the first portion 608 of the covering leg 606 to allow
moisture to drain from the channel 620.
[0059] In one possible application a minimum of one layer of grade
D building paper or other water resistive barrier (WRB) material is
installed over the sheathing or substrate provided on wood framing.
Next vertical framing locations are marked with for example, a
pencil or chalk line. It may also be helpful to mark horizontal
framing locations in areas around windows, doors and wall
terminations. After this, the installer determines and marks the
starting point for installation of the wall panel system. In one
application the system must maintain a clearance from grade of a
minimum of four inches over soil or two inches over a hard surface
such as paving or concrete. It is critical that the starting line
be a level line and positioned so that the appropriate clearance
from grade is achieved.
[0060] Next the installer verifies that the intended starting line
provides an equal height distance to overhang, trim or cladding.
Once the starting location has been determined, the user tacks or
tapes WRB material up and marks on the sheathing. The chalk line or
pencil line is then extended across the entire surface to be
covered. The user then installs the starter strip 500 to extend
perfectly level along the starting point line. This is completed by
using fasteners such as roofing nails or screws that are received
in the spaced apertures 510. Additional fasteners may be added to
ensure that the channel 506 does not easily pull away from the
sheathing along the bottom edge. The WRB material is then lapped
over the securing leg 502. In this position, the WRB material
directs any moisture away from the sheathing and toward the channel
506 from which that moisture can drain from the weep holes 507.
[0061] Next the trim element 600 is installed at desired locations
around windows, doors and the like. As with the starter strip 500,
discussed above, the trim element 600 is secured in place on the
sheathing by providing fasteners at spaced locations in the
apertures 616. As the starter strip 500 and trim element 600 are
subject to expansion and contraction with temperature change, the
user should allow clearance of, perhaps, 1/4 inch at all stops or
at material abut joints. The fasteners are placed in the center of
the elongated apertures 510, 616 and driven straight into the
sheathing. The fasteners are not nailed tight. Instead a slight
clearance is maintained between the fastener head and the starter
strip 500 and trim element 600 so as to more freely allow for
expansion and contraction.
[0062] Once the starter strips 500 and trim elements 600 are
properly mounted the wall panels 10, 100, 200, 300, 400 are
installed. Generally, corner panels are installed before flat
panels. Panels 10, 100, 200, 300, 400 are installed from bottom to
top and lapped in single fashion so that each seats properly.
Further the panels 10, 100, 200, 300, 400 are staggered from one
row to the next to avoid alignment of vertical joints. Fasteners F
are driven straight and flush and panels and corners are installed
level and plum.
[0063] More specifically, a flat wall panel 10, 100, 200, 300, 400
is positioned with the bottom edge (e.g. Tongue 40, 102 or 208 or
tab 72) in the channel 506 of the starter strip 500 and the
mounting element 16 up. The wall panel 10, 100, 200, 300, 400 is
then fastened in position using fasteners F. In one possible
embodiment, two fasteners F must penetrate the framing of the
building and end fasteners must be located within three inches of
the end of the panel 10, 100, 200, 300, 400 for optimum anchoring.
The next wall panel 10, 100, 200, 300, 400 is then positioned into
the channel 506 next to the first panel. The installer then slides
the second panel to nest edge to edge with the first panel and
fasteners F are installed as previously described. The installer
continues down the wall repeating this procedure until the end is
reached. The next course of panels is then started with a half
panel immediately above the first course of wall panels 10, 100,
200, 300, 400,
[0064] FIG. 13 illustrates the starter strip 500 mounted to the
framed wall W of a building. Two panels 700, 700' are mounted to
the wall W above the starter strip 500. Note how the tongue 702 on
the lowermost panel 700 is received in the channel 506 while the
design element 704 is supported on the shelf 504. Also note how the
WRB material M laps over the top of the securing leg 502 so that
moisture is directed into the channel 506 and then drained away
through the weep hole 507.
[0065] FIG. 14 illustrates a trim element 600 mounted on a framed
wall S of a building between a panel 700 and a window or end wall
W'. Note how the end 706 of the panel 700 is received in the wall
panel holding channel 620 formed by the legs 604 and 606.
[0066] FIG. 15 illustrates a trim element 600 mounted on a framed
wall W of a building between a panel 700 and a fascia or soffit S.
In this application, the top margin 708 of the panel 700 is
received and held in the channel 620 formed by the legs 604,
606.
[0067] The foregoing description of the various embodiments of the
present invention have been presented for purposes of illustration
and description. It is not intended to be exhaustive or to limit
the invention to the precise form disclosed. Modifications or
variations are possible in light of the above description. For
example, in the illustrated embodiments, the apertures 23 for
receiving a fastener are provided in the protrusion 21. In
alternative embodiments, such apertures 23 may be provided
substantially anywhere in the body 12. As another example, the
illustrated embodiment of FIG. 5E includes a mounting element 16
with a first end 18 extending in a first plane P.sub.1 and a second
end 20 extending in a second plane P.sub.2 where the planes P.sub.1
and P.sub.2 are parallel to one another. The mounting element 16
could include ends that extend in planes that are not parallel to
one another.
[0068] Still further, while the interlocking structures 102, 104,
204, 208, 306, 404, 408 are illustrated in only the top and bottom
edges of the panels 100, 200, 300, 400 in FIGS. 7A, 7B, 8A, 8B, 9
and 10, it should be appreciated that like interlocking structures
could be provided in the end or side edges so that the panels
interlocked together end-to-end in the same manner if desired. In
addition, while the panels 10 in FIG. 1 are elongated with
staggered ends 34, it should be appreciated that they could assume
most any shape. For example, the panels 10 could be rectangular or
square with straight, not staggered ends.
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