Note: Descriptions are shown in the official language in which they were submitted.
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This invention relates to a novel composite
bullding panel formed from a plurality of generally flat exterior
elements (natural stone) disposed in generally coplanar relative
relationship with each element being defined by inner, outer and
peripheral surfaces, the peripheral surfaces being disposed in
spaced relationship to define gaps therebetween, an adhesive for
at least partially filling the gaps and at least in part
covering inner surfaces of the elements, a generally planar sheet
of plastic material overlying the plurality of elements and
being bonded thereto by the adhesive, a support frame, and means
for connecting the elements and the plastic sheet to the support
frame.
Another object of this invention is to provide a
novel composite building panel of the type defined wherein the
connecting means include a plurality of studs bonded by the
adhesive means to at least one of the elements.
Still another object of this invention is to provide
a novel composite building panel of the type set forth Lmmedi-
ately heretofore, wherein the support frame includes an opening
for receiving each stud and the connecting means further includes
a fastener connected to each stud to connect the support frame
to the plastic material and to the plurality of elements.
Still another object of this invention is to provide
a novel composite building panel of the type set forth hereto
fore, wherein the connecting studs are each bonded by the
adhesive means in a bore of selected ones of the elements.
In keeping with the foregoing, a further object of
this invention is to provide a novel method of forming a
composite building panel of the type heretofore described
including the steps of arranging a plurality of generally flat
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exterior elements r such as natural stone, in generally coplanar
relative relationship and with peripheral surfaces o the elements
spaced to define at least one gap therebetween, applying an
adhesive upon an upper surface oE the elements and within the
gap, placing a sheet of plastic material atop the adhesive to
bond the elements thereto, Eormin~ a bore in at least one of
the elements and an opening in the plastic sheet generally co-
axial with the bore, and adhesively bonding a stud within the
bore in internal telescopic relation~hip to the opening.
Still another object of this invention is to provide
a novel method as set forth heretofore, including the step of
securing a support frame to the stud by utilizing a fastener.
Yet another object of this invention is to provide
a novel method of the type described including the step of
sanding the upper surfaces of the elements to a generally flat
configuration before applying the adhesive thereon, and insert
ing caulking material in the gap before applying adhesive
therein whereby the gap is only partially filled with the adhesive.
Still another object of this invention is to provide
a novel method of forming a composite building panel as
described herein, including the step of providing the support
~rame with at least one opening and forming the bore in the
element and the opening in the plastic sheet by placing the
support frame upon the plastic sheet, utilizing the support
frame opening to locate the desired position of the bore of
the element and the opening of the plastic sheet, and thereafter
forming the latter bore and opening at the desired position by an
appropriate drilling operation.
With the above and other objects in view that will
hereinafter appear, the nature of the invention will be more
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Clearly understood by reference to the following detailed
description, the appended claims and the several vie~s illustrated
in the accompanying drawings.
IN TH~ DRAWINGS:
FIGURE 1 is a fragmentary perspective view, and
illustrates an ini-tial step in the process of the present
invention, namely, that of cutting a generally rectangular
element from a piece of natural stone or the like.
FIGURE 2 is a perspective view of the element after
being cut, and illustrates a grinding operation to smooth upper
and lower surfaces of the element.
FIGURE 3 is a fragmentary perspective view of a
table, and illustrates a plurality of the elements ground in
accordance with Figure 1 and ~eing positioned atop the table
in a predetermined arrangement with gaps between the individual
elements being filled by flexible caulking material.
FIGURE 4 is an elnarged fragmentary sectional view
of the encircled portion of Figure 3, and illustrates the
caulking material disposed in gaps of adjoining elements.
FIGURE 5 is a fragmentary sectional view taken
generally along line 5-5 of Figure 3l and illus-trates adhesive
being applied atop an innermost surface of the elements and the
manner in which a trowel is utilized for applying the adhesive
thereto in a desired quantity.
FIGURE 6 is an enlarged fragmentary sectional view
of the circled portion of Figure 5, and illustrates the manner
in which the adhesive is applied in a relatively thin film or
coating to an inner surface of the elements and within the gap
therebetween prior to the application of a sheet of plastic
material thereatop.
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E'IGURE 7 is a sectional view similar to Figure 5
and illustrates a plurality of weights positioned atop the
plastic sheet and covered by a heating pad or the like to
accelerate the curing of the adhesive.
FIGURE 8 is a perspective view of the partially
completed composite building panel of Figure 7 after the
weights and heating panel have been removed, and illustrates a
supporting frame having openings which are utilized to mark
the plastic sheet for the eventual formation therein of openings
therein and coaxial bores in the elements.
FIGURE 9 is an enlarged fragmentary sectional view
of a portion of the panel of Figure 8, and illustrates the
manner in which a drill is utilized to form an opening in the
plastic sheet and a bore in an underlying one of the plurality
of elements.
FIGURE 10 is a fragmentary sectional view similar
to Figure 9, and illustrates the frame in position atop the
panel, a stud received in the opening and bore, and adhesive
within the bore to bind the stud within the bore of the element
and the opening of the plastic material.
FIGURE 11 is an enlarged sectional view similar to
Figure 5, and illustrates a plurality of elements of which
only one surface has been surface ground to a flat configuration
while a rougher unground surface has applied thereto a polyure~
thane foam (adhesive) for uniting or bonding a frame to associated
studs received in bores of the individual elements.
FIGURES 12 through 14 illustrate variations in the
patterns of elements in the overall composite building panel.
FIGURE 15 is a cross-sectional view, slightly enlarged,
taken generally along lines 15-15 of both Figures 12 and 13,
and illustratPs the manner in which metallic studs of the support
frame are positioned upon the plastic sheet and the relationship
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thereto to the underlying elements (stone or stone facing).
FIGURE 16 is a cross sectional view, again slightly
enlarged, taken generally along lines 16-16 of Figure 14, and
likewise illustrates metallic studs of a support frame positioned
S atop a plastic sheet with the added studs, as compared to
Figure 15, being utilized to accommodate t}le staggered vertical
joints of the composite panel of Figure 14, as compared to teh
nonstaggered vertical joints of the panels of Figures 12 and 13.
FIGURE 17 is a side elevational view of a composite
building panel, and illustrates the manner in which at least
one stud is connected by adhesive to each element ~stone facing)
for securing the same to an associated metallic stud.
FIGURE 18 is an enlarged sectional view taken
through portions of two adjoining composite building panels
of this invention, and i;llus~rates the manner in which adjacent
edges are field caulked.
FIGURE 19 is a fragmentary perspective view similar
to Figure 18 and illustrates a corner construction in which
additional elements along endmost ones of the metallic studs
are fastened thereto by appropriate fasteners.
FIGURE 20 is a fragmentary sectional view similar
to Figure 19, and illustrates a soffit detail of the invention,
including a drip groove in one of a plurality of external
elements.
FIGURE 21 is a fragmentary view similar to Figures
19 and 20, and illustrates another corner detail of the
invention in which adjacent stone facings are cut at approxi-
mately a 45 degree angle to each other.
A novel composite building panel constructed in
accordance with this invention is illustrated in Figures 10
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ana 12 through 21 of the drawings, and is generally desi~nated
by the reference numeral 10. The composite building panel 10
is manufactured by a novel method or process which will first
be described in connection with Figures 1, 2, etc. of the
drawings to which reference is now made.
In Figure 1 of the drawings, a slab S o~ natural
stone, although the same might be articifical, is shown being
cut by a saw 11 to a generally rectangular con:Eiguration to
form a rectangular element or stone facing 15. The element
or stone facing 15 includes a peripheral bounding edge 16, an
upper surface 17, and a lower surface 18. Though only a single
element 15 is shown being cut from the slab S, it is to be
understood that a plurality of such elements 15 are formed and
eventually each such element 15 is subjected to a grinding opera-
tion by a conventional abrading or grinding cylinder 20 which is
rotated by conventional means (not shown) such that both surfaces
17 and 18 are rendered relatively smooth or plumb. Preferably
the thickness of each element 15 at the end of the grinding
operation is approximately 1 and 1-1/~ inch.
After the individual stone facings or elements 15
have been ground (Figure 2), a plurality of such elements 15
are positioned atop a relatively flat planar horizo~tal surface
22 of a table or suitable support 23, and for purposes of
description the ind~vidual elements 15 in Figure 3 have been
provided with appropriate letters of the alphabet as subscripts
to distinguish adjacent elements 15 one from the other. Thus,
in Figure 3 the fiteen elements are identified by the reference
numerals 15a through 15p and all of the latter are spaced from
each other to define therebetween a plurality of gaps or spaces
24 through 26 running vertically and like gaps or spaces 27
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through 29 running horizontally. Once the individual elements
15a through 15p have been so positioned atop -the surface 22
of the table 23, removable caulking material in the form of
polystyrene caulking rope 30 is inserted in all of the gaps 24
through 29 in the manner best illustrated in Figure 4 of the
drawings. Thus, all of the gaps 24 -through 29 are filled with
the caulking rope 30 and each piece of caulking rope 30 is
positioned so as -to rest atop and against the surface 22 of the
table 23 such that each gap 24 through 29 is sealed at its
edge most adjacent the surface 18 of each element 15 and is
opened adjacent each surface 17 of each element 15 wi-th the
surfaces 18, 17 being nominally described as the outer and
inner surfaces, respectively, to designate the relationship of
those surfaces to the exterior of an associated building, as
will be more readily apparent hereinafter.
After all of the gaps 24 through 29 have been temporarily
caulked by the caulking rope 30 in the manner described rela-tive
to Figures 3 and 4, an appropriate epoxy resin adhesive 36 which
is heat curable is poured or otherwise applied atop the surfaces
17 of all of the elements 15 and a uniform thickness is achieved
by utilizing a trowel 35 which further flows the adhesive 36 into
the gaps 24 through 29 and a-top the caulking rope 30 in the manner
best illustrated in Figure 6. Once the adhesive 36 has been
smoothed and leveled to a desired thickness and all of the gaps
24 through 29 have been filled therewi-th, a relatively thick
sheet of polyurethene foam, polys-tryene foam,or like plastic
ma-terial 37 corresponding in size to the overall outer peripheral
dimension of the elements 15a through 15p is laid atop theadhesive
36 and, of course, in overlying relationship to all of the
elements 15a -through 15p, as is best illustrated in Figure 7. One
or more weights 38, 39, 40, etc. are then placed atop the
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polystyrene foam or like plastic sheet 37 to intima-tely urge the
same into contact with the layer of adhesive 36 and, of course,
urge the layer of adhesive 36 into intimate bonding relationship
with all of the elements 15a -through 15p. Furthermore, the
weights 58 through 40 also prevent the polystyrene foam sheet
37 from twisting, warping or otherwise deflecting from its generally
uniplanar position (Figure 7) as might ocur during the curing
operation of the adhesive 36 which can occur under ambient
tempera-ture conditions, but the curing opera-tion can be augmented
or hastened by covering the entire assemblage in Figure 7 with
an electric resis-tance heating blanket 41 or simply subjecting
the overall assemblage of Figure 7 to a heat source, such as
infrared lamps, a heating oven, etc. During this curing operation,
the adhesive ~6 cures or se-ts and intimately bonds all of the
elements 15a through 15p to the single polystyrene foam shee-t
37 but not to the caulking material or rope 30. Preferably,
the adhesive 36 has li-ttle bonding affini-ty relative to the
caulking rope 30 and after the adhesive 36 has cured, all of
the caulking rope 30 is removed from the gaps 24 through 29
leaving partial gaps between adjacent elements as is best illus-
trated in Figures 18 of the drawings.
The plurality of elements 15a through 15p, the
adhesive 36, and the plastic shee-t ~7 form a subassembly
which is generally designated by the reference numeral 45
(Figure 8), and temporarily positioned thereatop is a support
frame 50 formed of a plurality of individual metallic studs
51 through 56 disposed in generally parallel relationship to
each other and secured at opposite ends to similar metallic
studs 57, 58 thereby imparting a generally rectangular con-
figuration to the suppor-t frame 50 whose outer periphery
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corresponds generally to the outer periphery of the su~assembly
45. The U-shaped studs or beams 51 through 56 are provided
with a plurality of openings 60 in the flanges (unnumbered)
thereof, and the openings are so placed that at least one
opening is in regis~ration with each of the elements 15a through
15p. Like openings corresponding to the opening 16 might also
be placed in the webs or flanges of the U-shaped studs or
beams 57, 58. The frame 50 is then lowered upon the inside or
interior sur~aces 17 of the individual elements 15a. through 15p
and a pencil or like scribe is inserte~ through the openings 60
and:amark or marking 61, 62, etc. is made upon the exterior
surface 17 of each of the elements 15a through 15p.
Thereafter, the support frame 50 is removed and
a suitable tool (Figure 9) such as a drill hit 63 is utilized
to form an opening 64 through the plastic sheet 37 at each of
the markings 61, 62, a like openiny 65 through the adhesive
thereof, and a blind bore 66 in each of the elements 15a through
15p. The drill bit 63 might be wobbled such that the overall
cross-sectional configuration of the opening 64, the opening 65
and the blind bore 66 is of a generally frusto-conical configu-
ration, as is most readily apparent in Figure 10. Once such a
frusto-conical opening 64, 65, 66 is formed at each of the
markings 61, 62, adhesive means 70, such as an eopxy adhesive,
is poured into the bores 64, 65 and 66 after which a stud 71
having a threaded end portion 72 is positioned within each bore
and within the adhesive therein, as is clearly apparent from
Figure 10 of the drawings. The support frame 50 is then
lowered upon the plastic material 37 and each threaded end portion
72 oE an associated stud 71 is located in one of the openings
60 of the beams or studs 51 through 56. The openings 60 serve
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to hold the studs 71 in alignment during the curing or solidi-
fying of the adhesive 70 after which a washer 74 is inserted
upon the threaded end portion 72 of the studs 71 and, ~inally,
a nut 73 is threaded and tightened to connect the support
frame 50 to each of the individual elements 15a through 15p
through the studs 71 associated with each. This completes the
formation of the overall composite building panel which is
generally designated by the reference numeral 10 except that the
same type of epoxy 70 might be utilized to cover the tightened
nut 73 and the exposed end of the end portion 72 to hold these
elements in their locked position during travel, building
assembly, etc. From the latter descriptionl it will be noted
that each of the individual composite building panels is made
up of fifteen individual stone facings or elements 15a through
15p, but all of these are rigidly interconnected to the support
frame 50 through the studs 71 and the adhesive 70 while the
plastic sheet material 37 functions as insulation for heat,
cold, fire, sound, etc. The composite building panel 75 may
then be assembled along the exterior face of the building and
secured thereto in a conventional manner through the support
frame 50 with the overall size, shape, etc. of the individual
composite building panels 10 being variable to suit conditions,
building codes and characteristics, architects and builders
desires, etc.
The composite building panels 10 may be
configured with its individual elements 15 in a regular non-
staggered relationship, in the manner heretofore described
relative to Figure 8 and as best shown in Figure 12 or the
same elements 15 might be staggered, as shown in Figure 13.
The composite building panels 10 of Figures 12 and 13 are not
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376'~3
staggered along vertical lines but are staggered along hori-
zontal lines, but in each case the support frame 50
associat~d therewith need but ukilize six of the parallel
C-shaped studs or beams 51 through 56. However, if the elements
are staggered horizontally relative to each other, as illus-
trated in Figure 1~ relative to the composite building panel 10
thereof, it is necessary to include additional C-shaped beams or
studs, in the manner best indicated in Figure 16, so that each
of the elements 15 is bolted ~o at least one of the C shaped
studs or beams in the manner most readily apparent from
Figure 16.
Figures 17 and 18 depict the composite panels
10 as they would be mounted to a building to form the exterior
facing thereof, and when two of ~uch composite building panels
10-.are connected end-to-end, as shown in Figure 18, caulking
rope 30 of polystyrene is inserted between the adjacent spaced
edges at the building site during installation, and thereafter
conventional caul]cing material M is injected in the sp.ace so
that when viewed from the exterior, one can not determine where
one building panel ends and the other begins.
~ eference is now made to Figure 19 which shows
a slightly modified version of the composite building panel
heretofore described in which each element 15' along both
longitudinal edges projects beyond an associated one of the
U-shaped studs, channels or beams 51' or 56' and connected to
the latter in the manner heretofore described i5 a sheet of
insulating material 379, one or more additional elements or
stone facings 15'' and adhesive 36' therebetween with the usual
connecting studs 71'. This construction provides an overall
composite building panel 10' which can be located at the door,
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window, or the like to effect a smooth, unbroken and esthetically
acceptable corner.
The composite building panel lO'' of Figure 20
is similar to the composite building panel 10' of Figure 19
except that one or more facing elements, stone facings, or
li]ce elements 15''' are slotted as at 75 to provide a drip or
drain opening, and these are bolted by the studs and adhesive
heretofore noted to one of the upper or lower U-shaped studs
or beams 57', 58' corresponding to the U-shaped studs or beams
57, 58 of the composite panel 10~ Thus, the construction of
the composite building panel 10' of Figure 2 permits the
elements or stone facing 15''' to be disposed along either of
the shorter lengths or U-shaped channels 57, 58 or 57', 58',
whereas in Figure 19 the composite building panel 10 7 has the
additional elements or stone facings 15'' running along the
length of the channels 51 or 56.
A composite building panel 10''' of Figure 21
is similar to the panel 10 e~cept that the associated corres-
ponding plastic sheet material 37, adhesive 36, and endmost
elements or stone Eacings 15 project beyond the individual
longitudinal edges of the composite building panels 10 " ',
10'''' and the terminal edges are cut at 45 angles and caulked
in the manner described relative to Figure 18.
Reference is made to Figure 11 which shows the
manner in which a composite building panel may be formed in
the absence of (1) sanding the innermost surface 17 of each
of the elements 15 and (2) in -the absence of utilizing a
separate sheet of plastic material r such as the plastic
material 37. In this case because the surface 17 of the
elements 15 are not grounded, they are not planar and thus
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have a generally irregular or undulating appearance, as is
exaggera-ted in Figure 11. Eowever, bores corresponding to
those designated by reference numeral 66 in Figure 9 are
~ormed in all of the elements 15 o~ Figure 11, studs are
placed therein after being connected to an associated ~rame
50, and the latter is supported in spaced relationship above
the individual elements 15 by a suitable frame, support, or
simply by the fact that the individual studs 71 rest against
the bottom of the blind bores 66. The adjoining elements 15
are, of course, caulked with the usual caulking rope 30, as
was heretofore described relative to Figure 3. Thereafter,
polyurethane foam 80 is poured atop the s~bassembly which, of
course, is located in a peripheral reservoir or wall W to
preclude the polyurethane foam 80 from flowing over the sides
in an indiscriminate fashion. The polyurethane foam 80 i5
poured atop the individual elements 15 to a predetermined
height H which, of course, also fills the gaps between the
elements 15, and once the polyurethane foam 80 cures or soli-
difies, the entire composite building panel may be utiliz~d in
much the same manner as that heretofore described relative to
the panels 10, 10' etc.
The various perimeters relative to the manu-
facture and the eventual product are variable, but preferably
the individual panels 10, 10', etc. are made in convenient
sizes up to, though not limited to, 10' x 2~'. The individual
elements 15 are preferably ground to a standard 1-1/4'
thickness and, though preferably constructed ~rom natural
stone, the weight is approxima~ely only 15 lb. per 5q . ~t.,
the depth of the blind bore 66 in the element~ 15 is approxi-
mately 3/4" and the individual studs 71 are generally 3/8" bolts.
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Obviously, in any o-f these composite panels 10, 10', etc.,
the plastic material 37 and/or the poured polyurethane foam 80
are preferably approximately 1" thick. The gaps or spaces
24 through 29 can vary approximately between 1/8" to 1/2'~
and though the sizes of the individual elements 15 may vary,
in an 8' x 1' composite building panel 10, the individual
elements or stone facings were 24" x 48".
Although only a preferred embodiment of the
invention has been specifically i.llustrated and described herein,
it i5 to be understood that minor variations may be made in
the apparatus without departing from the spirit and scope of
the invention, as defined in the appended claims.
