CA2017847C - Composite building panel - Google Patents
Composite building panelInfo
- Publication number
- CA2017847C CA2017847C CA 2017847 CA2017847A CA2017847C CA 2017847 C CA2017847 C CA 2017847C CA 2017847 CA2017847 CA 2017847 CA 2017847 A CA2017847 A CA 2017847A CA 2017847 C CA2017847 C CA 2017847C
- Authority
- CA
- Canada
- Prior art keywords
- slurry
- surface layer
- mould
- panel
- insulating material
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
- E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
- E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Laminated Bodies (AREA)
- Panels For Use In Building Construction (AREA)
Abstract
The invention relates to a composite building panel and methods for the manufacture thereof. The panel comprises generally a surface layer of cementitious material having a scrim-cloth-type-material encapsulated therein and having a supporting layer of foamed insulating material. The panels are formed in moulds which impart a texture and appearance to the surface layer which can be made to resemble conventional surfacing materials, both natural and man-made.
Although the surface layer is moulded, the thickness of the surface layer is maintained substantially consistent and at a predetermined minimum.
Although the surface layer is moulded, the thickness of the surface layer is maintained substantially consistent and at a predetermined minimum.
Description
COMPOSITE BU~DING PANEL
Field Of The I~v~ ti()ll The invention relates to a composite building panel and to methods for the manufacLure of the panel. In particular, the inventioll is concerned with a composite panel comprising a supporting layer of insulating material which is adhered to a surface layer of cementitious material in a compression moulding process. An open weave scrim-cloth-type material is encapsulated into the surface layer to, amongst other things, minimi7e the possibility of breakage of the panel and to introduce dimensional stability. The moulding process is used to impart a texture 10 and appearance to the surface layer which can be made to replicate the texture and appearance of conventional surfacing materials.
Bacl~ ou~ Of The Il~vt;~
Stone has been employed as an exterior cladding, i.e. surfacing material, in the building and construction industry for hundreds of years. Today, the cost of natural stone construction tends to limit its application to that srnall portion of the market that can afford such a luxury. Brick and other siding materials have, for the most~part, been used as substitutes due to their relatively low cost compared to naeural stone. There is, however, a need for high quality sur~acing materials which exhibit all the authenticity of conventional surfacing 20 materials, i.e. texture, appearance and durability, but without the cost or application problems associated with natural stone or ex3sting substitutes.
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Prior Art Prefabricated composite building panels comprising an insulating material core and facing or surfacing materials are known and have been used in the construction industry. Canadian Patent No. 865,354, issued March 9, 1971 to Kenneth W. Pope, discloses a prefabricated building panel comprising a rigid layer of plastics material in cellular form, facing elements which are bonded to one face of the rigid layer in spaced-apart relation, and a granular material adhered to, and imbedded in the plastic between the facing elements. The granular material is generally used to produce a hard, skin-like surface between the facing elements 10 which, depending upon the type of granular material employed, may resemble mortar. The facing elements generally comprise segments of conventional surfacing materials such as brick and stone.
Canadian Patent No. 876,090, issued July 20, 1971 to Donald E.
Shirley et al. describes a composite building panel comprising a core of thermal insulating material encapsulated by a hardened hydraulic cement having disposed therein a fibrous synthetic material such as glass fibre. The method of production of these panels lends itself to long cycle times which the patent mentions as being 24 hours to produce one panel from start to finish.
United States Patent No. 4,044,520, issued August 30, 1977 to Albert 20 G. Barrows, describes a composite building panel comprising a base of expanded polystyrene to which is applied a polymer fortified concrete facing. An acrylic binder with quartz crystals carried thereon is provided over the concrete facing to enhance the appearance of the panel and to illlprove its resistance to impact.
yCC/ jm 2 Canaclian Patent No. 1,254,762, issued May 30, 1989 to David L.
Roodvoets, describes ~ prefabricated cement-fo~m composite p~nel co~ isil~g an insu]ating base of synthetic resinous foam and a layer of ]ight-weight cementitious material bonded by a latex adhesive thereto. The cementitious layer is constructed of foam cement and a light-weight aggregate. This panel is particularly suited for use ns a roofing panel.
SUMMARY OF THE lNVENTION
The present invention provides an innovative interior/exterior surfacing alternative to brick or conventional siding materials, without the costs and l0 application problems associated therewith. The invention represents an pl~vement over prior art composite building panels in that the surface of the panel can be made to replicate any conventional surfacing material, either natural or man-made, in texture aml appearance while exceeding the insulative properties thereo~ In addition, the panels are relatively light-weight, requiring less structure to support the weight of the fac~ade as compared wi~h that for natural stone, and they can be easily installed, even by inexperienced persons. Installation can be achieved year round in all weather conditions employing readily available industrial adhesives and fasteners. The panels can be cut by standard wood cutting tools such as a carpenter's handsaw, a circular saw or sabre saw and can be conveniently 20 drille~l using standard high-speed drill bits. The method of manufacture of the panels leads to fast production times and, therefore, a more cost-efficient panelg and results in a panel of generally uni~orm weight regardless of the surface ycc/ jm - - .
~7~
configuration. Various fininshing techniques allow the panels ~o be produced in a variety of colours or tones, including multi-tonal colour variations.
Accordingly, there is provided in one aspect of the invention a composite building panel which comprises a surface layer of cementitious material to which is adhered a supporting layer of foamed insulating material in a compression moulding proGess. An open weave scrim-cloth-type material is embodied within the surface layer to minimi7e the possibility of breakage (increases impact resistance) and to introduce dimensional stability to the panel. A mould is used to impart a texture and appearance to the surface layer which recreates all the 10 authenticity of the original surfacing or siding material from which the mould was produced. Although the surface ]ayer is moulded, the thickness of the surface layer is maintained subst~nti llly consistent and at a predetermined minimum.
According to a second aspect of the invention, there is provided a method of making a composiLè building panel co~ g the steps of:
a) dispensing a slurry of cementitious material in a mould;
b) placing a scrim-cloth-type material atop the slurry in the moukl;
c) colllpres~il.g the slurry to a predetermined thickness;
d) curing the compressed slurry to ~orm a shell;
e) injecting a foamable insu]ating material into the shell; and f) euring the foamable insulating material.
The density and rigidity of the foamed supporting layer may be increased significantly if, immediatély after the foamable insulating material is injected into the shell, the mould is capped and placed in a press for a ycc/ jï~ 4 predeterrnined amounl of time, thus l;miting the extent to which the foam expancls.
The thickness of the surface layer may be maintained substantially consistent and at a predetermined minimum by providing an inner moukl which is use(l to compress the slurry in the mould. The moulding surface of the inner mould resembles the moulding surface of the main mould, but provides areas of wider or narrower definition to maintain the thickness of the surface.
The curing of the slurry is an exothermic process wherein heat is generated during hydration and any excessive moisture is dissipated fram the mass.
Direct heat cannot be used to force-cure the slurry as the outer surface thereof 1() would cure before excessive moisture in the interior could be dissipated which would lend to cracking as the moisture tries to escape. In order to accelerate the hardening process, it is possible to employ infrared thermoreactor-type curing tunnels. The nature of these ~unnels is such that they do not cure or dry the slurry by means of direct heat but rather they aid in the dissipation of ~cessiv~ moisture by maintaining a very dry (low relative humidity) atmosphere in the tunnel. The use of such tunnels dramatically reduces the curing time for the surface layer and, thus, significantly decreases the overall production time for the panels. Because no t;~ccssive heat is generated in the thermoreactor tunnels, the hardened surface layer shells can be handled immediately upon removal from the tunnel arld problems ~0 associated with thermal expansion in the forrnation of laminar materials are avoided.
In an alternate method of making the composite building panel, the supporting layer of foamed insulating material may be pre-formed and used, instead of the inner mould, to con~ ess the slurry. Infrared thermoreactor-type tunnels ycc/jm 5 t~
may then be advantageously employed in curing the compressed slurry, without melting or burning the supporting layer of foarned insulating material.
Typically, a 4' x 4' x 2" panel producecl in accordance with the invention and having a surface layer thickness of a~plu~hllately 3/8" exhibits an over-all weight of about 80 Ibs or about S ]bs/ft2, and can be produced in a~ o.~ lately 30 minutes when infrared thermoreactor-type tunnels are used in the curing process.
The panel has zero surface flame spread, is impervious to moisture, and resists the freeze-thaw cycle which is destructive to many construction materials.
Further features and advantages will be described hereinbelow in 10 conjunction with the accompanying drawings.
BRIEF DESCRlPTION OF THE DI~W~N(;S
Fig. 1 is a plan view of a composite building panel in accordance with the preferred ernbodiment of the invention.
Fig. 2 is a cross-sectional view of the panel along line 2-2 in Fig. 1.
Figs. 3 to 6 are cross-sectional views, showing only those features at the plane of cross-section, of dirrerelll stages in the mould making procedure.
Figs. 7 and 8 are cross-sectional views of the surface layer shell being made in accordance with the method of the invention.
Fig. 9 is an oblique view in section of a typical surface layer shell 20 made in accordance with one method of the invention.
Fig. 10 is an oblique view in section alld partially broken away showing the panel made in accordance with the invention.
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7~7 Figs. 11 and 12 are cross-sectional views of the panel being made in accordance with the alternate metllod of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODlMENT
Figs. 1 and 2 illustrate a composite building panel 10 in accordance with the preferred embodiment of the invention. The panel 10 has a moulded surface 12, which can be made to replicate any textured design whether natural or man made, but is shown in the drawings as simulating a natural stone construction.
The surface 12 of the panel 10 has raised portions 14 which correspond to the ;ndividual stones of such a construction and which are separated by depressions 16 10 corresponding to the areas which the mortar occupies to mailltain the stones in position.
~ s shown in Fig. 2, the panel 1û colllplises a moulded surface layer 18 of cementitious material and a supporting layer 20 of foamed insulating material.
The surface layer 18 preferably covers one surface and all four edges of the supporting layer 20. The cementitious material used for the surface layer 18 is preferably a fast-setting portland/gypsum cement blend such as DURACAL (trade-mark), for exterior use, and HYDROCAL (trade-mark), for interior use. The supporting layer 20 of foamed insulating material is preferab]y a polymeric isocyanate based polyurethane foam which is water- or CO2-blown, and not freon-20 blown, in order to conform to building codes. Water-blown polyurethane foam has an added advantage in that it does not support a flame and, thereby, provides for a safer product.
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An open we~ve scrim-cloth-type material 22 of jute, sisal, polypropylene, ~olyethylene or the like, and preferably having woven openings of approximately l/~, is en~apsulated into the surface layer 18 to ",i~,i",;~t~ the possibility of breaking and to introduce dimensional stability to the panel. In addition, webs 24 may be provided to increase the overall strength and rigidity of the panel.
The thickness t of the surface layer 1~ is maintained substantially consistent and at a predetermined n~ illlulll value, even at the depressions 16, as most building codes require a minimum thickness of flame-resistant material for 10 shielding insulating materials. By making the surface layer 18 consistently thick, substantial weight and material savings can be realized as compared with a panel having a surface layer of a depth d in order to maintain the required Illinilllu thickness at the depression 16.
The panels may be produced in various configurations depending upon the type of surfacing material being simulated, i.e. natural stone, brick, flagstone, wood, etc. For instance, it rnay or may not be desirable to have surface patterns which repeat from panel to panel or to have rectilinear panel edges. In the panel 10 shown in Fig. 1, the pattern of the rnoulded surface 12 is random, simulating a natura.l stone construction. The configuration of the sides 26 is such 20 that the panels 10 may be nested or interlocked with panels having mating sides but having a different moulded surface pattern to eliminate excessive pattern repetition.
Where pattern repetition is not of concern, a single modular panel may be produced with four mating sides wherein the sides may be rectilinear, interlocl~ing ycc/sp 8 .. . .
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, . , ' ' '' . , ' Og~n~7~'~'7 or a combination of both.
According to the type of panel to be produced, model panels of the genuine material are laid out by skilled professionals, duplicating actual construction and me~hods. In the case of the panel 10 shown ;n the drawings, the model panels are laid out using real stone and mortar as would be prepared by a mason. Any one of several techniques such as sand casting, silicone casting or aluminum casting may be used to produce moulds of the model panels, however7 silicone casting is preferred for ease of release of the mould from the original and of the panel from the rnould, and for its ability to capture and duplicate the finest of details.
1() A simplified cross section o~ the resulting mould 30 is shown in Fig.
3. The moukling surface 32 complements precisely the surface of the original model. To create the irlner mould 54 (see Fig. 6), which will be used in the moulding process to maintain the thickness of the surface layer 18 consistent, a complementary "panel" 34 is produced (see Fig. 4) using a similar casting procedure and is removed from the main mould 30. The panel 34 is an exact replica of the original model having corresyonding stone-resembling regions 36 and mortar areas 38 (see Fig. 5). The panel is relieved at lines 40 to create wider definition for the mortar areas 38 and the sides are cut at 42, in order to provide for the predetermined minimum thickness of the surface layer 18. If strengthening webs 24 are to be provided, the panel 34 is cut at 44 into a plurality of sections 48 and trimmed at 46, preferably with a slight taper. The sections 48 are mounted to a support means 50 which may comprise a p]anar backing or a plurality o~ support members. The support means extends outwardly at least to the outer edge of the ycc/sp g -, : - . . ...
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main mould 30 and is employed to maintain the sections 48 in proper position rel~tive to the moulding surface 32, thu~ providing a consistently wide mould cavity 52 ~see Fig. 6).
Referring now to Fig. 7, a s]urry 56 of hydrous cement;tious material is dispensed evenly in the main mould 30. An open weave scrim-cloth-type material 22 is cut to size and is positioned atop the sl-lrry 56 in the mould 30. The scrim-cloth 22 is preferably cut larger than the moukl 30 in order to ensure that the entire surface layer including the edges has a scrim-cloth component.
Using the sectioned inner moulcl 54, the slurry 56 is compacted (see 10 Fig. 8), forcing it to flow throughout the mould cavity 52 and through the woven openings of the scrim-cloth 22 and into the recesses hetween the sections 48 to form the webs 24. The slurry 56 is cured in this campressed state, preferably in infrared thermoreactor-type tunnels, to form a hardened scrim-cloth-lined surface layer shell 58 as shown in Fig. 9. Such tunnels may be advantageously employe~l in the curing process with silicone rnoulds (from which more detailed panels can be produced) without any deleterious effects thereto.
By placing the scrim-cloth 22 atop the slurry, the scrim-cloth 22 is embedded in the surface layer to a sufficient depth to effect reinforcement thereof, yet shallow enough to provide a roughened inner surface 60 to which the foamable 20 insulating material of the supporting layer 20 will more readily adhere. It will be recognized that a smooth inner surface 60 of the surface layer 18 would increase the possibility of del~min~tion of the surface and supporting layers, resulting in a substantially weaker panel ycc/sp , 10 ''', . , ' .
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~r~ ~7~7 A foamable insulating material is injected into the shell 58 and is cured to form the supporting layer 20 (see Fig. 10) ancl to complete the panel 10.
The density and rigidity of the supporting layer 20 and, thus, the overall strength of the panel 10 may be increased significantly if, immediately afler the liquid plastic is injected intQ the surface layer shell 58, the mould is capped and placed in a press for a predetermined amount of time, limiting the extent to which the foam expands.
Preferably, a backing 62 of kraft paper or the like is applied prior to the pressing step. The backing 62 absorbs any gasing generated during curing of the foamed plastic thus elirnin~tin~ the possibility of voids forming in the supporting layer 20. Advanta~eously, the backing 62 becomes saturated with resin from the foam;ng plastics material becoming effectively a waterproof skin.
In an alternate methocl of making the composite building panel 10, the supporting layer 20 of foamed insulating material may be in the form of a pre-formec~ fs~amed insert 64 and used, instead of the inner mould 54, to compress the slurry (see Fig. 11). In this method9 a secondary mould (not shown) is produced in which the foamable insulating material may be formed. Preferably, the secondary mould is made by vacuum-forming a surface shell of plastic on the inner mould 54, thus allowing the foamed insert 64 to be formed with a surface configuration wbich ensures the same consistent surface layer thickness as does the inner mould 54.
The foamed insert 64 is produced in a similar manner as described above, i.e. by injecting a foamable insulating material into the vacuum-formed shell.
If desired, backing 62 is applied and the shell is capped and placed in a press to limit the extent to which the foam expands, thus producing a more dense and rigid ycc/sp 11 - ., .
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insert 64. As shown in Fig. 11, the foamed insert 64 comprises a p]urality of foamed insert sections 68 corresponcling to the inner mould sections 48. The sections 68 are temporarily mounted on support means 50 which maintain the sections 68 in proper position relat;ve to ~he nnoulding surface 32 of the mould 30.
It has been found that a supporting layer 20 which has been produced by injecting a foamable insulating material into the hardened scrim-cloth lined shell 58 adheres better to the surface layer 18 than does a pre-formed supporting layer inserted into a cementitious slurry which is then cured. A decrease in adhesion between the supporting and surface layers increases the tendency of the 10 layers to delaminate. Therefore, in order to increase adherence and to provide additional stability, the foamed sections 68 may be provided with through-ho]es 66 (either as part of their forming procedure or in a subsequent operation) which will allow the cementitious slurry material to flow therethrough during compression.
Various other means or techniques to prevent delamination of the surface and supporting layers may alternatively be employed.
To m~ke the panel in accordance with the alternate method of the invention, a slurry 56 of cementitious material is dispensed into the main rnould 30 and a scrirn-cloth 22 is placed atop the slurry 56. A pre-formed foam insert 64 is then used to compress the slurry 56 to a predetermined thickness (see Fig. 12) and 20 the slurry 56 is cured in this colllpresscd state, preferably in an infrared thermoreactor-type tunnel. When the slurry 56 has hardened, the panel is removed from the mould 30 and the foamed insert support means 50 are removed from the panel.
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In addition to the various surfacing materials which can be emulated, the building panels in accordance with the presen~ invention can be produced in a variety of colours. The slurry 56 may be tinted using conventional mortar tinting materials or elastomeric acrylic type materials, as well as some latex based materials. The main rnould 30 itself can be pre-tinted prior to the dispensing of the slurry by brush or other hand-wiped methods. Alternately, the product may he produced as a single, base-colour panel having the toning or colourant applied as a final operation over the entire surface or portions thereof. In either case, it is possible to produce multi-coloured panels. However, the post-production colouring 10 metho~l is preferable in that it enables panels to be produced and warehoused without finishing colourants, leaving the tinting as a separatc operation which can be performed on an as needed basis and in accordance with a customer's particular request.
Once the panel has been produced and, if desired, finished, the panel preferably undergoes a surface water rinse to remove any collected foreign material.
The washing serves to eliminate streaking or bleeding which occurs as water is dissipated during curing of the surface layer. Minerals contained in the water (or dissolved therein from the cementitious material) are drawn with the water to the surface where the water evaporates, leav;ng behind a residual layer of minerals.
20 This residual layer is susceptible to moisture and, therefore, is prone to the destruc.tive freeze~thaw cycle. The water rinse removes this residual layer thus rendering the surface layer impervious to moisture.
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~ 7 ~J L~ 7 The panels may be installed by app]ying a comnnercially a~ailable adhesive to the back of the panel (or backing 62 if provided) and/or to the surface to which the panel is to be applied and pressing the panel into place. For additional support, the panel may be further secured by standard fasteners such as screws. The panels can be cut by standard wood cutting tools such as a carpenter's handsaw, a circular saw or sabre saw and can be conveniently drilled using standard high-speed drill bits. A matching grouting material may be supplied along with the panels for filling screw holes and joints where necessary.
Although the panel of the present invention has been shown and 10 desired as being relatively planar, it is not necessarily limited to such an embodiment. For example, corner panels for both interior (90~) and exterior (270~) corners may be produced in accordance with the methods described hereinabove.
Such panels would facilitate installation by eliminating the need to form joints at the corners with planar panels, thus, adding to the realistic appearance of the entire panel construction. The present invention may also be extended to produce other constructive or decoratlve features such as lintels for above doorways, without departing from the spirit and scope of the invention as defined in the appended claims.
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Field Of The I~v~ ti()ll The invention relates to a composite building panel and to methods for the manufacLure of the panel. In particular, the inventioll is concerned with a composite panel comprising a supporting layer of insulating material which is adhered to a surface layer of cementitious material in a compression moulding process. An open weave scrim-cloth-type material is encapsulated into the surface layer to, amongst other things, minimi7e the possibility of breakage of the panel and to introduce dimensional stability. The moulding process is used to impart a texture 10 and appearance to the surface layer which can be made to replicate the texture and appearance of conventional surfacing materials.
Bacl~ ou~ Of The Il~vt;~
Stone has been employed as an exterior cladding, i.e. surfacing material, in the building and construction industry for hundreds of years. Today, the cost of natural stone construction tends to limit its application to that srnall portion of the market that can afford such a luxury. Brick and other siding materials have, for the most~part, been used as substitutes due to their relatively low cost compared to naeural stone. There is, however, a need for high quality sur~acing materials which exhibit all the authenticity of conventional surfacing 20 materials, i.e. texture, appearance and durability, but without the cost or application problems associated with natural stone or ex3sting substitutes.
ycc/sp Z't)1784~
Prior Art Prefabricated composite building panels comprising an insulating material core and facing or surfacing materials are known and have been used in the construction industry. Canadian Patent No. 865,354, issued March 9, 1971 to Kenneth W. Pope, discloses a prefabricated building panel comprising a rigid layer of plastics material in cellular form, facing elements which are bonded to one face of the rigid layer in spaced-apart relation, and a granular material adhered to, and imbedded in the plastic between the facing elements. The granular material is generally used to produce a hard, skin-like surface between the facing elements 10 which, depending upon the type of granular material employed, may resemble mortar. The facing elements generally comprise segments of conventional surfacing materials such as brick and stone.
Canadian Patent No. 876,090, issued July 20, 1971 to Donald E.
Shirley et al. describes a composite building panel comprising a core of thermal insulating material encapsulated by a hardened hydraulic cement having disposed therein a fibrous synthetic material such as glass fibre. The method of production of these panels lends itself to long cycle times which the patent mentions as being 24 hours to produce one panel from start to finish.
United States Patent No. 4,044,520, issued August 30, 1977 to Albert 20 G. Barrows, describes a composite building panel comprising a base of expanded polystyrene to which is applied a polymer fortified concrete facing. An acrylic binder with quartz crystals carried thereon is provided over the concrete facing to enhance the appearance of the panel and to illlprove its resistance to impact.
yCC/ jm 2 Canaclian Patent No. 1,254,762, issued May 30, 1989 to David L.
Roodvoets, describes ~ prefabricated cement-fo~m composite p~nel co~ isil~g an insu]ating base of synthetic resinous foam and a layer of ]ight-weight cementitious material bonded by a latex adhesive thereto. The cementitious layer is constructed of foam cement and a light-weight aggregate. This panel is particularly suited for use ns a roofing panel.
SUMMARY OF THE lNVENTION
The present invention provides an innovative interior/exterior surfacing alternative to brick or conventional siding materials, without the costs and l0 application problems associated therewith. The invention represents an pl~vement over prior art composite building panels in that the surface of the panel can be made to replicate any conventional surfacing material, either natural or man-made, in texture aml appearance while exceeding the insulative properties thereo~ In addition, the panels are relatively light-weight, requiring less structure to support the weight of the fac~ade as compared wi~h that for natural stone, and they can be easily installed, even by inexperienced persons. Installation can be achieved year round in all weather conditions employing readily available industrial adhesives and fasteners. The panels can be cut by standard wood cutting tools such as a carpenter's handsaw, a circular saw or sabre saw and can be conveniently 20 drille~l using standard high-speed drill bits. The method of manufacture of the panels leads to fast production times and, therefore, a more cost-efficient panelg and results in a panel of generally uni~orm weight regardless of the surface ycc/ jm - - .
~7~
configuration. Various fininshing techniques allow the panels ~o be produced in a variety of colours or tones, including multi-tonal colour variations.
Accordingly, there is provided in one aspect of the invention a composite building panel which comprises a surface layer of cementitious material to which is adhered a supporting layer of foamed insulating material in a compression moulding proGess. An open weave scrim-cloth-type material is embodied within the surface layer to minimi7e the possibility of breakage (increases impact resistance) and to introduce dimensional stability to the panel. A mould is used to impart a texture and appearance to the surface layer which recreates all the 10 authenticity of the original surfacing or siding material from which the mould was produced. Although the surface ]ayer is moulded, the thickness of the surface layer is maintained subst~nti llly consistent and at a predetermined minimum.
According to a second aspect of the invention, there is provided a method of making a composiLè building panel co~ g the steps of:
a) dispensing a slurry of cementitious material in a mould;
b) placing a scrim-cloth-type material atop the slurry in the moukl;
c) colllpres~il.g the slurry to a predetermined thickness;
d) curing the compressed slurry to ~orm a shell;
e) injecting a foamable insu]ating material into the shell; and f) euring the foamable insulating material.
The density and rigidity of the foamed supporting layer may be increased significantly if, immediatély after the foamable insulating material is injected into the shell, the mould is capped and placed in a press for a ycc/ jï~ 4 predeterrnined amounl of time, thus l;miting the extent to which the foam expancls.
The thickness of the surface layer may be maintained substantially consistent and at a predetermined minimum by providing an inner moukl which is use(l to compress the slurry in the mould. The moulding surface of the inner mould resembles the moulding surface of the main mould, but provides areas of wider or narrower definition to maintain the thickness of the surface.
The curing of the slurry is an exothermic process wherein heat is generated during hydration and any excessive moisture is dissipated fram the mass.
Direct heat cannot be used to force-cure the slurry as the outer surface thereof 1() would cure before excessive moisture in the interior could be dissipated which would lend to cracking as the moisture tries to escape. In order to accelerate the hardening process, it is possible to employ infrared thermoreactor-type curing tunnels. The nature of these ~unnels is such that they do not cure or dry the slurry by means of direct heat but rather they aid in the dissipation of ~cessiv~ moisture by maintaining a very dry (low relative humidity) atmosphere in the tunnel. The use of such tunnels dramatically reduces the curing time for the surface layer and, thus, significantly decreases the overall production time for the panels. Because no t;~ccssive heat is generated in the thermoreactor tunnels, the hardened surface layer shells can be handled immediately upon removal from the tunnel arld problems ~0 associated with thermal expansion in the forrnation of laminar materials are avoided.
In an alternate method of making the composite building panel, the supporting layer of foamed insulating material may be pre-formed and used, instead of the inner mould, to con~ ess the slurry. Infrared thermoreactor-type tunnels ycc/jm 5 t~
may then be advantageously employed in curing the compressed slurry, without melting or burning the supporting layer of foarned insulating material.
Typically, a 4' x 4' x 2" panel producecl in accordance with the invention and having a surface layer thickness of a~plu~hllately 3/8" exhibits an over-all weight of about 80 Ibs or about S ]bs/ft2, and can be produced in a~ o.~ lately 30 minutes when infrared thermoreactor-type tunnels are used in the curing process.
The panel has zero surface flame spread, is impervious to moisture, and resists the freeze-thaw cycle which is destructive to many construction materials.
Further features and advantages will be described hereinbelow in 10 conjunction with the accompanying drawings.
BRIEF DESCRlPTION OF THE DI~W~N(;S
Fig. 1 is a plan view of a composite building panel in accordance with the preferred ernbodiment of the invention.
Fig. 2 is a cross-sectional view of the panel along line 2-2 in Fig. 1.
Figs. 3 to 6 are cross-sectional views, showing only those features at the plane of cross-section, of dirrerelll stages in the mould making procedure.
Figs. 7 and 8 are cross-sectional views of the surface layer shell being made in accordance with the method of the invention.
Fig. 9 is an oblique view in section of a typical surface layer shell 20 made in accordance with one method of the invention.
Fig. 10 is an oblique view in section alld partially broken away showing the panel made in accordance with the invention.
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7~7 Figs. 11 and 12 are cross-sectional views of the panel being made in accordance with the alternate metllod of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODlMENT
Figs. 1 and 2 illustrate a composite building panel 10 in accordance with the preferred embodiment of the invention. The panel 10 has a moulded surface 12, which can be made to replicate any textured design whether natural or man made, but is shown in the drawings as simulating a natural stone construction.
The surface 12 of the panel 10 has raised portions 14 which correspond to the ;ndividual stones of such a construction and which are separated by depressions 16 10 corresponding to the areas which the mortar occupies to mailltain the stones in position.
~ s shown in Fig. 2, the panel 1û colllplises a moulded surface layer 18 of cementitious material and a supporting layer 20 of foamed insulating material.
The surface layer 18 preferably covers one surface and all four edges of the supporting layer 20. The cementitious material used for the surface layer 18 is preferably a fast-setting portland/gypsum cement blend such as DURACAL (trade-mark), for exterior use, and HYDROCAL (trade-mark), for interior use. The supporting layer 20 of foamed insulating material is preferab]y a polymeric isocyanate based polyurethane foam which is water- or CO2-blown, and not freon-20 blown, in order to conform to building codes. Water-blown polyurethane foam has an added advantage in that it does not support a flame and, thereby, provides for a safer product.
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An open we~ve scrim-cloth-type material 22 of jute, sisal, polypropylene, ~olyethylene or the like, and preferably having woven openings of approximately l/~, is en~apsulated into the surface layer 18 to ",i~,i",;~t~ the possibility of breaking and to introduce dimensional stability to the panel. In addition, webs 24 may be provided to increase the overall strength and rigidity of the panel.
The thickness t of the surface layer 1~ is maintained substantially consistent and at a predetermined n~ illlulll value, even at the depressions 16, as most building codes require a minimum thickness of flame-resistant material for 10 shielding insulating materials. By making the surface layer 18 consistently thick, substantial weight and material savings can be realized as compared with a panel having a surface layer of a depth d in order to maintain the required Illinilllu thickness at the depression 16.
The panels may be produced in various configurations depending upon the type of surfacing material being simulated, i.e. natural stone, brick, flagstone, wood, etc. For instance, it rnay or may not be desirable to have surface patterns which repeat from panel to panel or to have rectilinear panel edges. In the panel 10 shown in Fig. 1, the pattern of the rnoulded surface 12 is random, simulating a natura.l stone construction. The configuration of the sides 26 is such 20 that the panels 10 may be nested or interlocked with panels having mating sides but having a different moulded surface pattern to eliminate excessive pattern repetition.
Where pattern repetition is not of concern, a single modular panel may be produced with four mating sides wherein the sides may be rectilinear, interlocl~ing ycc/sp 8 .. . .
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, . , ' ' '' . , ' Og~n~7~'~'7 or a combination of both.
According to the type of panel to be produced, model panels of the genuine material are laid out by skilled professionals, duplicating actual construction and me~hods. In the case of the panel 10 shown ;n the drawings, the model panels are laid out using real stone and mortar as would be prepared by a mason. Any one of several techniques such as sand casting, silicone casting or aluminum casting may be used to produce moulds of the model panels, however7 silicone casting is preferred for ease of release of the mould from the original and of the panel from the rnould, and for its ability to capture and duplicate the finest of details.
1() A simplified cross section o~ the resulting mould 30 is shown in Fig.
3. The moukling surface 32 complements precisely the surface of the original model. To create the irlner mould 54 (see Fig. 6), which will be used in the moulding process to maintain the thickness of the surface layer 18 consistent, a complementary "panel" 34 is produced (see Fig. 4) using a similar casting procedure and is removed from the main mould 30. The panel 34 is an exact replica of the original model having corresyonding stone-resembling regions 36 and mortar areas 38 (see Fig. 5). The panel is relieved at lines 40 to create wider definition for the mortar areas 38 and the sides are cut at 42, in order to provide for the predetermined minimum thickness of the surface layer 18. If strengthening webs 24 are to be provided, the panel 34 is cut at 44 into a plurality of sections 48 and trimmed at 46, preferably with a slight taper. The sections 48 are mounted to a support means 50 which may comprise a p]anar backing or a plurality o~ support members. The support means extends outwardly at least to the outer edge of the ycc/sp g -, : - . . ...
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main mould 30 and is employed to maintain the sections 48 in proper position rel~tive to the moulding surface 32, thu~ providing a consistently wide mould cavity 52 ~see Fig. 6).
Referring now to Fig. 7, a s]urry 56 of hydrous cement;tious material is dispensed evenly in the main mould 30. An open weave scrim-cloth-type material 22 is cut to size and is positioned atop the sl-lrry 56 in the mould 30. The scrim-cloth 22 is preferably cut larger than the moukl 30 in order to ensure that the entire surface layer including the edges has a scrim-cloth component.
Using the sectioned inner moulcl 54, the slurry 56 is compacted (see 10 Fig. 8), forcing it to flow throughout the mould cavity 52 and through the woven openings of the scrim-cloth 22 and into the recesses hetween the sections 48 to form the webs 24. The slurry 56 is cured in this campressed state, preferably in infrared thermoreactor-type tunnels, to form a hardened scrim-cloth-lined surface layer shell 58 as shown in Fig. 9. Such tunnels may be advantageously employe~l in the curing process with silicone rnoulds (from which more detailed panels can be produced) without any deleterious effects thereto.
By placing the scrim-cloth 22 atop the slurry, the scrim-cloth 22 is embedded in the surface layer to a sufficient depth to effect reinforcement thereof, yet shallow enough to provide a roughened inner surface 60 to which the foamable 20 insulating material of the supporting layer 20 will more readily adhere. It will be recognized that a smooth inner surface 60 of the surface layer 18 would increase the possibility of del~min~tion of the surface and supporting layers, resulting in a substantially weaker panel ycc/sp , 10 ''', . , ' .
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~r~ ~7~7 A foamable insulating material is injected into the shell 58 and is cured to form the supporting layer 20 (see Fig. 10) ancl to complete the panel 10.
The density and rigidity of the supporting layer 20 and, thus, the overall strength of the panel 10 may be increased significantly if, immediately afler the liquid plastic is injected intQ the surface layer shell 58, the mould is capped and placed in a press for a predetermined amount of time, limiting the extent to which the foam expands.
Preferably, a backing 62 of kraft paper or the like is applied prior to the pressing step. The backing 62 absorbs any gasing generated during curing of the foamed plastic thus elirnin~tin~ the possibility of voids forming in the supporting layer 20. Advanta~eously, the backing 62 becomes saturated with resin from the foam;ng plastics material becoming effectively a waterproof skin.
In an alternate methocl of making the composite building panel 10, the supporting layer 20 of foamed insulating material may be in the form of a pre-formec~ fs~amed insert 64 and used, instead of the inner mould 54, to compress the slurry (see Fig. 11). In this method9 a secondary mould (not shown) is produced in which the foamable insulating material may be formed. Preferably, the secondary mould is made by vacuum-forming a surface shell of plastic on the inner mould 54, thus allowing the foamed insert 64 to be formed with a surface configuration wbich ensures the same consistent surface layer thickness as does the inner mould 54.
The foamed insert 64 is produced in a similar manner as described above, i.e. by injecting a foamable insulating material into the vacuum-formed shell.
If desired, backing 62 is applied and the shell is capped and placed in a press to limit the extent to which the foam expands, thus producing a more dense and rigid ycc/sp 11 - ., .
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insert 64. As shown in Fig. 11, the foamed insert 64 comprises a p]urality of foamed insert sections 68 corresponcling to the inner mould sections 48. The sections 68 are temporarily mounted on support means 50 which maintain the sections 68 in proper position relat;ve to ~he nnoulding surface 32 of the mould 30.
It has been found that a supporting layer 20 which has been produced by injecting a foamable insulating material into the hardened scrim-cloth lined shell 58 adheres better to the surface layer 18 than does a pre-formed supporting layer inserted into a cementitious slurry which is then cured. A decrease in adhesion between the supporting and surface layers increases the tendency of the 10 layers to delaminate. Therefore, in order to increase adherence and to provide additional stability, the foamed sections 68 may be provided with through-ho]es 66 (either as part of their forming procedure or in a subsequent operation) which will allow the cementitious slurry material to flow therethrough during compression.
Various other means or techniques to prevent delamination of the surface and supporting layers may alternatively be employed.
To m~ke the panel in accordance with the alternate method of the invention, a slurry 56 of cementitious material is dispensed into the main rnould 30 and a scrirn-cloth 22 is placed atop the slurry 56. A pre-formed foam insert 64 is then used to compress the slurry 56 to a predetermined thickness (see Fig. 12) and 20 the slurry 56 is cured in this colllpresscd state, preferably in an infrared thermoreactor-type tunnel. When the slurry 56 has hardened, the panel is removed from the mould 30 and the foamed insert support means 50 are removed from the panel.
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In addition to the various surfacing materials which can be emulated, the building panels in accordance with the presen~ invention can be produced in a variety of colours. The slurry 56 may be tinted using conventional mortar tinting materials or elastomeric acrylic type materials, as well as some latex based materials. The main rnould 30 itself can be pre-tinted prior to the dispensing of the slurry by brush or other hand-wiped methods. Alternately, the product may he produced as a single, base-colour panel having the toning or colourant applied as a final operation over the entire surface or portions thereof. In either case, it is possible to produce multi-coloured panels. However, the post-production colouring 10 metho~l is preferable in that it enables panels to be produced and warehoused without finishing colourants, leaving the tinting as a separatc operation which can be performed on an as needed basis and in accordance with a customer's particular request.
Once the panel has been produced and, if desired, finished, the panel preferably undergoes a surface water rinse to remove any collected foreign material.
The washing serves to eliminate streaking or bleeding which occurs as water is dissipated during curing of the surface layer. Minerals contained in the water (or dissolved therein from the cementitious material) are drawn with the water to the surface where the water evaporates, leav;ng behind a residual layer of minerals.
20 This residual layer is susceptible to moisture and, therefore, is prone to the destruc.tive freeze~thaw cycle. The water rinse removes this residual layer thus rendering the surface layer impervious to moisture.
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~ 7 ~J L~ 7 The panels may be installed by app]ying a comnnercially a~ailable adhesive to the back of the panel (or backing 62 if provided) and/or to the surface to which the panel is to be applied and pressing the panel into place. For additional support, the panel may be further secured by standard fasteners such as screws. The panels can be cut by standard wood cutting tools such as a carpenter's handsaw, a circular saw or sabre saw and can be conveniently drilled using standard high-speed drill bits. A matching grouting material may be supplied along with the panels for filling screw holes and joints where necessary.
Although the panel of the present invention has been shown and 10 desired as being relatively planar, it is not necessarily limited to such an embodiment. For example, corner panels for both interior (90~) and exterior (270~) corners may be produced in accordance with the methods described hereinabove.
Such panels would facilitate installation by eliminating the need to form joints at the corners with planar panels, thus, adding to the realistic appearance of the entire panel construction. The present invention may also be extended to produce other constructive or decoratlve features such as lintels for above doorways, without departing from the spirit and scope of the invention as defined in the appended claims.
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Claims (26)
1. A method of making a composite building panel comprising the steps of:
a) dispensing a slurry of cementitious material into a mould;
b) positioning a scrim-cloth-type material atop the slurry in the mould;
c) compressing the slurry to a consistent predetermined thickness;
d) curing the compressed slurry to form a surface layer shell;
e) injecting a foamable insulating material into the surface layer shell; and f) curing the foamable insulating material
a) dispensing a slurry of cementitious material into a mould;
b) positioning a scrim-cloth-type material atop the slurry in the mould;
c) compressing the slurry to a consistent predetermined thickness;
d) curing the compressed slurry to form a surface layer shell;
e) injecting a foamable insulating material into the surface layer shell; and f) curing the foamable insulating material
2. The method according to claim 1, wherein the slurry is cured in a tunnel employing infrared thermoreactors.
3. The method according to claim 1, wherein the slurry is compressed in the mould by an inner mould for maintaining the thickness of the compressed slurry substantially at a consistent and predetermined minimum.
4. The method according to claim 1, wherein after the step of injecting the foamable insulating material into the surface layer shell, the mould is capped and placed in a press to limit the extent to which the foamable insulating material expands.
5. The method according to claim 4, wherein a backing is appled prior to capping the mould.
6. Method according to claim 1, including the further step of rinsing the surface layer with water.
7. The method according to claim 1, wherein prior to the step of dispensing the slurry, the slurry is tinted.
8. The method according to claim 1, wherein prior to the step of dispensing the slurry, the mould is pre-tinted.
9. The method according to claim 6 including the further step of applying a colourant to the surface layer.
10. A method of making a composite building panel comprising the steps of:
a) dispensing a slurry of cementitious material in a mould;
b) positioning a scrim-cloth atop the slurry in the mould;
c) producing a pre-formed section of foamed insulating material;
d) compressing the slurry with the pre-formed section to a consistent predetermined thickness;
e) curing the compressed slurry to form the panel.
a) dispensing a slurry of cementitious material in a mould;
b) positioning a scrim-cloth atop the slurry in the mould;
c) producing a pre-formed section of foamed insulating material;
d) compressing the slurry with the pre-formed section to a consistent predetermined thickness;
e) curing the compressed slurry to form the panel.
11. The method according to claim 10 wherein the slurry is cured in a tunnel employing infrared thermoreactors.
12. The method according to claim 10, wherein the preformed section of foamed insulating material is produced by:
injecting a foamable insulating material into a secondary mould; and curing said foamable material.
injecting a foamable insulating material into a secondary mould; and curing said foamable material.
13. The method according to claim 11, wherein after the step of injecting the foamable insulating material into the secondary mould, the secondary mould is capped and placed in a press to limit the extent to which the foamable insulating material expands.
14. The method according to claim 13, wherein a backing is appled prior to capping the secondary mould.
15. Method according to claim 8, including the further step of rinsing the surface layer with water.
16. The method according to claim 10, wherein prior to the step of dispensing the slurry, the slurry is tinted.
17. The method according to claim 10, wherein prior to the step of dispensing the slurry, the mould is pre-tinted.
18. The method according to claim 15 including the further step of applying a colourant to the panel.
19. A composite building panel comprising:
a surface layer of cementitious material simulating conventional surfacing materials in texture and appearance and having a consistent predetermined thickness;
an open weave scrim-cloth-type material encapsulated within said surface layer of cementitious material; and a supporting layer of foamed insulating material adhered to said surface layer.
a surface layer of cementitious material simulating conventional surfacing materials in texture and appearance and having a consistent predetermined thickness;
an open weave scrim-cloth-type material encapsulated within said surface layer of cementitious material; and a supporting layer of foamed insulating material adhered to said surface layer.
20. The panel of Claim 19 wherein said supporting layer is adhered to said surface layer is a compression moulding process.
21. The panel of Claim 19 wherein said cementitious material is a fast-setting gypsum/portland cement blend.
22. The panel of Claim 19 wherein said scrim-cloth-type material is chosen from the group consisting of sisal, jute, polypropylene and polyethylene.
23. The panel of Claim 19 wherein said foamed insulating material is polyurethane.
24. The panel of Claim 19 wherein said surface layer covers one surface and all four edges of said supporting layer.
25. A composite building panel comprising a surface layer of cementitious material having an open weave scrim-cloth-type material encapsulated within said surface layer and a supporting layer of foamed insulating material, said panel produced by the process of:
a) dispensing a slurry of said cementitious material into a mould;
b) positioning said scrim-cloth-type material atop the slurry in the mould;
c) compressing the slurry to a consistent predetermined thickness;
d) curing the compressed slurry to form a surface layer shell;
e) injecting said foamable insulating material into the surface layer shell;
and f) curing the foamable insulating material.
a) dispensing a slurry of said cementitious material into a mould;
b) positioning said scrim-cloth-type material atop the slurry in the mould;
c) compressing the slurry to a consistent predetermined thickness;
d) curing the compressed slurry to form a surface layer shell;
e) injecting said foamable insulating material into the surface layer shell;
and f) curing the foamable insulating material.
26. A composite building panel comprising a surface layer of cementitious material having an open weave scrim-cloth-type material encapsulated within said surface layer and a supporting layer of foamed insulating material, said panel produced by the process of:
a) dispensing a slurry of said cementitious material into a mould;
b) positioning a scrim-cloth atop the slurry in the mould;
c) producing a pre-formed section of said foamed insulating material;
d) compressing the slurry with the pre-formed section to a consistent predetermined thickness; and e) curing the compressed slurry to form the panel.
a) dispensing a slurry of said cementitious material into a mould;
b) positioning a scrim-cloth atop the slurry in the mould;
c) producing a pre-formed section of said foamed insulating material;
d) compressing the slurry with the pre-formed section to a consistent predetermined thickness; and e) curing the compressed slurry to form the panel.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2017847 CA2017847C (en) | 1990-05-30 | 1990-05-30 | Composite building panel |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2017847 CA2017847C (en) | 1990-05-30 | 1990-05-30 | Composite building panel |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2017847A1 CA2017847A1 (en) | 1991-11-30 |
| CA2017847C true CA2017847C (en) | 1998-12-22 |
Family
ID=4145098
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2017847 Expired - Fee Related CA2017847C (en) | 1990-05-30 | 1990-05-30 | Composite building panel |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2017847C (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CA2312657A1 (en) * | 1999-06-30 | 2000-12-30 | Shinichi Kaneko | Building boards, manufacturing apparatus and prefoamed plastics |
| GB2480253B (en) * | 2010-05-10 | 2016-08-03 | Acell Ind Ltd | Composite products |
| CN108590017B (en) * | 2018-04-20 | 2019-11-26 | 长安大学 | A kind of fabric concrete segment and preparation method |
-
1990
- 1990-05-30 CA CA 2017847 patent/CA2017847C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CA2017847A1 (en) | 1991-11-30 |
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