U.S. patent application number 14/013084 was filed with the patent office on 2014-03-06 for reinforced architectural panel.
This patent application is currently assigned to Archibuild Limited. The applicant listed for this patent is Archibuild Limited. Invention is credited to Albert Kwok Hung Kwan, Dominic Yiu Wah Lai.
Application Number | 20140065349 14/013084 |
Document ID | / |
Family ID | 49355807 |
Filed Date | 2014-03-06 |
United States Patent
Application |
20140065349 |
Kind Code |
A1 |
Kwan; Albert Kwok Hung ; et
al. |
March 6, 2014 |
REINFORCED ARCHITECTURAL PANEL
Abstract
An architectural panel includes a substantially rectangular
prismatic main body cast from lightweight concrete that has first
and second major faces which are substantially planar and parallel
to one another. First and second reinforcing mesh sheets are
disposed substantially parallel to one another, next to the first
and second major faces, respectively, and embedded in the main
body. Recesses are arrayed in the first major face. Each recess
extends through a respective opening in the first mesh sheet.
Inventors: |
Kwan; Albert Kwok Hung;
(Hong Kong, CN) ; Lai; Dominic Yiu Wah; (Kwun
Tong, CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Archibuild Limited |
Kowloon |
|
CN |
|
|
Assignee: |
Archibuild Limited
Kowloon
CN
|
Family ID: |
49355807 |
Appl. No.: |
14/013084 |
Filed: |
August 29, 2013 |
Current U.S.
Class: |
428/99 ; 428/138;
428/139 |
Current CPC
Class: |
Y10T 428/24331 20150115;
E04C 2/326 20130101; E04C 2/049 20130101; Y10T 428/24339 20150115;
E04C 2/06 20130101; E04C 2/044 20130101; E04C 2/30 20130101; Y10T
428/24008 20150115 |
Class at
Publication: |
428/99 ; 428/138;
428/139 |
International
Class: |
E04C 2/30 20060101
E04C002/30; E04C 2/06 20060101 E04C002/06; E04C 2/04 20060101
E04C002/04 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 3, 2012 |
HK |
12108586.9 |
Claims
1. An architectural panel comprising: a main body cast from
lightweight concrete; first and second major faces on the main body
which are substantially planar and parallel to one another; first
and second mesh sheets disposed substantially parallel to one
another, next to the first and second major faces, respectively,
and embedded in the main body, wherein edges of each of the first
and second mesh sheets are disposed adjacent respective edges of
the main body, and the first mesh sheet includes an array of
openings; and an array of recesses in the first major face, wherein
each recess extends through a respective one of the openings in the
first mesh sheet.
2. The architectural panel of claim 1 wherein the main body has a
substantially rectangular prismatic form and the mesh sheets are
rectangular.
3. The architectural panel of claim 1 wherein no undercut is
provided in the recesses.
4. The architectural panel of claim 1 wherein each recess tapers
inwardly from a mouth at the first major face to a base.
5. The architectural panel of claim 1 wherein each recess comprises
a plurality of intersecting flat faces.
6. The architectural panel of claim 1 wherein each recess comprises
five flat faces.
7. The architectural panel of claim 4 wherein the openings in the
first mesh are square and each mouth is square.
8. The architectural panel of claim 7 wherein each recess includes
four tapered faces that extend from the square mouth to a square
face at the base.
9. The architectural panel of claim 8 wherein the four tapered
faces have rotational symmetry about a central axis of each recess
that extends substantially orthogonal to the first face.
10. The architectural panel of claim 1 wherein the lightweight
concrete comprises one of aerated concrete and foamed concrete,
and, as aggregate, one chosen from the group consisting of:
sintered expanded clay, expanded polystyrene beads, pumice,
expanded shale, bottom ash, ceramics.
11. The architectural panel of claim 1, further comprising a
plurality of fixtures cast into the main body to provide mounting
points, each fixture comprising a plate fixed to a projecting
bracket extending substantially perpendicular to the plate, wherein
each bracket includes an aperture with an internal screw
thread.
12. The architectural panel of claim 11 wherein the panel has a
thickness and each fixture has a dimension generally the same as
the thickness of the panel.
13. The architectural panel of claim 11 wherein the fixtures are
fixed to the first and second mesh sheets.
14. The architectural panel of claim 11 wherein the bracket has a
length and substantially all of the length of the bracket is
embedded in the concrete.
15. The architectural panel of claim 1, further comprising a
backing layer extending over the first major face and keyed into
the recesses, the backing layer being formed by casting, after
casting the main body.
16. The architectural panel of claim 1 further comprising a facing
layer of lightweight concrete bonded to the second major face.
17. An architectural panel of generally rectangular prismatic form
comprising: a main body cast from lightweight concrete comprising
one of aerated concrete and foamed concrete, and, as aggregate, one
chosen from the group consisting of: sintered expanded clay,
expanded polystyrene beads, pumice, expanded shale, bottom ash,
ceramics; first and second major faces on the main body which are
substantially planar and parallel to one another; first and second
rectangular sheets or first and second wire reinforcing mesh sheets
embedded in the main body and disposed substantially parallel to
one another, next to the first and second major faces,
respectively, wherein edges of each of the first and second wire
reinforcing mesh sheet are disposed adjacent respective edges of
the main body, and the first wire reinforcing mesh sheet includes
an array of openings; and an array of recesses in the first major
face, wherein each recess extends through a respective one of the
openings in the first wire reinforcing mesh sheet and tapers
inwardly from a relatively large mouth at the first major face to a
relatively small base.
18. The architectural panel of claim 17, further comprising a
plurality of fixtures embedded in the main body to provide mounting
points for the panel, each fixture comprising a plate fixed to a
projecting bracket, wherein each plate is disposed adjacent the
second major face, each bracket extends substantially perpendicular
to the plate, an axial end of each bracket is disposed adjacent the
first major face, each bracket includes an aperture extending
through the axial end, with an internal screw thread in the
aperture and the fixtures are fixed to the first and second wire
reinforcing mesh sheets.
19. The architectural panel of claim 18, further comprising a
backing layer extending over the first major face and keyed into
the recesses, the backing layer being formed by casting, after
casting the main body.
20. The architectural panel of claim 18 further comprising a facing
layer of lightweight concrete bonded to the second major face.
Description
TECHNICAL FIELD
[0001] The present invention relates generally to architectural
cladding and lining, and particularly to reinforced concrete
panels.
BACKGROUND OF THE INVENTION
[0002] Modern large buildings generally consist of a basic load
bearing structure supporting the exterior cladding and internal
linings of the walls. This wall cladding or lining material should
be lightweight, durable, of pleasing appearance and compatible with
overall environmental objectives for the interior of the building.
The interior or exterior of some buildings are finished in polished
natural stone, such as granite or marble or in a decorative
concrete finish. This has a pleasing appearance, but these panels
are generally large, and in order to have sufficient strength to
avoid breakage must be heavy. Mounting such stone and concrete
panels can therefore be difficult, and in some cases there has been
a tendency for unevenly distributed weight to cause panel joints to
fail over time.
[0003] Architectural panels have been made from light weight
reinforced concrete to address these difficulties. However, while
satisfactory strength-to-weight ratios have been attained by some
prior panels, their performance has typically been compromised in
other respects, such as simplicity and cost of manufacture and
thermal performance. It will be understood that there remains a
need for an optimised or improved design which suffers less from
such compromises. It is an object of the present invention to
address this need or, more generally, to provide an improved
architectural panel.
DISCLOSURE OF THE INVENTION
[0004] According to one aspect of the present invention there is
provided an architectural panel comprising: [0005] a main body cast
from lightweight concrete; [0006] first and second major faces on
the main body which are substantially planar and parallel to one
another; [0007] first and second mesh sheets disposed substantially
parallel to one another next to the first and second major faces
respectively and embedded in the main body such that edges of each
mesh sheet are disposed adjacent a respective edge of the main
body, the first mesh sheet defining an array of openings, and
[0008] an array of recesses in the first major face, each recess
extending through a respective one of the openings in the first
mesh sheet.
[0009] It has been found that a panel according to the invention
has a high strength-to-weight ratio, and exceptional thermal
performance when correctly installed with the second major face
disposed outwardly. In hot climates, when provision is made for air
flow over the first major face, the panel is effective in reducing
solar gains by dissipating heat to the air. In cool climates, when
provision is made to prevent air flow over the first major face,
the panel is effective in reducing heat loss from the building
envelope.
[0010] Preferably the main body has a substantially rectangular
prismatic form and the mesh sheets are rectangular.
[0011] Preferably no undercut is provided in the recesses.
[0012] Preferably each recess tapers inwardly from a mouth at the
first major face to a base.
[0013] Preferably each recess comprises a plurality of intersecting
flat faces. Preferably each recess comprises five flat faces.
[0014] Preferably the openings in the first mesh are square and the
mouth is square.
[0015] Preferably four tapered faces of each recess extend from the
square mouth to a square face at the base.
[0016] Preferably the four tapered faces have rotational symmetry
about a central axis of each recess that extends substantially
orthogonal to the first face.
[0017] Preferably the lightweight concrete may one of: sintered
expanded clay as aggregate, expanded polystyrene beads as
aggregate, pumice as aggregate, expanded shale as aggregate, bottom
ash as aggregate, ceramics as aggregate, aerated concrete and
foamed concrete.
[0018] Preferably a plurality of fixtures cast into the main body
to provide for mounting points, each fixture comprising a plate
fixed to a projecting bracket and extending substantially
perpendicular to the plate, an aperture in the bracket with an
internal screw thread.
[0019] Preferably the fixture has generally the same dimension as
the thickness of the panel.
[0020] Preferably the fixtures are fixed to the mesh sheets.
[0021] Preferably substantially the full length of the bracket is
embedded in the concrete.
[0022] Preferably a backing layer extends over the first major face
and keyed into the recesses, formed as by casting the backing layer
after the body.
[0023] Advantageously, a facing layer may be bonded to the second
major face so as to be exposed on installation for aesthetic
purposes. The facing layer may comprise lightweight concrete with a
decorative finish, such as a patterned finish, or exposed aggregate
finish. The facing layer may alternatively comprise stone, such as
polished marble or granite. Optionally, a decorative finish may
instead be applied directly to the second major face.
[0024] This invention provides an architectural panel which is
effective and efficient in operational use, which may be
economically constructed and has an overall simple design which
minimizes manufacturing costs and improves structural and thermal
performance.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] Preferred forms of the present invention will now be
described by way of example with reference to the accompanying
drawings, wherein:
[0026] FIG. 1 is an isometric view of a panel according to an
embodiment of the invention;
[0027] FIG. 2 is a fragmentary section indicated by AA on FIG.
1;
[0028] FIG. 3 is a fragmentary section indicated by BB on FIG.
1;
[0029] FIG. 4 is a fragmentary section corresponding to FIG. 2 but
showing an additional facing layer bonded to the panel of FIG.
1;
[0030] FIG. 5 is a longitudinal section through a fixture of the
invention;
[0031] FIG. 6 is a fragmentary section through of a panel according
to a second embodiment of the invention;
[0032] FIGS. 7 and 8 are fragmentary views of a major face of the
panel of FIG. 6, and
[0033] FIG. 9 is a fragmentary section through of a panel according
to a third embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] Referring to FIGS. 1 to 3 of the drawings, a lightweight and
structurally efficient architectural panel according to a first
embodiment of the invention may have a generally rectangular
prismatic main body 10 cast from lightweight concrete, and having a
first major face 11 and an opposing second major face 12. The major
faces 11, 12 are substantially planar and parallel to one
another.
[0035] A rectangular array of recesses 13 are disposed in the first
major face 11, and may be of like form and regularly spaced, with
an uninterrupted margin 14 extending about the perimeter of the
array of recesses 13 adjacent to a peripheral edge 15 of the main
body 10.
[0036] The main body 10 is reinforced with first and second
substantially rectangular reinforcing mesh sheets 17, 18 disposed
substantially parallel to one another next to the first and second
major faces 11, 12 respectively. A corner section of the mesh sheet
17 is illustrated by the dashed lines in FIG. 1, while both sheets
17, 18 are illustrated by the circular section wires in FIGS. 2-4.
The mesh sheets 17, 18 may be made of stainless steel wire and are
embedded in the main body 10 such that edges 19 of each mesh sheet
17, 18 are disposed inside and adjacent to the peripheral edge 15.
Each mesh sheet 17, 18 defines an array of square openings 20, the
two sheets being aligned such that the openings 20 are in
registration with one another, and with the recesses 13.
[0037] Each recess 13 has a mouth 16 at the first major face 11 and
tapers inwardly from the mouth 16 to a base 21. The base 21 is
below the level of the mesh sheet 17 such that each recess 13
extends through a respective one of the openings 20 in the first
mesh sheet 17, but stops short of the second mesh sheet 18.
[0038] Each recess 13 has a concave form without undercut, allowing
the recesses to be cast readily. Each recess may have four
intersecting planar faces 22a-22d that taper inward as they extend
toward the base 16. A face of the base 21 forms a fifth face
bounding the recess. In the preferred embodiment the mesh openings
20 and recesses 13 are centred on a transverse axis 24 that extends
substantially orthogonal to the first and second major faces 11,
12, the recesses 13 having a symmetrical shape such that the four
tapered faces have rotational symmetry about a central axis.
[0039] FIG. 4 illustrates a composite panel comprising a facing
layer 26 bonded to the second major face 12 of the main body 10.
The facing layer 26 may be formed with an exposed face 27 with a
decorative finish, such as a patterned finish, or exposed aggregate
finish.
[0040] The main body 10 and facing layer 26 may be cast from
lightweight concrete, such as concrete including lightweight
aggregates, especially expanded polystyrene beads, pumice, expanded
shale, bottom ash and ceramics. Alternatively, the lightweight
concrete may be foamed or aerated concrete. The panels are
self-supporting but may be non-structural and suitable lightweight
concretes may have a density of about 1400-1500 kg/m.sup.3 and
compressive strength of 25-30 MPa.
[0041] Providing recesses 13 allows a further weight saving to be
achieved and it is believed that the recessed inner major face 11
contributes to the improved thermal performance in reducing solar
gains in hot climates (when provision is made for air flow over the
first major face) by improving heat dissipation to the air. In cool
climates, when made substantially airtight the recess provide a
still air gap effective in reducing heat loss from the building
envelope. The recesses 13 also provide suitable locations for
fasteners for fixing the panels.
[0042] Referring to FIGS. 5-8, a plurality of fixtures 30 are cast
into the main body 10, to provide mounting points on the panel for
connection to the frame of a building. Each fixture 30 may comprise
a plate 31 fixed to a projecting bracket 32, as by a screw fastener
33. The bracket 32 may extend perpendicular to the plate 31, and
include a longitudinally through-extending aperture 34 with an
internal screw thread 35. An opening in the plate 31 for receiving
the screw 33 may be disposed generally centrally. The fixture 30
may have generally the same dimension as the thickness of the
panel, such that the outer face 37 of the bracket 32 and outer face
36 of the plate 31 are generally coplanar with the first and second
major faces 11, 12 respectively. Edges 39 of the recesses 13 may be
radiused.
[0043] As best seen in FIGS. 6 and 7, the fixtures 30 may also be
fixed to the mesh sheets 17, 18. By securing the mesh sheets 17,
18, as by welding, to the bracket 32 the fixtures 30 can also be
used for supporting the mesh sheets 17, 18 in position during
casting, as with the outer faces 36, 37 abutting opposite walls of
a form (not shown) in which the panel is cast. The bracket 32 may
be connected to both wires 40a, 40b of the mesh panels 17, 18 as by
locating the bracket 32 adjacent the intersection between the wires
40a, 40b. Substantially the full length of the bracket 32 is
preferably embedded in the concrete, and this is achieved by
locating the fixtures 30 outside the recesses 13. For instance, as
shown in FIG. 8, the regular, rectangular array of recesses 13 may
be interrupted by areas adjacent the fixtures 30 without recesses
13.
[0044] FIG. 6 also illustrates a second embodiment of the
architectural panel comprising the body 10 with a facing layer 42
bonded to the second major face 12 and formed, for instance, from
stone. Strips 43 of the same stone as the facing layer 42 may be
fixed along the edges of the panel. The outer face 36 may be bonded
to the inner side 44 of the facing layer 42 as by a layer 45 of
adhesive, such as epoxy. A cementitous bond is achieved between the
rest of the inner side 44 and the body 10 by casting the body
against the facing layer 42, and the edge strips 43.
[0045] A third embodiment of the architectural panel is illustrated
in FIG. 9, having generally like construction to the second
embodiment of FIG. 6, but further including a backing layer 50
extending over the first major face 11 and keyed into the recesses
13, being formed as by casting the backing layer 50 after casting
the body 10 to provide a cementitous bond between the two. The
backing layer 50 may be formed from a lightweight concrete of lower
density than that of the body 10, and which provides increased
thermal insulation. The backing layer 50 may be fibre reinforced,
as by glass fibre or synthetic fibre, providing a high
strength-to-weight ratio. The fixture 130 used with this panel is
of like construction to the fixture 30, but includes a longer
bracket 132 that extends to the rear face 51 of the backing layer
50.
[0046] Aspects of the present invention have been described by way
of example only and it should be appreciated that modifications and
additions may be made thereto without departing from the scope
thereof.
* * * * *