CA1189718A - Prefabricated building panels - Google Patents
Prefabricated building panelsInfo
- Publication number
- CA1189718A CA1189718A CA000420182A CA420182A CA1189718A CA 1189718 A CA1189718 A CA 1189718A CA 000420182 A CA000420182 A CA 000420182A CA 420182 A CA420182 A CA 420182A CA 1189718 A CA1189718 A CA 1189718A
- Authority
- CA
- Canada
- Prior art keywords
- matrix
- prefabricated building
- concrete matrix
- modified concrete
- building panel
- 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
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
- E04C2/30—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
- E04C2/38—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 with attached ribs, flanges, or the like, e.g. framed panels
- E04C2/384—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 with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
Abstract
ABSTRACT OF THE DISCLOSURE
Prefabricated building panels and methods for their manufacture is provided wherein the panels comprise a frame support structure, in one embodiment, a sheathing layer attached thereto, and a means for bonding a modified concrete matrix onto the support frame, the matrix includ-ing in its uncured state. aggregate, cement, water, sand, an acrylic emulsion, an anti-foamer and a plasticizer.
The matrix is then smoothed and textured to become the outer facing of the panel, or a facing layer is bonded onto the matrix. Alternatively, a cushioning material is bonded onto matrix and covered with a bonding agent into which a facing layer is embedded.
Prefabricated building panels and methods for their manufacture is provided wherein the panels comprise a frame support structure, in one embodiment, a sheathing layer attached thereto, and a means for bonding a modified concrete matrix onto the support frame, the matrix includ-ing in its uncured state. aggregate, cement, water, sand, an acrylic emulsion, an anti-foamer and a plasticizer.
The matrix is then smoothed and textured to become the outer facing of the panel, or a facing layer is bonded onto the matrix. Alternatively, a cushioning material is bonded onto matrix and covered with a bonding agent into which a facing layer is embedded.
Description
BACKGROUND OF THE INVENTION
-Field of the Invention The present invention relates to unique prefabricated building panels and to methods for their manufacture.
Description of the Background In the past, prefabricated building panels have been manufactured by mounting rigid board material onto a frame and applying the facing material to the board with a bonding agent.
Another prior method mounted the rigid board to the frame, stapled a waterproof material to the board, secured a metal lath to the board and frame and applied several coats of Portland cement plaster~ Prior methods included the addition of styrene-butadiene rubber and fiberglass strands to the cement. Finally, ridge-backed tile was beaten into the thin set cement and allowed to setO
Tile failure has been a problem with prior types of panels. E~pansion and contraction due to changing weather 2S conditions, and movement due to earth tremors and quakes, wind, shifting and settling of the building, sonic booms, freezing in the presence of moisture and the like may stress the support structure for the buildingls facing sufficiently to bend and separate the support structure from the rest of the panel causing the facing to crack or disbond. The unique strength and flexibility of the building panels disclosed in the present invention allows greater stress to be placed on the panel while maintaining deflection of the support frame and differential movement 7~
between the frame and the rest of the panel within toler-able limits, thereby lessening the possibility of cracking and disbonding of the facing material.
U.S. Patent 3,666,606 to Stokes disclo~ed a manufac-tured composite membrane sheet without a support struc~ure which was adhesively bonded directly onto an architectural substrate. The system was used for outdoor and indoor tile flooring as well as for indoor walls. The system com-prised a rubber elastomeric layer, such as polychloroprene rubber, bonded to a sheet of synthetic polymer resin in-cluding a plasticizer, a stabilizer and a synthetic resin fiber scrim embedded therein.
The use of an elastomeric layer to isolate tile from substrate movement improves the art by lessening the pos-sibility of impairment of the membrane and tile system.
However, in application of facing material to multistoried buildings greater strength of the paneling system must be achieved. It would be desirable to develop a prefabri-cated building panel which incorporated both supericr strength and cushioning efEect. This unique and useful product and method is provided with ~he present inven~ion.
SUMMARY OF THE INVENTION
In accordance with the present invention, a prefabri-cated building panel is provided comprising a support frame having an upper surfaceO A layer of sheathing material covers the upper surface of the frame and is attached to the frameO A means for bonding a modified concrete matrix to the frame is attached to the frame.
The modified concrete matrix, includes additives to increase self-curing properties, strength and flexibility, 3~ and decrease air content in the matrix~
.
In a presently preferred embodiment, the bonding means is a wire mesh attached to the support frame and which i5 covered by and embedded into the concrete ma~rix.
The cement matrix can be te~tured and the matrix itself becomes the facing of the tile panel, or alternatively, a facing layer can be bonded onto the matrix.
In an alternative embodiment, a bonding means such as wire mesh is attached to the outer sur~ace of a support frame. A layer of modified concrete matrix is spread on a surface and the outer surface of the support frame covered with the wire mesh is embedded into the matrix.
In a presently preferred embodiment of the present invention the support frame is a steel stud support frame.
The modified concrete matrix is comprised of aggregates, cementy water and sand as well as an acrylic emulsion, an anti-foamer and a plasticizer.
Alternatively, the matrix is covered with a layer of cushioning material which is attached to the matrix. The cushioning material is covered with a bonding agent into which a facing layer is embedded.
?5 In a presently preferred embodiment, the cushioning material is liquid polyurethane rubber, the bonding agent is an epoxy polyamide and the acing layer is tile, granite or aggregate.
In accordance with the present invention, a method of manufacturing a prefabricated building panel is also provided~ The method comprises a support frame, attaching a means for bonding a modified concrete matrix to the frame~ the modifieâ concrete matrix including additives to aid self-curing properties, strength and flexibility, and decrease air content of the matrix, curing the matrix and grinding it until it is smooth.
Alternatively, the method comprises the initial steps of covering the outer surface of a support frame with sheathing material and attaching the sheathing material to the support frame.
The resulting outer surface of the concrete matrix is then tex~ured to provide the facing for the panel. This texturing is achieved by sandblasting9 grinding, grooving or the like. Alternatively, the method further includes bonding to the concrete matrix a layer of cushioning material, covering the cushioning material with a bonding agent and embedding a facing layer in the bonding agentO
In the accompanying drawings wherein like numerals designate like parts in the figures:
Figure 1 is an enlarged fragmentary cross-sectional view of a prefabricated building panel in accordance with the present invention with the sandblasted concrete matrix as the facing material.
Figure 2 is an enlarged fragmentary cross-sectional view of a prefabricated building panel in accordance with the present invention with tile as the facing materialO
It will be appreciated that the present invention can take many forms and embodimentsc Some embodiments of the invention are described so as to give an understanding o the invention. It is not intended that the illustrative embodiments described herein should limit the invention~
DESCRIPTION OF SPECIFIC EMBODIMENTS
Referring to Figure 1, there is illustrated a cross-sectional view of an embodiment of prefabricated building panel 100. Panel 100 comprises support frame 102.
Attached to support rame 102 is a layer of sheathing material 104. Also attached to support frame 102 through the sheathing material is bonding means, such as wire mesh 106. Covering wire mesh 106 and embedded therein is a modified concrete matrix 108.
In an alternative embodiment sheathing material 104 is eliminated. Bonding means such as wire mesh 106 is attached to the outer surface of support frame 102.
Modified concrete matrix 108 is spread out on a preferably level surface~ The outer surface of support frame 102 with bonding means attached is embedded in modified concrete matrix 108.
In a preferred embodiment of the present invention, support frame 102 is a welded rigid metal stud framework.
The rigid metal frame is constructed of 12 to 20 gauge steel in the preferred embodiment, and most preferably of 16 gauge steelO The studs are placed 12 inches to 24 inches on center. The sheathing material, if used, is preferably gypsum board but can be cement asbestos board, foam board or any rigid board material. The thickness range oE the sheathing material is 1/4 inch to 1 inch, preferably 1/2 to 5/8 inch. The wire mesh is preferably 1 inch by 1 inch, 1 inch by 2 inches, 2 inches by 2 inches, or factions thereof, galvanized wire mesh~ constructed of 10 to 18 gauge, preferably 1~ gauge, metal wire.
Typically, the initial, uncured composition of the modified concrete matrix of the present invention has the following range of compositions:
m unt (Percent by Weight) Broad Preferred Com~nent Ran~e _ Range Aggregate 40-45% 42-43%
Cement 15-20% 17-19 Water 1-6% 2-5%
Acrylic Emulsion 1-10~ 3-5%
Sand 30-35% 32-34 Antifoamer . a 5-o15~ .08-.12~
Plasticizer oO5~~15% ~08-.12%
Because of its superior strength~ Portland cement is preferred among the hydraulic cements for use in the above composition. The term "Portland cementN as used herein includes those materials as normally understood in the art.
The additive of concrete matrix 108 which increases strength and adds self-curing properties is preferably an acrylic emulsion~ The acrylic emulsion is preferably an etnulsion polymerization of methyl and butyl esters of methyl acrylic acid such as that avail~ble from Rohm &
Haas Co. under the trade na~e "Rhoplex MC-76."
The additive of concrete matrix 10~ which improves workability is preferably a plasticizer which is compatible with the sel~-curing additive being used and more prefer-ably an anionic naphthalene.
~ 4 ~ k The additive of modified concrete matrix 108 which prevents or reduces air content in the matrix, thereby increasing the strength of the concrete is preferably an alkyl silane defoamer such as that avail~ble from Dow Chemical under the trade name "Antifoam s."
It should be understood that the present invention encompasses the use of other additives in the concrete matrix which add self-curing properties, increase strength~
improve flexibility and decrease air content of the matrix.
In one embodiment of the present invention, the modified concrete matrix 108 forms the facing layer of the prefabricated tile panel. The large (preferably 3/8 inch) aggregates and the fine sand may be colored to suit architectural taste. Matrix 108 is smoothed to remove inperfections and produce a substantially smooth exposed surface. Optionally, this substantially smooth exposed surface may be textured by any convenient means, such as sandblasting, grinding, ribbing and the like, to form the outer facing of panel 100.
In another embodiment of the present invention, a facing layer is bonded directly onto the concrete matrix using any suitable bonding material.
Alternatively, if other forms of facing are to be used, panel 100, as shown in Figure 2, further comprises a layer of cushioning material 1~0 covering and bonded to modified concrete matrix 108, a bonding agent 112 covering cushion-ing material 110 and a facing layer 114 embedded in bondin~
agent 112 k 3~
~8~37~
In the preferred embodiment of the present invention, cushioning material 110 is a liquid synthetic rubber.
Cushioning material 110 varies in thickness from 10 to 60 mils, preferably being 30 mils thick. The liquid synthetic rubber is preferably a two-component polyurethane rubber.
It is understood that any type of cushioning material capable of both preventing moisture penetration and absorbing shock is encompassed by the present invention.
Bondin~ agent 112 is preferably a two-component epoxy polyamide which results in a flexible bond. The epoxy polyamide available from C.E. Kaiser Co. under the trade name "KB Epoxyment" has been found to produce satisfactory bonding. The layer of bonding agent is preferably 1/16 to 1/8 inch thick.
In the preferred embodiment of the present invention, facing layer 114 comprises a ceramic or quarry tile, an aggregate, granite or marble slabs or any other type of facing capable of being embedded into bonding agent 112 and providing a durable and attractive finish.
The method for prefabricating building panel 100 comprises the initial step of attaching a means for bond-ing modified concrete matrix 108 to the outer surface ofsupport frame 102, the bonding means preferably wire mesh 106.
Modified concrete matrix 108 is prepared in a conven-tional mixer by conventional methods. After mixing, thematrix is spread out on a preferably level surface and the outer surface of support frame 102 with bonding means attached is embedded in the matrix. The preferable thick-ness of the matrix is one inch. Matrix 108 is partially ~ ~`r~ k cured for at least 24 hours. After this partial curîng, the matri~ is smoothed, preferably by grinders with dia-mond stone, until it is substantially smooth and prefer-ably to a thickness of 7/8 inch.
In an alternative embodiment, the method comprises the initial step of attaching sheathing material 104, preferably gypsum board, to support ~rame 102. sondin9 means, preferably wire mesh 106 is then attached through the sheathing material to the frame. The modified con-crete matrix 108 is spread atop wire mesh 106 so that the mes~ is completely covered and the matrix penetrates the mesh to surround and embed the wire. The panel is vibrated by a vibrator so that the matri~ embeds and 1~ covers the wire mesh.
In an alternative embodiment of the present invention matrix 108 is textured~ as by sandblasting, grinding, ribbing or the like to form the facing layer of the pre fabricated building panel.
In another alternative embodiment of the present invention a facing layer is bonded directly onto the concrete matrix using any suitable bonding means.
In the preferred embodiment, matrix 108 is covered with a layer of cushioning material 110 which is bonded to the matrix. This cushioning material is preferably self-bonding, such as a liquid synthetic rubber. If a liquid~ self-bonding cushioning material is used, the material s at least partially cured for a period of time from 4 hours to 4 days, preferably for 24 hours.
If the cushioning material is not self-bonding, it may be attached to the matrix by any suitable bonding means.
Bonding agent 112, as described above~ is applied ~o a un;form thickness of preferably 1/16 to 1/8 inch to cover the cushioning material. Facing layer 114, as previously described, i5 embedded into bonding agent 112. Such embedding must be performed while bonding agent 112 is still tackyy preferably within no more than two hours, most preferably immediatelyO
The unlque strength and stress cushioning ability of the present invention which greatly decreases the possibility of disbonding and cracking of the facing layer is illustrated in the following examples where tests were performed on applicant's improved panels and on panels constructed by previously known methods.
The steel framing for all of the panels was manufac-tured from 16 gauge, 6 inch galvanized 50,000 yield wide flange channel stud with one inch welded joints. On panel A, a cement asbestos board was applied with cad plated screws, 16 inches on center. An epoxy polyamide was applied and an aggregate facing layer was embedded into the epoxy.
On panels B, C, D and E, the same steel frame was used. The frame was covered with 1/2 inch gypsum board sheathing. The sheathing was overlaid with a galvanized steel mesh attached to the frame with cad plated screws, 16 inches on center. The modified concrete matrix was applied, partially cured, ground and smoothed to a thick-ness of 7/8 inch according to the method of the present inventionO
In panel B, tile facing was applied directly to the concrete matrix layer with an epoxy polyamide bonding agent.
In panel C, no other facing was applied~ The matrix was sandblasted to produce the facing layer.
In panel D, a 60 mil layer of liquid polyurethane rubber was applied by the applicant's method and at least partially cured to a panel manufactured similar to panel B. Tile was then applied with the epoxy polyamide.
Panel E w~s manufactured identically to Panel D, with the exception that the polyurethane rubber layer was only 30 mils thick.
All panels were designed to withstand a 50 lb. wind load with a deflection of .400 inch. The panels were exposed to positive (inward) pressures oE 25, 50, 75 and 100 pounds per square foot, (P,S.F.~ and to negative (outward) pressures of 25, 50, 75 and 100 pounds per square foot (P.S.F.). The deflection was measured after each 10 second exposure to the pressure levell The differential movemen~ of the span between the steel studs and the back side of the panel was also measured. The ~results of these tests are summarized as follows:
~5 ~3 Panel A Panel B
Pressure Def in Dif inPressure Def in Dif in n P.S.F. inches inchesin P.S.F. inches inches +~5 .120 O040 ~25 .090 .000 +50 .295 .040 ~50 .200 .010 5+75 .415 .030 +75 .290 .010 +lO0 .605 .040 +100 .365 .010 -25 .150 .030 -25 .075 .010 -50 .295 .030 -50 .160 .030 -75 .450 .060 -75 .265 .030 -100 .570 .180 -100 .400 .030 Panel C Panel D
Pressure Def in Dif inPressure Def in Dif in in P.S.F. inches inches in_P.S.F. inches inches +25 .140 .020 +25 .090 .010 +50 .300 .030 +50 .215 .020 +75 .2~0 .0~0 +75 .410 .040 +100 .580 .050 +100 .520 a 050 -25 ~140 .020 -25 .085 .030 _50 .175 .030 -50 .220 .060 -75 .425 .060 -75 .345 .090 -100 .500 .llO -100 .570 .150 Panel E
Pressure Def in Dif in in P S F. inches inches -+25 .085 .000 +50 .210 .000 25~75 .320 .000 +100 .425 .000 -25 .075 .000 .200 .020 -75 .320 .020 -100 .600 .020 + indicates inward pressure; - indicates outward pressure;
def. indicates deflection; dif. indicates differential movement.
.
The results of these tests show that in the range of pressures from -75 PoS~F~ to ~100 P.S.F., the resultant deflection in panels constructed in accordance with ~he presen~ invention (panels s, C~ D and E) w~s less than that of the panel constructed by previous methods (Panel A) and less than the allowable deflection of .400 inch.
At pressure levels of +25, ~50, and -100~ the differential movement exhibited by all of the panels constructed in accordance with the present invention was less than that of the panel constructed by previous methods. Panel E
showed an exceptional lack of differential movement and was within the allowable deflection in the range of pressure from 75 P.S.F. to +75 P.S.F.
At a negative pressure of 104 P.S.F. Panel A buclcled the steel studs at vertical midspan and the exterior face blew outO At a negative pressure of 130 P.S.F. Panels B
and D broke and bulged outward at the vertical midspan area. All tile remained in place.
~0 The foregoing description has been directed to par ticular embodiments of the invention in accordance with the Patent Statute for purposes of illustration and expla-nation. It will be apparent, however, to those skilled in this art that many modifications and changes in the pre-fabricated building panels and methods set forth will be possible without departing from the scope and spirit of the invention. It is intended that the following claims be interpre~ed to embrace all such modifications and changesO
-Field of the Invention The present invention relates to unique prefabricated building panels and to methods for their manufacture.
Description of the Background In the past, prefabricated building panels have been manufactured by mounting rigid board material onto a frame and applying the facing material to the board with a bonding agent.
Another prior method mounted the rigid board to the frame, stapled a waterproof material to the board, secured a metal lath to the board and frame and applied several coats of Portland cement plaster~ Prior methods included the addition of styrene-butadiene rubber and fiberglass strands to the cement. Finally, ridge-backed tile was beaten into the thin set cement and allowed to setO
Tile failure has been a problem with prior types of panels. E~pansion and contraction due to changing weather 2S conditions, and movement due to earth tremors and quakes, wind, shifting and settling of the building, sonic booms, freezing in the presence of moisture and the like may stress the support structure for the buildingls facing sufficiently to bend and separate the support structure from the rest of the panel causing the facing to crack or disbond. The unique strength and flexibility of the building panels disclosed in the present invention allows greater stress to be placed on the panel while maintaining deflection of the support frame and differential movement 7~
between the frame and the rest of the panel within toler-able limits, thereby lessening the possibility of cracking and disbonding of the facing material.
U.S. Patent 3,666,606 to Stokes disclo~ed a manufac-tured composite membrane sheet without a support struc~ure which was adhesively bonded directly onto an architectural substrate. The system was used for outdoor and indoor tile flooring as well as for indoor walls. The system com-prised a rubber elastomeric layer, such as polychloroprene rubber, bonded to a sheet of synthetic polymer resin in-cluding a plasticizer, a stabilizer and a synthetic resin fiber scrim embedded therein.
The use of an elastomeric layer to isolate tile from substrate movement improves the art by lessening the pos-sibility of impairment of the membrane and tile system.
However, in application of facing material to multistoried buildings greater strength of the paneling system must be achieved. It would be desirable to develop a prefabri-cated building panel which incorporated both supericr strength and cushioning efEect. This unique and useful product and method is provided with ~he present inven~ion.
SUMMARY OF THE INVENTION
In accordance with the present invention, a prefabri-cated building panel is provided comprising a support frame having an upper surfaceO A layer of sheathing material covers the upper surface of the frame and is attached to the frameO A means for bonding a modified concrete matrix to the frame is attached to the frame.
The modified concrete matrix, includes additives to increase self-curing properties, strength and flexibility, 3~ and decrease air content in the matrix~
.
In a presently preferred embodiment, the bonding means is a wire mesh attached to the support frame and which i5 covered by and embedded into the concrete ma~rix.
The cement matrix can be te~tured and the matrix itself becomes the facing of the tile panel, or alternatively, a facing layer can be bonded onto the matrix.
In an alternative embodiment, a bonding means such as wire mesh is attached to the outer sur~ace of a support frame. A layer of modified concrete matrix is spread on a surface and the outer surface of the support frame covered with the wire mesh is embedded into the matrix.
In a presently preferred embodiment of the present invention the support frame is a steel stud support frame.
The modified concrete matrix is comprised of aggregates, cementy water and sand as well as an acrylic emulsion, an anti-foamer and a plasticizer.
Alternatively, the matrix is covered with a layer of cushioning material which is attached to the matrix. The cushioning material is covered with a bonding agent into which a facing layer is embedded.
?5 In a presently preferred embodiment, the cushioning material is liquid polyurethane rubber, the bonding agent is an epoxy polyamide and the acing layer is tile, granite or aggregate.
In accordance with the present invention, a method of manufacturing a prefabricated building panel is also provided~ The method comprises a support frame, attaching a means for bonding a modified concrete matrix to the frame~ the modifieâ concrete matrix including additives to aid self-curing properties, strength and flexibility, and decrease air content of the matrix, curing the matrix and grinding it until it is smooth.
Alternatively, the method comprises the initial steps of covering the outer surface of a support frame with sheathing material and attaching the sheathing material to the support frame.
The resulting outer surface of the concrete matrix is then tex~ured to provide the facing for the panel. This texturing is achieved by sandblasting9 grinding, grooving or the like. Alternatively, the method further includes bonding to the concrete matrix a layer of cushioning material, covering the cushioning material with a bonding agent and embedding a facing layer in the bonding agentO
In the accompanying drawings wherein like numerals designate like parts in the figures:
Figure 1 is an enlarged fragmentary cross-sectional view of a prefabricated building panel in accordance with the present invention with the sandblasted concrete matrix as the facing material.
Figure 2 is an enlarged fragmentary cross-sectional view of a prefabricated building panel in accordance with the present invention with tile as the facing materialO
It will be appreciated that the present invention can take many forms and embodimentsc Some embodiments of the invention are described so as to give an understanding o the invention. It is not intended that the illustrative embodiments described herein should limit the invention~
DESCRIPTION OF SPECIFIC EMBODIMENTS
Referring to Figure 1, there is illustrated a cross-sectional view of an embodiment of prefabricated building panel 100. Panel 100 comprises support frame 102.
Attached to support rame 102 is a layer of sheathing material 104. Also attached to support frame 102 through the sheathing material is bonding means, such as wire mesh 106. Covering wire mesh 106 and embedded therein is a modified concrete matrix 108.
In an alternative embodiment sheathing material 104 is eliminated. Bonding means such as wire mesh 106 is attached to the outer surface of support frame 102.
Modified concrete matrix 108 is spread out on a preferably level surface~ The outer surface of support frame 102 with bonding means attached is embedded in modified concrete matrix 108.
In a preferred embodiment of the present invention, support frame 102 is a welded rigid metal stud framework.
The rigid metal frame is constructed of 12 to 20 gauge steel in the preferred embodiment, and most preferably of 16 gauge steelO The studs are placed 12 inches to 24 inches on center. The sheathing material, if used, is preferably gypsum board but can be cement asbestos board, foam board or any rigid board material. The thickness range oE the sheathing material is 1/4 inch to 1 inch, preferably 1/2 to 5/8 inch. The wire mesh is preferably 1 inch by 1 inch, 1 inch by 2 inches, 2 inches by 2 inches, or factions thereof, galvanized wire mesh~ constructed of 10 to 18 gauge, preferably 1~ gauge, metal wire.
Typically, the initial, uncured composition of the modified concrete matrix of the present invention has the following range of compositions:
m unt (Percent by Weight) Broad Preferred Com~nent Ran~e _ Range Aggregate 40-45% 42-43%
Cement 15-20% 17-19 Water 1-6% 2-5%
Acrylic Emulsion 1-10~ 3-5%
Sand 30-35% 32-34 Antifoamer . a 5-o15~ .08-.12~
Plasticizer oO5~~15% ~08-.12%
Because of its superior strength~ Portland cement is preferred among the hydraulic cements for use in the above composition. The term "Portland cementN as used herein includes those materials as normally understood in the art.
The additive of concrete matrix 108 which increases strength and adds self-curing properties is preferably an acrylic emulsion~ The acrylic emulsion is preferably an etnulsion polymerization of methyl and butyl esters of methyl acrylic acid such as that avail~ble from Rohm &
Haas Co. under the trade na~e "Rhoplex MC-76."
The additive of concrete matrix 10~ which improves workability is preferably a plasticizer which is compatible with the sel~-curing additive being used and more prefer-ably an anionic naphthalene.
~ 4 ~ k The additive of modified concrete matrix 108 which prevents or reduces air content in the matrix, thereby increasing the strength of the concrete is preferably an alkyl silane defoamer such as that avail~ble from Dow Chemical under the trade name "Antifoam s."
It should be understood that the present invention encompasses the use of other additives in the concrete matrix which add self-curing properties, increase strength~
improve flexibility and decrease air content of the matrix.
In one embodiment of the present invention, the modified concrete matrix 108 forms the facing layer of the prefabricated tile panel. The large (preferably 3/8 inch) aggregates and the fine sand may be colored to suit architectural taste. Matrix 108 is smoothed to remove inperfections and produce a substantially smooth exposed surface. Optionally, this substantially smooth exposed surface may be textured by any convenient means, such as sandblasting, grinding, ribbing and the like, to form the outer facing of panel 100.
In another embodiment of the present invention, a facing layer is bonded directly onto the concrete matrix using any suitable bonding material.
Alternatively, if other forms of facing are to be used, panel 100, as shown in Figure 2, further comprises a layer of cushioning material 1~0 covering and bonded to modified concrete matrix 108, a bonding agent 112 covering cushion-ing material 110 and a facing layer 114 embedded in bondin~
agent 112 k 3~
~8~37~
In the preferred embodiment of the present invention, cushioning material 110 is a liquid synthetic rubber.
Cushioning material 110 varies in thickness from 10 to 60 mils, preferably being 30 mils thick. The liquid synthetic rubber is preferably a two-component polyurethane rubber.
It is understood that any type of cushioning material capable of both preventing moisture penetration and absorbing shock is encompassed by the present invention.
Bondin~ agent 112 is preferably a two-component epoxy polyamide which results in a flexible bond. The epoxy polyamide available from C.E. Kaiser Co. under the trade name "KB Epoxyment" has been found to produce satisfactory bonding. The layer of bonding agent is preferably 1/16 to 1/8 inch thick.
In the preferred embodiment of the present invention, facing layer 114 comprises a ceramic or quarry tile, an aggregate, granite or marble slabs or any other type of facing capable of being embedded into bonding agent 112 and providing a durable and attractive finish.
The method for prefabricating building panel 100 comprises the initial step of attaching a means for bond-ing modified concrete matrix 108 to the outer surface ofsupport frame 102, the bonding means preferably wire mesh 106.
Modified concrete matrix 108 is prepared in a conven-tional mixer by conventional methods. After mixing, thematrix is spread out on a preferably level surface and the outer surface of support frame 102 with bonding means attached is embedded in the matrix. The preferable thick-ness of the matrix is one inch. Matrix 108 is partially ~ ~`r~ k cured for at least 24 hours. After this partial curîng, the matri~ is smoothed, preferably by grinders with dia-mond stone, until it is substantially smooth and prefer-ably to a thickness of 7/8 inch.
In an alternative embodiment, the method comprises the initial step of attaching sheathing material 104, preferably gypsum board, to support ~rame 102. sondin9 means, preferably wire mesh 106 is then attached through the sheathing material to the frame. The modified con-crete matrix 108 is spread atop wire mesh 106 so that the mes~ is completely covered and the matrix penetrates the mesh to surround and embed the wire. The panel is vibrated by a vibrator so that the matri~ embeds and 1~ covers the wire mesh.
In an alternative embodiment of the present invention matrix 108 is textured~ as by sandblasting, grinding, ribbing or the like to form the facing layer of the pre fabricated building panel.
In another alternative embodiment of the present invention a facing layer is bonded directly onto the concrete matrix using any suitable bonding means.
In the preferred embodiment, matrix 108 is covered with a layer of cushioning material 110 which is bonded to the matrix. This cushioning material is preferably self-bonding, such as a liquid synthetic rubber. If a liquid~ self-bonding cushioning material is used, the material s at least partially cured for a period of time from 4 hours to 4 days, preferably for 24 hours.
If the cushioning material is not self-bonding, it may be attached to the matrix by any suitable bonding means.
Bonding agent 112, as described above~ is applied ~o a un;form thickness of preferably 1/16 to 1/8 inch to cover the cushioning material. Facing layer 114, as previously described, i5 embedded into bonding agent 112. Such embedding must be performed while bonding agent 112 is still tackyy preferably within no more than two hours, most preferably immediatelyO
The unlque strength and stress cushioning ability of the present invention which greatly decreases the possibility of disbonding and cracking of the facing layer is illustrated in the following examples where tests were performed on applicant's improved panels and on panels constructed by previously known methods.
The steel framing for all of the panels was manufac-tured from 16 gauge, 6 inch galvanized 50,000 yield wide flange channel stud with one inch welded joints. On panel A, a cement asbestos board was applied with cad plated screws, 16 inches on center. An epoxy polyamide was applied and an aggregate facing layer was embedded into the epoxy.
On panels B, C, D and E, the same steel frame was used. The frame was covered with 1/2 inch gypsum board sheathing. The sheathing was overlaid with a galvanized steel mesh attached to the frame with cad plated screws, 16 inches on center. The modified concrete matrix was applied, partially cured, ground and smoothed to a thick-ness of 7/8 inch according to the method of the present inventionO
In panel B, tile facing was applied directly to the concrete matrix layer with an epoxy polyamide bonding agent.
In panel C, no other facing was applied~ The matrix was sandblasted to produce the facing layer.
In panel D, a 60 mil layer of liquid polyurethane rubber was applied by the applicant's method and at least partially cured to a panel manufactured similar to panel B. Tile was then applied with the epoxy polyamide.
Panel E w~s manufactured identically to Panel D, with the exception that the polyurethane rubber layer was only 30 mils thick.
All panels were designed to withstand a 50 lb. wind load with a deflection of .400 inch. The panels were exposed to positive (inward) pressures oE 25, 50, 75 and 100 pounds per square foot, (P,S.F.~ and to negative (outward) pressures of 25, 50, 75 and 100 pounds per square foot (P.S.F.). The deflection was measured after each 10 second exposure to the pressure levell The differential movemen~ of the span between the steel studs and the back side of the panel was also measured. The ~results of these tests are summarized as follows:
~5 ~3 Panel A Panel B
Pressure Def in Dif inPressure Def in Dif in n P.S.F. inches inchesin P.S.F. inches inches +~5 .120 O040 ~25 .090 .000 +50 .295 .040 ~50 .200 .010 5+75 .415 .030 +75 .290 .010 +lO0 .605 .040 +100 .365 .010 -25 .150 .030 -25 .075 .010 -50 .295 .030 -50 .160 .030 -75 .450 .060 -75 .265 .030 -100 .570 .180 -100 .400 .030 Panel C Panel D
Pressure Def in Dif inPressure Def in Dif in in P.S.F. inches inches in_P.S.F. inches inches +25 .140 .020 +25 .090 .010 +50 .300 .030 +50 .215 .020 +75 .2~0 .0~0 +75 .410 .040 +100 .580 .050 +100 .520 a 050 -25 ~140 .020 -25 .085 .030 _50 .175 .030 -50 .220 .060 -75 .425 .060 -75 .345 .090 -100 .500 .llO -100 .570 .150 Panel E
Pressure Def in Dif in in P S F. inches inches -+25 .085 .000 +50 .210 .000 25~75 .320 .000 +100 .425 .000 -25 .075 .000 .200 .020 -75 .320 .020 -100 .600 .020 + indicates inward pressure; - indicates outward pressure;
def. indicates deflection; dif. indicates differential movement.
.
The results of these tests show that in the range of pressures from -75 PoS~F~ to ~100 P.S.F., the resultant deflection in panels constructed in accordance with ~he presen~ invention (panels s, C~ D and E) w~s less than that of the panel constructed by previous methods (Panel A) and less than the allowable deflection of .400 inch.
At pressure levels of +25, ~50, and -100~ the differential movement exhibited by all of the panels constructed in accordance with the present invention was less than that of the panel constructed by previous methods. Panel E
showed an exceptional lack of differential movement and was within the allowable deflection in the range of pressure from 75 P.S.F. to +75 P.S.F.
At a negative pressure of 104 P.S.F. Panel A buclcled the steel studs at vertical midspan and the exterior face blew outO At a negative pressure of 130 P.S.F. Panels B
and D broke and bulged outward at the vertical midspan area. All tile remained in place.
~0 The foregoing description has been directed to par ticular embodiments of the invention in accordance with the Patent Statute for purposes of illustration and expla-nation. It will be apparent, however, to those skilled in this art that many modifications and changes in the pre-fabricated building panels and methods set forth will be possible without departing from the scope and spirit of the invention. It is intended that the following claims be interpre~ed to embrace all such modifications and changesO
Claims (19)
1. A prefabricated building panel comprising:
a rigid metal stud support frame having an outer surface;
a layer of sheathing material covering the outer surface of the frame and attached thereto;
a wire mesh covering the sheathing material and attached to the frame; and a modified concrete matrix bonded to the wire mesh, the matrix comprising by weight in its uncured state: 15-20% hydraulic cement, 2-5% water, 1-10%
acrylic emulsion, .05-15% anti-foamer, .05-.15% plastici-zer, 40-45% aggregate and 30-35% sand.
a rigid metal stud support frame having an outer surface;
a layer of sheathing material covering the outer surface of the frame and attached thereto;
a wire mesh covering the sheathing material and attached to the frame; and a modified concrete matrix bonded to the wire mesh, the matrix comprising by weight in its uncured state: 15-20% hydraulic cement, 2-5% water, 1-10%
acrylic emulsion, .05-15% anti-foamer, .05-.15% plastici-zer, 40-45% aggregate and 30-35% sand.
2. A prefabricated building panel as defined in claim 1 further comprising:
a layer of liquid synthetic rubber from 10 to 60 mils in thickness covering the matrix;
a bonding agent affixed to the liquid synthetic rubber; and a facing layer embedded in the bonding agent.
a layer of liquid synthetic rubber from 10 to 60 mils in thickness covering the matrix;
a bonding agent affixed to the liquid synthetic rubber; and a facing layer embedded in the bonding agent.
3. A prefabricated building panel comprising:
a support frame having an outer surface;
a bonding means covering and attached to the outer surface of the frame; and a modified concrete matrix including an acrylic emulsion, a plasticizer, and an anti-foamer as additives, the matrix bonded to the bonding means.
a support frame having an outer surface;
a bonding means covering and attached to the outer surface of the frame; and a modified concrete matrix including an acrylic emulsion, a plasticizer, and an anti-foamer as additives, the matrix bonded to the bonding means.
4. A prefabricated building panel as defined in claim 3 further comprising a layer of sheathing material covering the outer surface of the frame and attached thereto.
5. A prefabricated building panel as defined in claim 3 wherein the bonding means is wire mesh.
6. A prefabricated building panel as defined in claim 3 wherein the initial, uncured modified concrete matrix comprises by weight: 15-20% hydraulic cement, 2-5% water, 1-10% acrylic emulsion, .05-.15% anti-foamer, .05-.15% plasticizer, and the balance sand and aggregate.
7. A prefabricated building panel as defined in claim 3 wherein said initial, uncured, modified concrete matrix comprises by weight: 40-45% aggregate and 30-35% sand.
8. A prefabricated building panel as defined in claim 3 wherein the modified concrete matrix is textured.
9. A prefabricated building panel as defined in claim 3 wherein the support frame is a rigid metal stud support frame.
10. A prefabricated building panel as defined in claim 3 further comprising a facing layer bonded onto the modi-fied concrete matrix.
11. A prefabricated building panel as defined in claim 3 further comprising:
a layer of cushioning material bonded to the modified concrete matrix;
a bonding agent affixed to the cushioning mate-rial; and a facing layer embedded in the bonding agent.
a layer of cushioning material bonded to the modified concrete matrix;
a bonding agent affixed to the cushioning mate-rial; and a facing layer embedded in the bonding agent.
12. A prefabricated building panel as defined in claim 11 wherein the cushioning material is liquid synthetic rubber.
13. A prefabricated building panel as defined in claim 11 wherein the bonding agent is an epoxy polyamide.
14. A method of prefabricating building panels, comprising the steps of:
attaching to a support frame a means for bonding a modified concrete matrix to the support frame;
covering and embedding the bonding means with the modified concrete matrix, the matrix comprising additives to aid self-curing, increase strength, improve flexibility and reduce air content of the matrix;
curing at least partially the modified concrete matrix; and smoothing the modified concrete matrix.
attaching to a support frame a means for bonding a modified concrete matrix to the support frame;
covering and embedding the bonding means with the modified concrete matrix, the matrix comprising additives to aid self-curing, increase strength, improve flexibility and reduce air content of the matrix;
curing at least partially the modified concrete matrix; and smoothing the modified concrete matrix.
15. The method of claim 14 further comprising the initial step of attaching a sheathing material to at least a por-tion of a support frame.
16. The method of claim 14 further comprising the step of texturing the exposed surface of the modified concrete matrix.
17. The method of claim 14 further comprising the step of bonding a facing layer onto the modified concrete matrix.
18. The method of claim 14 further comprising the steps of:
bonding a cushioning material to the modified concrete matrix;
affixing a bonding agent to the cushioning mate-rial; and embedding a facing layer in the bonding agent.
bonding a cushioning material to the modified concrete matrix;
affixing a bonding agent to the cushioning mate-rial; and embedding a facing layer in the bonding agent.
19. The method of claim 14 further comprising the steps of:
covering the modified concrete matrix with a liquid synthetic rubber;
curing, at least partially, the liquid synthetic rubber;
affixing a bonding agent to the liquid synthetic rubber; and embedding a facing layer in the bonding agent.
covering the modified concrete matrix with a liquid synthetic rubber;
curing, at least partially, the liquid synthetic rubber;
affixing a bonding agent to the liquid synthetic rubber; and embedding a facing layer in the bonding agent.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US06/347,567 US4525965A (en) | 1982-02-10 | 1982-02-10 | Prefabricated building panels |
| US347,567 | 1982-02-10 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1189718A true CA1189718A (en) | 1985-07-02 |
Family
ID=23364264
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000420182A Expired CA1189718A (en) | 1982-02-10 | 1983-01-25 | Prefabricated building panels |
Country Status (2)
| Country | Link |
|---|---|
| US (1) | US4525965A (en) |
| CA (1) | CA1189718A (en) |
Families Citing this family (28)
| Publication number | Priority date | Publication date | Assignee | Title |
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| US5220762A (en) * | 1984-02-27 | 1993-06-22 | Georgia-Pacific Corporation | Fibrous mat-faced gypsum board in exterior and interior finishing systems for buildings |
| US4674245A (en) * | 1984-03-19 | 1987-06-23 | Diversitech Corporation | Roof walkway panel |
| US5048254A (en) * | 1989-10-31 | 1991-09-17 | Valders Stone And Marble, Inc. | Prefabricated building panel |
| WO1991015345A1 (en) * | 1990-04-04 | 1991-10-17 | Peterson Carl W | Waterproof and corrosion resistant concrete articles and process of preparing the same |
| JP2948909B2 (en) * | 1993-04-01 | 1999-09-13 | デー ヌン インダストリアル カンパニー リミテッド | Construction method of prestressed composite beam structure and prestressed composite beam for continuous beam |
| US5697195A (en) * | 1995-03-07 | 1997-12-16 | Alabama Metal Industries Corporation | Plaster security barrier system |
| US5794402A (en) * | 1996-09-30 | 1998-08-18 | Martin Marietta Materials, Inc. | Modular polymer matrix composite support structure and methods of constructing same |
| US6081955A (en) * | 1996-09-30 | 2000-07-04 | Martin Marietta Materials, Inc. | Modular polymer matrix composite support structure and methods of constructing same |
| US6023806A (en) * | 1996-09-30 | 2000-02-15 | Martin Marietta Materials, Inc. | Modular polymer matrix composite support structure and methods of constructing same |
| US5732520A (en) * | 1996-12-10 | 1998-03-31 | Multicoat Corporation | Synthetic stucco system |
| US6233892B1 (en) | 1997-10-25 | 2001-05-22 | The Namlyt Company | Structural panel system |
| US6516580B1 (en) | 2000-11-13 | 2003-02-11 | Multicoat Corporation | Synthetic stucco system with moisture absorption control |
| US20040058089A1 (en) * | 2001-10-10 | 2004-03-25 | Sport Court, Inc. | Floor tile coating method and system |
| GB0227564D0 (en) * | 2002-11-26 | 2002-12-31 | Spaceover Ltd | Building |
| US6729094B1 (en) * | 2003-02-24 | 2004-05-04 | Tex Rite Building Systems, Inc. | Pre-fabricated building panels and method of manufacturing |
| US7393583B1 (en) * | 2003-04-14 | 2008-07-01 | Starquartz Industries, Inc. | Flooring tile |
| EP2010343A2 (en) * | 2006-04-14 | 2009-01-07 | Genesistp, Inc. | Method and system for manufacturing a structure |
| US20090000214A1 (en) * | 2007-02-01 | 2009-01-01 | Newman Stanley | Integrated, high strength, lightweight, energy efficient building structures |
| WO2009033224A1 (en) * | 2007-09-11 | 2009-03-19 | Cilc International Pty Ltd | Building panel and method of formation of building panel |
| US9303403B2 (en) * | 2009-06-26 | 2016-04-05 | Joel W. Bolin | Composite panels and methods and apparatus for manufacture and installtion thereof |
| US9027300B2 (en) | 2010-01-20 | 2015-05-12 | Propst Family Limited Partnership | Building panel system |
| US9032679B2 (en) | 2010-01-20 | 2015-05-19 | Propst Family Limited Partnership | Roof panel and method of forming a roof |
| US7984594B1 (en) | 2010-01-20 | 2011-07-26 | Propst Family Limited Partnership, Llc | Composite building and panel systems |
| US20140150362A1 (en) | 2010-01-20 | 2014-06-05 | Propst Family Limited Partnership | Building panels and method of forming building panels |
| US8695299B2 (en) | 2010-01-20 | 2014-04-15 | Propst Family Limited Partnership | Building panel system |
| US8555583B2 (en) * | 2010-04-02 | 2013-10-15 | Romeo Ilarian Ciuperca | Reinforced insulated concrete form |
| US9499994B2 (en) | 2012-11-01 | 2016-11-22 | Propst Family Limited Partnership | Tools for applying coatings and method of use |
| JP6815805B2 (en) * | 2016-09-30 | 2021-01-20 | 積水化学工業株式会社 | outer wall |
Family Cites Families (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3327442A (en) * | 1964-06-23 | 1967-06-27 | Gail Internat | Prefabricated synthetic resin bonded tile wall unit |
| US3666606A (en) * | 1970-02-18 | 1972-05-30 | William S Stokes | Composite membrane and tile system |
| US4263372A (en) * | 1976-05-19 | 1981-04-21 | Rohm And Haas Company | Method of coating and/or impregnating porous substrates, and products obtained thereby |
| DE2850861A1 (en) * | 1978-11-24 | 1980-06-04 | Friedrich Heck | METHOD FOR PRODUCING INSULATED PLASTERING FACADES AND INSULATING PANEL ELEMENTS FOR IMPLEMENTING THE METHOD |
| US4327536A (en) * | 1980-03-07 | 1982-05-04 | Linx Building Systems Corp. | Composite building panel |
| US4364213A (en) * | 1980-08-22 | 1982-12-21 | Tru-Split Tool Company | Composite building panel |
| US4349398A (en) * | 1980-12-08 | 1982-09-14 | Edward C. Kearns | Protective coating system |
-
1982
- 1982-02-10 US US06/347,567 patent/US4525965A/en not_active Expired - Fee Related
-
1983
- 1983-01-25 CA CA000420182A patent/CA1189718A/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| US4525965A (en) | 1985-07-02 |
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