ES2925889T3 - Insulated wall panel with a plurality of aesthetic cladding elements - Google Patents

Abstract

A wall panel may have a skin layer, an intermediate layer made of magnesium oxide, and an insulating layer made of two-part rigid urethane foam. The insulation layer can be chemically bonded to the intermediate layer. The skin layer may include a poured substrate made of polyurethane or plastic. The skin layer can further include aesthetic elements embedded in and bonded to the poured substrate. Aesthetic elements may include one or more of brick, ceramic tile, porcelain tile, natural stone, engineered stone, wood, ceramic, plastic, or vinyl. A finished surface of the aesthetic elements may extend above the top surface of the poured substrate. The poured substrate may include sand which causes the top surface of the poured substrate to have a mortared appearance. (Automatic translation with Google Translate, without legal value)

Description

DESCRIPTION

Insulated wall panel with a plurality of aesthetic cladding elements

The invention relates to the field of building construction materials. More particularly, the invention relates to the field of building components used in the construction of walls, ceilings and other flat, angled and curved surfaces for buildings.

Humans have used bricks and other hard surfaces as building construction components for thousands of years. The first sun-dried bricks were made in Ancient Egypt. Later, the bricks were dried by using a fuel source. The Book of Genesis records that fired brick was used in the construction of the Tower of Babel. Therefore, from ancient times to the present, brick has remained a popular building material.

Brick's enduring presence is due in large part to its stellar properties as an exterior surface. The bricks are able to resist the strong heat of the summer, as well as the cold winters and the changes between them. In addition to these thermal properties, brick provides a strong outer shell for a building. Brick resists wind, rain, snow, dust, and other damaging environmental elements. Brick can be a fireproof surface for buildings. Bricks can be made in a wide variety of sizes, textures, and colors. Also, although it is not necessary to paint it, when a brick is painted, the paint adheres well to the brick.

However, despite these positive characteristics, the brick has some drawbacks, mainly related to installation. For example, while other exterior surfaces can be applied relatively easily to an existing building structure, brick is much more difficult to install in an existing building as an alternative cladding option during a renovation. Furthermore, laying bricks during the construction of a building is a labor intensive operation. Each brick must be puttyed and placed, one on top of the other, brick by brick, by a skilled mason. As labor prices rise in a given market, so do the costs associated with using brick as a building material. It is also difficult or impossible to install brick during the winter because the mortar does not cure well or does not cure at all in sub-zero temperatures.

Therefore, there is a need for a building product that has the same or better construction characteristics and aesthetic appeal than traditional brick, but can also be applied without the need for an extensive team of skilled labor masons. In addition, there is a need for a building product that has the same or better building characteristics and aesthetic appeal than traditional brick that can be used as a retrofit product to provide cladding to an existing building structure. Additionally, as energy costs and environmental awareness rise, so does the demand for better insulation. Therefore, there is also a need for building materials that offer improved insulation of a building envelope.

US 3 868 801 A teaches a wall panel comprising a poured substrate comprising a polyester mortar with a reinforcing mesh embedded therein; an insulation layer having a first side chemically bonded to the substrate; and a plurality of aesthetic elements embedded in and attached to the poured substrate; wherein the aesthetic elements are selected from the group consisting of brick, ceramic tile, porcelain tile, natural stone, engineered stone, wood, ceramic, plastic, and vinyl; wherein the insulation layer comprises a urethane foam; wherein a finished surface of the aesthetic elements extends above the top surface of the poured substrate; and wherein each of the aesthetic elements is in a spaced relationship with another of the aesthetic elements.

Similar wall panels are taught in US 2014/069050 A1 and US 2014/083040 A1.

Summary of the invention

The present invention is therefore a wall panel as defined in claim 1 that exhibits many of the same characteristics as traditional brick without the need for the high labor costs associated with traditional brick masonry. Furthermore, the invention is not limited to new construction applications, but can be used in existing construction as a retrofit application.

The invention has the same aesthetic appeal as traditional brick and has the same or better engineering benefits. The invention functions as a building structural element, a water-resistive barrier, a fire-retardant layer, an insulating envelope, and an aesthetically finished exterior surface. The invention is lightweight and energy efficient.

The invention may include an outer layer of cladding, an intermediate layer of cement, and an inner layer of insulation.

The exterior cladding layer may be thin brick, stone, tile, or other similar material (hereinafter referred to as "brick" unless otherwise specified) as desired for both aesthetic and engineering appeal. These can be referred to as an architectural or aesthetic element. Alternatively, the outer cladding layer may be in two parts comprising thin brick, stone, tile or other material that is embedded in a substrate. This substrate can be a polyurethane or other plastic. According to this two-part facing layer embodiment of the invention, the brick is placed in a mold in a desired pattern and polyurethane, plastic or other material is poured into the mold and bonded to the brick. A finished brick surface will extend above the level of the poured substrate once the substrate hardens. In accordance with another embodiment of the invention, sand may be added to the substrate so that an upper surface of the substrate, visible between the bricks, has the appearance of mortar. In the example above, additional mortar or a mortar substitute (such as a sand based adhesive) can be used to cover the screw holes or gaps between sections.

The intermediate layer of cement can be concrete reinforced with fiberglass. Alternatively, the cement interlayer may be magnesium oxide. The cement interlayer may be poured and cured in place or may be obtained as a prefabricated product, particularly with respect to the magnesium oxide material.

The inner insulation layer includes a rigid cast foam which is a two part rigid cast urethane foam.

In accordance with the invention, a wall panel includes a poured substrate selected from the group consisting of polyurethane and plastic. The wall panel may further include a plurality of aesthetic elements, embedded in and bonded to the poured substrate. The aesthetic element is selected from the group consisting of brick, ceramic tile, porcelain tile, natural stone, engineered stone, wood, ceramic, plastic, and vinyl. A finished surface of the aesthetic elements extends above the top surface of the poured substrate. Each of the aesthetic elements is disposed in a spaced relationship with another of the aesthetic elements.

In accordance with the invention, the wall panel includes an intermediate layer having a first side that is bonded to a rear surface of the poured substrate. The wall panel also includes an insulation layer having a first side chemically bonded to a second side of the intermediate layer. The insulation layer includes a two-part rigid urethane pour foam. The insulation layer can be chemically bonded to the intermediate layer during pouring.

According to another embodiment of the invention, the intermediate layer can be magnesium oxide.

According to another embodiment of the invention, the intermediate layer can be made of fiber-reinforced cement.

According to another embodiment of the invention, the interlayer can be attached to the poured substrate using attachment means such as screws, nails, bolts, welds, construction adhesive, rivets, and hooks.

In accordance with another embodiment of the invention, the wall panel may be attached to a building structure through the use of attachment means such as screws, nails, bolts, welds, construction adhesive, rivets, and hooks.

In accordance with another embodiment of the invention, the poured substrate may also include sand, which gives the top surface of the poured substrate a mortar-like appearance.

In accordance with another embodiment of the invention, the wall panel may further include sanded adhesive to cover imperfections in the top surface of the poured substrate and to make the top surface of the poured substrate have a grouted appearance.

In accordance with one embodiment of the invention, a wall panel may include an intermediate layer made of magnesium oxide. The intermediate layer has a first and a second side. A skin layer may be bonded to the first side of the intermediate layer. According to such an embodiment, the veneer layer may include one or more of brick, ceramic tile, porcelain tile, natural stone, engineered stone, wood, ceramic, plastic, vinyl, and paint.

In accordance with another embodiment of the invention, an insulation layer may have a first side chemically bonded to a second side of the intermediate layer. The insulation layer includes a two-part rigid urethane pouring foam and the insulation layer can be chemically bonded to the interlayer during pouring.

In accordance with one embodiment of the invention, a wall panel may include an intermediate layer made of magnesium oxide. The intermediate layer has a first and a second side. The wall panel may also include a facing layer bonded to the first side of the intermediate layer. The wall panel also has an insulation layer. The insulation layer may have a first side chemically bonded to a second side of the intermediate layer. The Insulation layer is made from a two-part rigid urethane foam and can be chemically bonded to the interlayer during pouring.

In one embodiment, the inner insulation layer is poured over and fixedly attached to the intermediate layer of cement. The exterior cladding layer is bonded to the cement interlayer with mortar or another cement product. Alternatively, in the embodiment utilizing the two-part liner layer, the liner layer substrate may be attached to the cement interlayer by means of set screws (or nails, wall ties, or other similar means of attachment). Such set screws can be placed between spaces in the brick and extend through the veneer layer substrate into the cement layer and even into the insulation layer. Preferably, the sheathing screws do not extend beyond the insulation layer in exterior applications.

According to another embodiment, the skin layer may be bonded to the intermediate layer with a chemical or other construction adhesive. The decal can be a one-piece design or a multi-piece design.

In accordance with another embodiment of the invention, the cladding layer may be brick, tile, stone, engineered stone, or another similar product that is desired for aesthetic purposes. The mortar or other adhesive used to bond the veneer can also be used to grout the lines between the brick, stone, or tile in the veneer, or another product such as a grout can be applied.

In accordance with another embodiment of the invention, the skin layer may include spaced apart latitudinal ridges on a rear surface of the skin layer. Such latitudinal ridges may have a width narrower than the space between the ridges. Latitudinal ridges can create channels for the escape of moisture, gas, and other fluids that can collect between the liner layer and the interlayer.

In accordance with one embodiment of the invention, in embodiments where a two-part facing layer is not used and the bricks are adhered directly to the cement layer, the intermediate cement layer may include relief lines or lines of relief. guide. The relief lines serve as a guide when bonding the coating layer to the cement layer. For example, when the veneer layer uses rectangular brick, the relief lines will be in the shape of the rectangular brick and slightly larger than the perimeter of the brick, so that the brick fits snugly within the relief lines when laying. the application. Similarly, if stone is the veneer layer, the relief lines will match and be slightly larger than the perimeter of the stone being installed.

According to another embodiment of the invention, the respective inner layer and intermediate cement layer are built into panels designed to be attached to a building frame. The panels may be attached directly to the studs of a building or may be attached to some other structural component of the building.

In accordance with another embodiment of the invention, the panels are joined by the use of screws such as structural insulated panel (SIP) screws. SIP screws are attached to the building through through holes in the panel. The holes can be countersunk so that the screw heads are flush with the panel surface.

According to another embodiment, the points of attachment or other elements, such as a PVC inlay, can be incorporated in the intermediate layer of cement. Such items shall be of a material that does not adversely affect the performance or other property of the insulation or cause a conductive source of thermal absorption.

In accordance with another embodiment of the invention, the panels are joined by the use of nails, construction adhesive, bolts, rivets, hooks, or other similar joining devices.

According to another embodiment of the invention, once the panels are fixed to the building, the joints between the panels are sealed.

According to another embodiment of the invention, once sealed, the lining layer is applied over the intermediate layer of cement. In embodiments utilizing the two part liner layer, screws may be used to attach the liner layer to the cement interlayer as described above. However, in the modes where the brick is attached directly to the cement layer (the mode without the substrate in the facing layer), during application, mortar or other fixing material is applied to the panels and brick. or other material is placed between the relief lines. The bricks cover the SIP screw holes and also, more importantly, cover the panel seams. Therefore, there are no exposed seams or other panel openings.

According to another embodiment of the invention, trim pieces are applied around openings in the building envelope, such as around windows and doors. These trim pieces can be in the form of headers and can include various shapes as desired for structural and aesthetic purposes. The trim pieces can be formed in two parts as described above with respect to the skin layer. That is, the trim pieces may comprise bricks embedded in a substrate. In this way, according to a manufacturing process, the brick can be placed in a mold and can be coated with wax. Liquid substrate (polyurethane or plastic) can be poured into the mold around the brick. This substrate adheres to the brick.

In accordance with another embodiment of the invention, the corner pieces are attached to the ends of the panel at the corners of the building, or where corners are required, and then brick or other material is laid as desired over the corner pieces with only panels. The corner pieces may alternatively be formed using the two-part cladding system as described above with respect to the trim pieces and the outer cladding layer.

In accordance with another embodiment of the invention, the panels provide a continuous insulating envelope for the walls of a structure. The inner insulation layer can be one inch thick and can also be three inches thick or more. Such insulation can provide panels with an insulation factor of R7 to R21 or higher depending on various design factors.

Such insulation regimen applied to the exterior walls of a structure may, depending on other building and environmental factors such as zoning, building codes, etc., free up space within the stud walls for other building elements. , such as wiring, plumbing, etc. and it can also reduce the size of studs required for a particular building plan. For example, while 2X6 or 2X8 studs may have been required to achieve a desired insulation factor, when using the invention as an outer envelope, 2X4 studs may suffice. Similarly, in a retrofit application, where an older building may have little or no insulation, significant insulation, as well as aesthetics, can be obtained by applying the invention to the existing building.

Brief description of the drawings

The characteristics, aspects and advantages of a preferred embodiment of the invention will be better understood when the detailed description is read with reference to the accompanying drawings, in which:

Figure 1 is an exploded perspective view of one embodiment of the invention showing the layers; Figure 2 is a partial perspective view of one embodiment of the invention showing two adjacent panels and highlighting the joining of the panels to a wall;

Figure 3 is a perspective view of one embodiment of the invention showing a panel without the outer skin layer attached;

Figure 4 is a perspective view of an embodiment of the invention showing two adjacent panels with the outer cladding layer partially attached and covering the joint between the two adjacent panels;

Figure 5 is a perspective view of one embodiment of the invention showing adjacent panels with the outer skin layer partially attached and covering the joint between two adjacent panels;

Figure 6 is an exploded view of one embodiment of the invention showing the layers;

Figure 7 is a partially exploded view of one embodiment of the invention showing the cement interlayer adhered to the insulation layer and showing the brick embedded in the substrate forming the two-part cladding layer;

Figure 8 is a sectional view of an embodiment of the invention attached to a flat surface;

Figure 9 is a sectional view of an embodiment of the invention attached to a plurality of uprights; Figure 10 is a sectional view of one embodiment of the invention showing the use of dovetail bricks;

Figure 11 is a partial front view of an embodiment of the invention showing the joints between panels and joint means; Y

Figure 12 is a partial front view of one embodiment of the invention showing the pointed mortar between the brick and the joints between the panels and the joining means which have not yet been covered with mortar or other concealing compound;

Detailed description

It should be understood by one of ordinary skill in the art that the present description is a description of illustrative embodiments only and is not intended to limit the broader aspects of the present invention. The following example is provided to further illustrate the invention and should not be construed as unduly limiting the scope of the invention.

Referring to Figures 1-5, the invention is an insulated wall panel 10 having three layers, 20, 30, and 40. Panel 10 provides a finished aesthetic surface to a building, a structural component to a building, and a factor. insulation to a building. As such, the installed wall panel 10 includes an interior insulation layer 20, a cement interlayer 30, and an exterior cladding layer 40. The panel 10 may be attached to a building wall 50.

Exterior cladding layer 40 may include brick (as shown in the drawings), but may also include stone, tile, engineered stone, and/or similar material depending on the desired finish effect. Therefore, the use of the term "brick" in the present description is synonymous with and includes other coatings so listed. The liner layer 40 is relatively thin and is attached to the cement interlayer 30 by using mortar 44 or another suitable material, such as a chemical adhesive, as best shown in Figure 4. Each brick (or other material that desired) of skin layer 40 is thin and defined by a perimeter.

Intermediate layer 30 provides a substrate to which the facing brick 40 is applied after installation in a building structure 50. Intermediate layer 30 has a plurality of sets of raised lines 32. Each set of raised lines 32 defines a boundary that is slightly greater than the perimeter of a particular brick of the facing layer 40 to be applied to the intermediate layer 30. The relief lines 32 can be formed with the desired grout gap thickness 42 between the facing brick. the coating layer 40.

Intermediate layer 30 is made of a cementitious product with a fiberglass reinforcing material embedded therein. The fiberglass has a high strength and is the main load carrying member of the interlayer 30 while the cement forms a matrix that allows the fibers to retain their desired location and orientation. The resulting product is lean and strong.

To form the intermediate layer 30, a mold is first constructed into which a suspension of uncured cementitious product of the intermediate layer 30 is poured. The mold will have the negatives of the relief lines 32 formed therein. These negatives will appear as small ditches within the mold, so that when the cement cures and the interlayer 30 is removed from the mold, the relief lines 32 will protrude outwardly from the generally flat outer surface 34 of the interlayer. The inner surface 36 of the interlayer 30 will also be generally flat but will not have such raised lines 32. The interlayer 30 may remain in the mold while it cures. Curing time depends on the thickness, the particulars of the mix design and the environment in which the cement is cured. Preferably, the cement interlayer 30 is cured in a chamber.

Once cured, the interlayer 30 is placed in a fixture that allows the inner insulation layer 20 to be applied and bonded to the inner surface 36 of the interlayer 30. The inner insulation layer 20 is a rigid, poured foam that is formed from a two part Class I rated urethane. The foam does not contain CFCs or HCFCs. The foam is applied to the interior surface 36 of the intermediate layer 30 using a machine calibrated to provide a suitable and consistent mixture of components. The finished urethane material 20 will have an in-place density of approximately 2.2 pounds per cubic foot. The foam 20 is adhered to the intermediate layer 30 in such a way that the delivery and mixing of the components by machine provides a complete bond between the intermediate layer 30 and the inner insulation layer 20. Therefore, no adhesives or other bonds are required. chemicals to achieve the strength of the final insulated panel 10. The inner insulation layer 20 can be as thick as one inch or up to three inches or more depending on the level of insulation desired for a particular application.

Alternatively, instead of being poured, the intermediate layer 30 may be pressure molded, extruded, vibration cast, sprayed or slip formed. If, in alternate embodiments, tie points or other elements are incorporated into the structure, they are placed in the mold prior to injection of the urethane.

Once the cement and urethane foam of the respective middle 30 and inner 20 layers have cured, the panel 10 is ready to be applied to a building 50. As shown in Figure 2, the panels 10 are screwed with screws 52 to the wall 50 or other structural element of a building. End pieces, headboards, and other trim pieces, which have been similarly fabricated, are also attached to the building. The joints 22 between the respective panels and trim pieces are sealed with a sealing compound, such as Laticrete® air and water barrier. Next, as shown in Figure 4, an adhesive such as mortar 44 is applied to the outer surface of the interlayer 30. Next, the facing layer brick 40 is applied over the adhesive 44 and between the layers. relief lines 32. Facing brick 40 is applied to overlap 38 joints 22 in panels 10. This overlapping 38 of joints is best shown in Figures 4 and 5. Finally, a grout 42 or other material is applied. between the spaces in the facing brick 40.

Referring to Figures 6-12, the invention includes an embodiment 100 that utilizes a two part liner layer 140. The top of the liner layer may be brick 146 as shown. However, the invention contemplates that concrete, tile, stone, wood, plastic, vinyl, and other materials may be used. As used in the present description, unless otherwise specified, the term "brick" shall include all other materials.

In addition to the two-part coating layer 140, the invention may use an intermediate layer 130. This intermediate layer 130 may be formed of cement or magnesium oxide or other composite material. Preferably, an insulation layer 120 is adhered to the intermediate layer 120. The inner insulation layer 120 is preferably a rigid cast foam that is formed from a two-part Class I rated urethane.

Brick 146 is embedded in a substrate 144. This substrate 144 may be a polyurethane or other plastic. The two part layer is formed by positioning the brick 146 in a mold according to the desired pattern. Brick 146 may be coated with wax or other protective coating. Sand can be used as a release agent. Substrate 144 is then poured into the mold and surrounds a lower portion of brick 146, thereby embedding brick 146 in substrate 144 as the substrate hardens. The brick 146 may have a smooth bottom surface or it may have indentations which may be dovetail notches 145 as shown in Figure 10.

It is important to note that, especially for exterior applications, the mold (not shown) includes a plurality of parallel slots which, when filled with substrate 144, form ridges 148 in substrate 144. These ridges 148 can be seen in the sectional views. assemblies of Figures 8, 9, and 10. Between each ridge is a void 149 that forms a channel through which moisture, water, and other fluids can pass between the substrate 144 and the cement interlayer 130. Said fluid it can exit through the drain holes (not shown). For interior application, such a vacuum 149 may not be necessary and substrate layer 144 may not have the ridges and may be bonded directly to intermediate layer 130. Similarly, for interior application, intermediate layer 130 and intermediate layer insulation 120 may not be used and the substrate may be adhered directly to an underlying building element, such as stud walls.

In practice, the two-part facing layer 140 may be supplied to construction contractors as one item and the combination of intermediate layer 130 and insulation layer 120 may be supplied to construction contractors as a second. element. The second element 120, 130 may be attached by attachment means such as screws 152 to a block wall 150 as shown in Figure 6 or studs 151 as shown in Figure 9. The first element 140 may be attached to the second element 120 , 130 through attachment means such as screws 154. Preferably, the screws 154 do not extend completely through the second element 120, 130 so that the thermal barrier is not breached. After these first and second elements have been added to the structure of a building, the grout/mortar 142 can be pointed into the voids between the brick 146. This grout/mortar 142 can hide the screw heads/holes as shown. shown in Figure 9. Different grout/mortar joints are possible, including raked, vine, extruded, cove, V-shaped, tapped, flush, tapped, and convex.

Alternatively, the substrate 144 may further comprise a sand additive that mimics the appearance of grout. In this mode, it is not necessary to add additional grout/mortar after installation of the top coat, except that a small amount of grout/mortar or similar equivalent corrector, such as caulking, may be added to conceal the screws/joints and/or the joints between panels.

The above description has contemplated use in a wall system for exterior or interior use. However, the invention 100 contemplates use in both roof applications (not shown) and paving and flooring applications (not shown). As shown in Figures 11 and 12, the seams between the panels of the two-part cladding top layer 140 may be staggered to form an interlocking pattern. It is contemplated that the panels of the invention 100 can be cut as needed in a particular application. The corners, the reliefs, the edges of the windows, the voussoirs and the initial courses are also contemplated under the same methods described above. A system of wall panels 10, 100 in accordance with the invention has been described with reference to specific embodiments and examples. Various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description of the preferred embodiments of the invention and the best mode for carrying out the invention are provided for purposes of illustration only and not for purposes of limitation, the invention is defined by the claims. It is anticipated that other modalities may perform similar functions and/or achieve similar results. Any and all such equivalent embodiments and examples are within the scope of the present invention if covered by the appended claims.

Claims (8)

Yo. A wall panel (10, 100) comprising: a cast substrate (144) selected from the group consisting of polyurethane and plastic; an intermediate layer (30, 130) having a first side that is bonded to a rear surface of the poured substrate (144); an insulation layer (20, 120) having a first side chemically bonded to a second side of the intermediate layer (30, 130); Y a plurality of aesthetic elements embedded in and attached to the poured substrate (144); wherein the aesthetic elements are selected from the group consisting of brick (146), ceramic tile, porcelain tile, natural stone, engineered stone, wood, ceramic, plastic, and vinyl; wherein the insulation layer (20, 120) comprises a two-part rigid urethane cast foam in which a finished surface of the aesthetic elements extends above the top surface of the cast substrate (144); Y wherein each of the aesthetic elements is in a spaced relationship with another of the aesthetic elements. 2. The wall panel of claim 1, wherein the insulation layer (20, 120) is chemically bonded to the intermediate layer (30, 130) during pouring. 3. The wall panel of claim 2, wherein the intermediate layer (30, 130) is magnesium oxide. 4. The wall panel of claim 2, wherein the intermediate layer (30, 130) is fiber-reinforced cement. 5. The wall panel of claim 3, wherein the interlayer (30, 130) is bonded to the poured substrate (144) by use of a bond selected from the group consisting of: screws (154), nails, bolts, welds, construction adhesives, rivets and hooks. 6. The wall panel of claim 4, wherein the wall panel (10, 100) is attached to a building structure (50) by use of a bond selected from the group consisting of: screws (152), nails, bolts, welds, construction adhesives, rivets and hooks. The wall panel of claim 1, wherein the poured substrate (144) further comprises sand which causes the top surface of the poured substrate (144) to have a mortar-like appearance. The wall panel of claim 7 further comprising sanded adhesive to cover imperfections in the top surface of the poured substrate (144) and to make the top surface of the poured substrate (144) have a grouted appearance.