US2964800A - Manufacture of a wall - Google Patents

Manufacture of a wall Download PDF

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Publication number
US2964800A
US2964800A US530285A US53028555A US2964800A US 2964800 A US2964800 A US 2964800A US 530285 A US530285 A US 530285A US 53028555 A US53028555 A US 53028555A US 2964800 A US2964800 A US 2964800A
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Prior art keywords
concrete
wall
asphaltum
metal
matrix
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Expired - Lifetime
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US530285A
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Dorsett Roscoe
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
    • E04B2/84—Walls made by casting, pouring, or tamping in situ
    • E04B2/86—Walls made by casting, pouring, or tamping in situ made in permanent forms
    • E04B2/8605—Walls made by casting, pouring, or tamping in situ made in permanent forms without spacers

Definitions

  • Aluminum foil used in the construction of masonry and concrete buildings is subjected to attack by the elements of concrete and masonry materials.
  • An object of this invention is to provide an improved method for constructing concrete walls in which one or more continuous air spaces exist, the air space being lined with a thin sheet or foil of metal.
  • Another object of this invention is to provide a means of constructing concrete walls having an inner and an outer member, the outer member being either plain, or
  • Another object of this invention is to provide a thin metal sheet or foil moisture barrier and heat reflector, having one side coated with asphaltum or other suitable material not subject to chemical attack by elements of concrete upon which a layer of sand or other material to which mortar or concrete will adhere has been applied.
  • Another object of this invention is to provide a means of lining cellular wall air spaces with metal foil moisture barrier and heat reflector.
  • Figure 1 is a fragmentary side elevational view of a section of wall made according to this invention.
  • Figure 2 is a horizontal cross-section of Figure 1.
  • Figure 3 is a curvilineal view of a sheet of metal foil prepared according to this invention with a coating of asphaltum and a layer of sand adhering to the asphaltum.
  • Figure 4 is an isometric perspective view of a section of matrix made according to this invention.
  • the wall member 3 may be fere'cted as a wall for a building under any conditions and many manner desired.
  • Fniembers 1a'nd6 of the form members maysupport' any smooth "surface opposite layers of material, such as plywood'5 and 7 to permit the "concrete 3 to be made as'a jflat' member for a building.
  • the plywood surface Z may 'be used injb'are condition or it may be the inner face of'theplyw'ood 7.
  • the matrix Z' may be made of any suitablematerial such as rubber and is placed in position against and secured to the inside surface of the plywood 7 in a manner that will permit the removal of the form from the concrete wall member without removing the matrix. This can be accomplished by any one of a number of ways.
  • a simple way of installing the matrix is to install metal eyelets near the top edge of the matrix through which pins may be driven into the form.
  • the matrix may be suspended in its proper position for any required distance.
  • the moisture barrier and heat reflector 4 is placed in contact with the plywood 5.
  • the sheet of metal foil 4 in Figure 3 has been prepared according to this invention.
  • the reflective side is indicated by the number 11.
  • the number 10 indicates the opposite side of the sheet of metal foil which has been prepared in a manner that facilitates its adherance to wet concrete or other similar wet materials, such as, for example, gypsum and plaster.
  • the moisture barrier and heat reflector can be made by any one of several methods.
  • a simple method is to spread the sheet of metal on a fiat surface and apply by brush, spraying, pouring, or other means of application, a coating of asphaltum or other suitable material in liquid state.
  • a layer of sand or other material to which concrete will adhere is now spread over the layer of asphaltum.
  • the sand becomes imbedded in the asphaltum and is bound thereby to the metal sheet.
  • the sand coming in contact'with the wet concrete becomes an element of the concrete through the action of the cement in the concrete.
  • the coating of asphaltum also prevents the metal coming in contact with the concrete, thereby protesting the metal from chemical and/or electrolytic att-ack' by the elements of the concrete.
  • the asphaltum backing may be strengthened by the admixture of mineral and/or other fibrous material.
  • the form or mold is ready for filling with concrete 3 or similar material.
  • the form members being assembled and arranged in their proper place, the concrete is then poured into the space provided by the forms.
  • the wet concrete coming in contact with the sand or other material imbedded in the asphaltum backing on the moisture barrier and heat reflector becomes a part of the concrete.
  • beads or grooves may hold to the solidified concrete after the form members have been removed.
  • a reasonable force applied in a manner to pull the matrix from the concrete will not afiect the release, and the wall will retain the design, shape or imprint of the matrix.
  • the method of manufacture of a wall for a building comprising: coating a flexible metal foil with asphaltum; coating said asphaltum with a layer of relatively small solid particles adherent to both concrete and said asphaltum; maintaining said foil in flat condition against a the form of a flat wall against said particles until said concrete sets; and removing said wall mold to provide a concrete wall with a metal foil face.

Description

Dec 20, 1960 R. DORSETT MANUFACTURE OF A WALL Filed Aug. 24, 1955 FIG. 2
FIG. I
INVENTOR ROSCOE DORSETT HIS ATTORNEY States Patent 0. Tree 2,964,800 MANUFACTURE-oak WALL RoscoeDorsett, 551 WestwoodAve, Dayton, Ohio i ileami z4,'19s's,sr. No.'sso,zss
1 Claim. (c1. -18-'60) Buildin' gs' with eencrete "or Ia'asenr walls have been Also these walls of the wall.
Those who are acquainted with chemicals and metals know that most metals are subject to chemical and elect-rolytic attack. Aluminum foil used in the construction of masonry and concrete buildings is subjected to attack by the elements of concrete and masonry materials.
All who have knowledge in the art of building know that it is desirable to provide an air space in the wall members. They also know that because of the porosity of concrete it is desired that a moisture barrier be provided to prevent moisture passing through the wall. They are aware of the need of a wall that resists the passing of heat. They know the value of providing a design that will improve the appearance of the wall. Heretofore walls have not incorporated these functions- An object of this invention is to provide an improved method for constructing concrete walls in which one or more continuous air spaces exist, the air space being lined with a thin sheet or foil of metal.
Another object of this invention is to provide a means of constructing concrete walls having an inner and an outer member, the outer member being either plain, or
having an imprinted design, and there being a single or plurality of walls of concrete or other material spaced between the inner and outer members.
Another object of this invention is to provide a thin metal sheet or foil moisture barrier and heat reflector, having one side coated with asphaltum or other suitable material not subject to chemical attack by elements of concrete upon which a layer of sand or other material to which mortar or concrete will adhere has been applied.
Another object of this invention is to provide a means of lining cellular wall air spaces with metal foil moisture barrier and heat reflector.
Other advantages and objects inhere in the construction of parts and mode of operation. From the following description the objects and advantages shall become more apparent.
In the drawings:
Figure 1 is a fragmentary side elevational view of a section of wall made according to this invention.
Figure 2 is a horizontal cross-section of Figure 1.
Figure 3 is a curvilineal view of a sheet of metal foil prepared according to this invention with a coating of asphaltum and a layer of sand adhering to the asphaltum.
Figure 4 is an isometric perspective view of a section of matrix made according to this invention.
Referring to the drawings in detail:
In the construction of poured concrete wall members, form members 5 and 6 of any suitable construction covered by a rubberr'natrix '2 which may be held along 2,964,806 patented 20, 9
maybe'u'se d. Forin members 1 "and '7ofany suitable "oiistruction may *als'ob'e u's'ed. Such mold construction be of any character to .p'ermit'the metal 'foil '4 to be 'rna'ihtained i'n flat condition against themold or plywood "5"a'nd"to"permitunset concrete to be placed and bernaintairied infiat form against a layer of relatively small .particles adherent to both the concrete "and the asphaltum on said foil'4'until the concrete sets to provide a conci'ete wall member-or panel 3 with 'a metal foil face 4,
which may be produced in any manner for a building.
The wall member 3 may be fere'cted as a wall for a building under any conditions and many manner desired.
Fniembers 1a'nd6 of the form members maysupport' any smooth "surface opposite layers of material, such as plywood'5 and 7 to permit the "concrete 3 to be made as'a jflat' member for a building. If desired, the plywood surface Z may 'be used injb'are condition or it may be the inner face of'theplyw'ood 7. h
The matrix Z'may be made of any suitablematerial such as rubber and is placed in position against and secured to the inside surface of the plywood 7 in a manner that will permit the removal of the form from the concrete wall member without removing the matrix. This can be accomplished by any one of a number of ways. A simple way of installing the matrix is to install metal eyelets near the top edge of the matrix through which pins may be driven into the form. The matrix may be suspended in its proper position for any required distance.
The moisture barrier and heat reflector 4 is placed in contact with the plywood 5.
The sheet of metal foil 4 in Figure 3 has been prepared according to this invention. The reflective side is indicated by the number 11. The number 10 indicates the opposite side of the sheet of metal foil which has been prepared in a manner that facilitates its adherance to wet concrete or other similar wet materials, such as, for example, gypsum and plaster.
The moisture barrier and heat reflector can be made by any one of several methods. A simple method is to spread the sheet of metal on a fiat surface and apply by brush, spraying, pouring, or other means of application, a coating of asphaltum or other suitable material in liquid state. A layer of sand or other material to which concrete will adhere is now spread over the layer of asphaltum. The sand becomes imbedded in the asphaltum and is bound thereby to the metal sheet. The sand coming in contact'with the wet concrete becomes an element of the concrete through the action of the cement in the concrete. The coating of asphaltum also prevents the metal coming in contact with the concrete, thereby protesting the metal from chemical and/or electrolytic att-ack' by the elements of the concrete. The asphaltum backing may be strengthened by the admixture of mineral and/or other fibrous material.
Having assembled the form members 1, 5, 6 and 7, having positioned the matrix 2 in place on plywood 7, and having placed the moisture barrier and heat reflector 10, 11 in place on plywood 5, the form or mold is ready for filling with concrete 3 or similar material.
The form members being assembled and arranged in their proper place, the concrete is then poured into the space provided by the forms. The wet concrete coming in contact with the sand or other material imbedded in the asphaltum backing on the moisture barrier and heat reflector becomes a part of the concrete.
After waiting for a period of time for the concrete to become suificiently solidified, the forms are removed.
being smooth, or having indentations, beads or grooves may hold to the solidified concrete after the form members have been removed. However, a reasonable force applied in a manner to pull the matrix from the concrete will not afiect the release, and the wall will retain the design, shape or imprint of the matrix.
The concrete wall member is now complete with mois- :ture barrier and heat reflector having become an integral member. .While the specific method now preferred has been disclosed as required by statute, such method may be modi- Ified in any manner coming within the scope of the claimed method which follows.
Having thus described my invention, I claim:
The method of manufacture of a wall for a building comprising: coating a flexible metal foil with asphaltum; coating said asphaltum with a layer of relatively small solid particles adherent to both concrete and said asphaltum; maintaining said foil in flat condition against a the form of a flat wall against said particles until said concrete sets; and removing said wall mold to provide a concrete wall with a metal foil face.
References Cited in the file of this patent UNITED STATES PATENTS 1,175,376 Patee Mar. 14, 1916 1,830,397 Kleitz Q. -Q' Nov. 3, 1931 1,841,581 Garrett Jan. 19, 1932 1,862,544 McWane June 14, 1932 1,898,864 1Young' Feb. 21,- 1933 1,915,896 .Maul g June 27, 1933 1,917,062 Reinhard July 4, 1933 2,059,520 I-' I'a1rshb erger- Nov. 3, 1936 2,149,732 Groff Mar. 7, 1939 2,210,960 St. Pierre Aug. 13, 1940 2,371,124 Austin et a1 Mar. 13, 1945 2,422,461 Arquette June 17, 1947 2,424,353 Essig July 22, 1947 2,427,780 Haines Sept. 23, 1947 j 2,441,695 Feagin et al. May 18, 1948 2,444,533 Richardson July 6, 1948 2,558,632 Trozmuller June 26, 1951 2,595,142 Herck Apr. 29, 1952 2,739,881 Kepple Mar. 27,
US530285A 1955-08-24 1955-08-24 Manufacture of a wall Expired - Lifetime US2964800A (en)

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Cited By (27)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3177279A (en) * 1961-10-19 1965-04-06 Cavrok Mfg Company Method of molding a decorative building panel
US3759481A (en) * 1972-01-04 1973-09-18 S Scott Multiple use concrete form liner
US3950477A (en) * 1974-06-20 1976-04-13 Giacomo Philip A Di Process for artificially forming rocks
US3958790A (en) * 1974-05-06 1976-05-25 Scott Samuel C Concrete wall forming panel with inflatable liner means
US4037816A (en) * 1976-04-23 1977-07-26 Scott Samuel C Apparatus for forming a liner on a planar form means
US4264549A (en) * 1978-07-11 1981-04-28 Siemens Aktiengesellschaft Process for batch-coating of electric components
US4798364A (en) * 1987-01-22 1989-01-17 Scott Samuel C Reinforced form liner for surface texturing of concrete structures
US5169573A (en) * 1990-02-09 1992-12-08 Mitsui Petrochemical Industries, Ltd. Method of forming three-dimensional pattern
US5268137A (en) * 1992-07-28 1993-12-07 Scott Samuel C Method of making an object retention liner for concrete construction
US5320790A (en) * 1992-07-10 1994-06-14 Michael Lowe Method for producing a durable tactile warning surface
US5398472A (en) * 1993-02-19 1995-03-21 The Shandel Group Fiber-bale composite structural system and method
US6112473A (en) * 1997-01-22 2000-09-05 Pdg Domus Corporation Molded wall panel and house construction
US6857248B2 (en) * 2001-05-24 2005-02-22 Les Materiaux De'construction Oldcastle Canada Inc. Panel, a kit and a method for forming a masonry wall
US20060080921A1 (en) * 2004-10-14 2006-04-20 Peterson Robbie R Wall surfacing template
US20080005858A1 (en) * 2006-07-07 2008-01-10 Miguel Wang Paint applicator
US20090108490A1 (en) * 2007-10-24 2009-04-30 Brent Condie Material curing constructions and methods for curing material
US20090112405A1 (en) * 2007-10-30 2009-04-30 Jtektcorporation Electric power steering apparatus
US20090233054A1 (en) * 2007-10-24 2009-09-17 Brent Condie Material Curing Constructions and Methods for Curing Material
US7658050B2 (en) 2002-05-22 2010-02-09 Les Materiaux De Construction Oldcastle Canada Inc. Artificial masonry unit, a masonry wall, a kit and a method for forming a masonry wall
US20120000593A1 (en) * 2009-03-12 2012-01-05 Qiangte Energy-Saving Materials Co. Ltd. Decorative brick mould for in-situ production on building
US8101113B2 (en) 2005-04-21 2012-01-24 Oldcastle Building Products Canada, Inc. Molding apparatus for producing dry cast products having textured side surfaces
US8888067B1 (en) * 2007-03-12 2014-11-18 Advanced Formliners, Llc Thermoplastic liner for casting textures and objects into poured wall
US10060143B2 (en) 2011-09-28 2018-08-28 Advanced Formliners Formliner layout member
US10106989B2 (en) 2013-03-14 2018-10-23 Advanced Formliners, Llc Apparatus for setting objects
US10119280B2 (en) 2014-07-11 2018-11-06 Advanced Formliners, Llc Form liner for visually enhanced concrete
US10202773B2 (en) * 2014-04-15 2019-02-12 Paul James Bishop Ip Holdings Limited Flexible cladding wrap, system and methods
USD860479S1 (en) 2017-12-01 2019-09-17 SpeedyMason, LLC Architectural panel

Citations (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1175376A (en) * 1911-08-28 1916-03-14 Fred Patee Thermally-insulated structure.
US1830397A (en) * 1927-09-03 1931-11-03 Kleitz William Concrete molding apparatus
US1841581A (en) * 1926-12-18 1932-01-19 Garrett Neal Method of building walls
US1862544A (en) * 1930-09-20 1932-06-14 Robert C Mcwane Concrete wall and method for making it
US1898864A (en) * 1931-01-12 1933-02-21 Katinka W Young Metallic faced building unit
US1915896A (en) * 1930-08-16 1933-06-27 Peter J Maul Building block
US1917062A (en) * 1930-09-10 1933-07-04 Lawrie L Witter Concrete wall construction
US2059520A (en) * 1936-11-03 Building material and process of
US2149732A (en) * 1931-07-15 1939-03-07 Union Carbide & Carbon Corp Composite molded article and process for making the same
US2210960A (en) * 1937-05-17 1940-08-13 Pierre Octave J St Air conditioning system
US2371124A (en) * 1945-03-13 Method of making sheet metal
US2422461A (en) * 1947-06-17 Method for manufacturing faced
US2424353A (en) * 1944-10-14 1947-07-22 Farnsworth Television & Radio Method of forming glass film on metal
US2427780A (en) * 1944-06-10 1947-09-23 Mcdowell & Torrence Lumber Com Air conditioning of buildings by passing air through hollow foundation blocks
US2441695A (en) * 1944-05-31 1948-05-18 Austenal Lab Inc Casting mold
US2444533A (en) * 1946-03-07 1948-07-06 Polaroid Corp Method of manufacturing reflecting optical elements
US2558632A (en) * 1940-09-07 1951-06-26 Semperit Ag Process for forming bodies of artificial resin and fibrous material
US2595142A (en) * 1949-02-12 1952-04-29 Ce Brick Corp Method for producing designs on building walls
US2739881A (en) * 1953-06-19 1956-03-27 Westinghouse Electric Corp Thermoset synthetic resin laminate with special surface and method of making same

Patent Citations (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2371124A (en) * 1945-03-13 Method of making sheet metal
US2059520A (en) * 1936-11-03 Building material and process of
US2422461A (en) * 1947-06-17 Method for manufacturing faced
US1175376A (en) * 1911-08-28 1916-03-14 Fred Patee Thermally-insulated structure.
US1841581A (en) * 1926-12-18 1932-01-19 Garrett Neal Method of building walls
US1830397A (en) * 1927-09-03 1931-11-03 Kleitz William Concrete molding apparatus
US1915896A (en) * 1930-08-16 1933-06-27 Peter J Maul Building block
US1917062A (en) * 1930-09-10 1933-07-04 Lawrie L Witter Concrete wall construction
US1862544A (en) * 1930-09-20 1932-06-14 Robert C Mcwane Concrete wall and method for making it
US1898864A (en) * 1931-01-12 1933-02-21 Katinka W Young Metallic faced building unit
US2149732A (en) * 1931-07-15 1939-03-07 Union Carbide & Carbon Corp Composite molded article and process for making the same
US2210960A (en) * 1937-05-17 1940-08-13 Pierre Octave J St Air conditioning system
US2558632A (en) * 1940-09-07 1951-06-26 Semperit Ag Process for forming bodies of artificial resin and fibrous material
US2441695A (en) * 1944-05-31 1948-05-18 Austenal Lab Inc Casting mold
US2427780A (en) * 1944-06-10 1947-09-23 Mcdowell & Torrence Lumber Com Air conditioning of buildings by passing air through hollow foundation blocks
US2424353A (en) * 1944-10-14 1947-07-22 Farnsworth Television & Radio Method of forming glass film on metal
US2444533A (en) * 1946-03-07 1948-07-06 Polaroid Corp Method of manufacturing reflecting optical elements
US2595142A (en) * 1949-02-12 1952-04-29 Ce Brick Corp Method for producing designs on building walls
US2739881A (en) * 1953-06-19 1956-03-27 Westinghouse Electric Corp Thermoset synthetic resin laminate with special surface and method of making same

Cited By (32)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3177279A (en) * 1961-10-19 1965-04-06 Cavrok Mfg Company Method of molding a decorative building panel
US3759481A (en) * 1972-01-04 1973-09-18 S Scott Multiple use concrete form liner
USRE29945E (en) * 1972-01-04 1979-03-27 Multiple use concrete form liner
US3958790A (en) * 1974-05-06 1976-05-25 Scott Samuel C Concrete wall forming panel with inflatable liner means
US3950477A (en) * 1974-06-20 1976-04-13 Giacomo Philip A Di Process for artificially forming rocks
US4037816A (en) * 1976-04-23 1977-07-26 Scott Samuel C Apparatus for forming a liner on a planar form means
US4264549A (en) * 1978-07-11 1981-04-28 Siemens Aktiengesellschaft Process for batch-coating of electric components
US4798364A (en) * 1987-01-22 1989-01-17 Scott Samuel C Reinforced form liner for surface texturing of concrete structures
US5169573A (en) * 1990-02-09 1992-12-08 Mitsui Petrochemical Industries, Ltd. Method of forming three-dimensional pattern
US5320790A (en) * 1992-07-10 1994-06-14 Michael Lowe Method for producing a durable tactile warning surface
US5268137A (en) * 1992-07-28 1993-12-07 Scott Samuel C Method of making an object retention liner for concrete construction
US5398472A (en) * 1993-02-19 1995-03-21 The Shandel Group Fiber-bale composite structural system and method
US6112473A (en) * 1997-01-22 2000-09-05 Pdg Domus Corporation Molded wall panel and house construction
US6857248B2 (en) * 2001-05-24 2005-02-22 Les Materiaux De'construction Oldcastle Canada Inc. Panel, a kit and a method for forming a masonry wall
US7658050B2 (en) 2002-05-22 2010-02-09 Les Materiaux De Construction Oldcastle Canada Inc. Artificial masonry unit, a masonry wall, a kit and a method for forming a masonry wall
US20060080921A1 (en) * 2004-10-14 2006-04-20 Peterson Robbie R Wall surfacing template
US7238406B2 (en) 2004-10-14 2007-07-03 Dasa Enterprises, Llc Wall surfacing template
US8101113B2 (en) 2005-04-21 2012-01-24 Oldcastle Building Products Canada, Inc. Molding apparatus for producing dry cast products having textured side surfaces
US20080005858A1 (en) * 2006-07-07 2008-01-10 Miguel Wang Paint applicator
US8888067B1 (en) * 2007-03-12 2014-11-18 Advanced Formliners, Llc Thermoplastic liner for casting textures and objects into poured wall
US20090108490A1 (en) * 2007-10-24 2009-04-30 Brent Condie Material curing constructions and methods for curing material
US20090233054A1 (en) * 2007-10-24 2009-09-17 Brent Condie Material Curing Constructions and Methods for Curing Material
US20090112405A1 (en) * 2007-10-30 2009-04-30 Jtektcorporation Electric power steering apparatus
US20120000593A1 (en) * 2009-03-12 2012-01-05 Qiangte Energy-Saving Materials Co. Ltd. Decorative brick mould for in-situ production on building
US8444789B2 (en) * 2009-03-12 2013-05-21 Qiangte Energy-Saving Materials Co. Ltd. Decorative brick mould for in-situ production on building
US20130234002A1 (en) * 2009-03-12 2013-09-12 Qiangte Energy-Saving Materials Co. Ltd Decorative brick mould for in-situ production on building
US9074380B2 (en) * 2009-03-12 2015-07-07 Qiangte Energy-Saving Materials Co. Ltd Decorative brick mould for in-situ production on building
US10060143B2 (en) 2011-09-28 2018-08-28 Advanced Formliners Formliner layout member
US10106989B2 (en) 2013-03-14 2018-10-23 Advanced Formliners, Llc Apparatus for setting objects
US10202773B2 (en) * 2014-04-15 2019-02-12 Paul James Bishop Ip Holdings Limited Flexible cladding wrap, system and methods
US10119280B2 (en) 2014-07-11 2018-11-06 Advanced Formliners, Llc Form liner for visually enhanced concrete
USD860479S1 (en) 2017-12-01 2019-09-17 SpeedyMason, LLC Architectural panel

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