US3885008A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method for producing prefabricated wall section with molded panels
Assignee: Individual
•
Filing: 1972-08-11
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Granted: 1975-05-20
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Expires: 1992-08-11
Abstract
Abstract A prefabricated wall or roof section includes a frame with a molded panel bonded thereto, for installation as a unit with like units to form a building wall structure. The molded panel has a simulated masonry face; and the wall section includes integral insulation material applied to the back face of the panel within the frame. In the fabrication of the wall sections, a mold is formed from a plurality of perimetrically precision finished modular sections defining the base and confined within a frame or chase. The panel is formed from a homogeneous mixture of a high percentage of a comminuted sand-like material with a liquid containing appropriate bonding and chemical ingredients, which is applied within the mold and leveled with the mold frame. The wall section frame is immediately placed over the mixture, a layer of fiberglass reinforce plastic is applied to the mixture surface and to the adjacent frame surfaces for sealing and bonding of the mixture and frame. The assembly is then cured at a suitable temperature. After curing and cooling, an insulation coating is applied to the back surface of the panel within the wall section frame.
Inventors
- 👤 Robert E Martin
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 01:12
CPC Classifications
E; E04; E04C; E04C2/00; E04C2/30; E04C2/38; E04C2/386; E04C2/02; E04C2/10; E04C2/24
Claims Analysis
Total Claims: 9
Claim 1
Independent Claim
238 words
A METHOD FOR MANUFACTURING A PREFABRICATED BUILDING WALL SECTION INCLUDING A THIN WALL PANEL DEFINING A SIMULATED MASONRY SURFACE AND A SUPPORT FRAME INTEGRALLY ATTACHED TO ONE SURFACE THEREOF INCLUDING THE STEPS PROVIDING A SHALLOW MOLD HAVING A SUBSTANTIALLY PLANAR BOTTOM WALL, DEFINING THE MOLD SURFACE FOR FORMING THE EX POSED FINISH SURFACE OF A MOLDED WALL PANEL, AND HAVING SIDE WALLS OF UNIFORM HEIGHT TO DEFINE THE EDGES OF THE MOLDED WALL PANEL; MIXING A LIQUID COMPONENT INCLUDING, BY VOLUME, ABOUT 60% OF A THERMOSETTING RESIN, ABOUT 25% RESIN THINNER, ABOUT 9% FLOW ENHANCER. AND A CURING AGENT; MIXING THOROUGHLY ABOUT 18 TO 30% BY WEIGHT OF SAID LIQUID COMPONENTS WITH ABOUT 70 TO 82% OF A SOLIDS COMPONENT CONSISTING OF A COMMUNITED, CRYSTALLINE, INSOLUBLE EARTHEN MATERIAL, TO PRODUCE A HOMOGENEOUS PANEL MIXTURE; FILLING SAID SHALLOW MOLD WITH SAID PANEL MIXTURE AND LEVELING SAID MIXTURE WITH THE MOLD SIDE WALLS; PLACING A UNITARY, OPEN PANEL SUPPORTING FRAME CONTIGUOUS TO THE SURFACE OF SAID PANEL MIXTURE EXPOSED BY SAID MOLD, WHILE SAID MIXTURE REMAINS IN SAID MOLD, IN POSITION TO BE BONDED TO SAID MIXTURE; APPLYING A COATING OF FIBERGLASS REINFORCED PLASTIC TO THE EX TRANSVERSE SURFACES OF THE WALL FRAME MEMBERS, TO EFFECT A BOND BETWEEN SAID PANEL AND FRAME; EFFECTING THE CURE OF SAID PANEL MIXTURE AND THE BONDING OF SAID FRAME THERETO; AND REMOVING THE INTEGRAL ASSEMBLY OF CURED PANEL AND FRAME FROM SAID MOLD.
Claim 2
Independent Claim
238 words
A METHOD FOR MANUFACTURING A PREFABRICATED BUILDING WALL SECTION INCLUDING A THIN WALL PANEL DEFINING A SIMULATED MASONRY SURFACE AND A SUPPORT FRAME INTEGRALLY ATTACHED TO ONE SURFACE THEREOF INCLUDING THE STEPS PROVIDING A SHALLOW MOLD HAVING A SUBSTANTIALLY PLANAR BOTTOM WALL, DEFINING THE MOLD SURFACE FOR FORMING THE EX POSED FINISH SURFACE OF A MOLDED WALL PANEL, AND HAVING SIDE WALLS OF UNIFORM HEIGHT TO DEFINE THE EDGES OF THE MOLDED WALL PANEL; MIXING A LIQUID COMPONENT INCLUDING, BY VOLUME, ABOUT 60% OF A THERMOSETTING RESIN, ABOUT 25% RESIN THINNER, ABOUT 9% FLOW ENHANCER. AND A CURING AGENT; MIXING THOROUGHLY ABOUT 18 TO 30% BY WEIGHT OF SAID LIQUID COMPONENTS WITH ABOUT 70 TO 82% OF A SOLIDS COMPONENT CONSISTING OF A COMMUNITED, CRYSTALLINE, INSOLUBLE EARTHEN MATERIAL, TO PRODUCE A HOMOGENEOUS PANEL MIXTURE; FILLING SAID SHALLOW MOLD WITH SAID PANEL MIXTURE AND LEVELING SAID MIXTURE WITH THE MOLD SIDE WALLS; PLACING A UNITARY, OPEN PANEL SUPPORTING FRAME CONTIGUOUS TO THE SURFACE OF SAID PANEL MIXTURE EXPOSED BY SAID MOLD, WHILE SAID MIXTURE REMAINS IN SAID MOLD, IN POSITION TO BE BONDED TO SAID MIXTURE; APPLYING A COATING OF FIBERGLASS REINFORCED PLASTIC TO THE EX TRANSVERSE SURFACES OF THE WALL FRAME MEMBERS, TO EFFECT A BOND BETWEEN SAID PANEL AND FRAME; EFFECTING THE CURE OF SAID PANEL MIXTURE AND THE BONDING OF SAID FRAME THERETO; AND REMOVING THE INTEGRAL ASSEMBLY OF CURED PANEL AND FRAME FROM SAID MOLD.
Claim 3
Dependent Claim
23 words
A method as set forth in claim 1 wherein said thermosetting resin is a polyester resin; and wherein said resin thinner is styrene.
Claim 4
Dependent Claim
29 words
A method as set forth in claim 1 wherein said solids component is a material selected from a group consisting of sand, dolomite, perlite, silica, ground quartz and slack.
Claim 5
Dependent Claim
30 words
A method as set forth in claim 1 including the step of applying, after curing, a coating of polyurethane foam to the panel surface between the members of said frame.
Claim 6
Dependent Claim
26 words
A method as set forth in claim 1 including the step of preheating the mold to about 140*F. before applying the panel mixture to the mold.
Claim 7
Dependent Claim
33 words
A method as set forth in claim 1 wherein said unitary frame includes peripheral frame members dimensioned to correspond with the peripheral dimension of the panel within the mold, and internal frame members.
Claim 8
Dependent Claim
45 words
A method as set forth in claim 1 wherein said panel is formed with a thickness of about three-eighths inch; and wherein said frame is formed from framing members having a nominal 4 inch width in a direction perpendicular to the plane of the panel.
Claim 9
Dependent Claim
29 words
A method as set forth in claim 1 including providing a textured bottom wall for said mold for producing a correspondingly textured exposed finish surface of the molded panel.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-05-19 | 1978-11-18 | 1979-05-20 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-05-19 | 1982-11-18 | 1983-05-20 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-05-19 | 1986-11-18 | 1987-05-20 | $7700.00 | Window Closed / Lapsed |