Method of forming a wall panel
AssigneeBoral IP Holdings (Australia) PTY Limited
InventorsDavid H. Wolf, James S. Belt, William Smith, Donn R. Vermilion, Wayne Buoni, Joy Stickel
Life of this patent
Estimating the term…
Abstract
A prefabricated wall panel has a precast body including at least one decorative design element. In addition, the wall panel includes a mounting element having a first end embedded in the precast body and a second end projecting from the precast body. A groove is formed between the precast body and the second end of the mounting element along a first edge of the precast body. A tongue is formed along a second edge of the precast body opposite the first edge. The tongue and groove cooperate to allow prefabricated wall panels to be more easily installed on a support substrate.
Claims24
A method of forming a wall panel, comprising:
- positioning a first portion of a mounting element within a mold cavity of a mold;
- adding casting material into the mold cavity so as to embed the first portion of the mounting element in the casting material;
- forming a groove along an edge of the casting material, the groove defined by an edge of the casting material and a second portion of the mounting element extending from the edge of the casting material, wherein the second portion of the mounting element comprises a weep hole configured to allow water to drain from the groove;
- and
- allowing the casting material to set and form the wall panel.
A method of making a panel, the method comprising:
- adding casting material into a mold cavity of a mold, the mold cavity being defined by a bottom surface having a perimeter and at least first and second side surfaces that intersect a portion of the perimeter of the bottom surface at a lower edge of each side surface, the first and second side surfaces being opposite and spaced apart from each other, wherein:
- the mold further comprises a mounting element support surface that extends along and from the upper edge of the first side surface in a direction away from the second side surface, the upper edge being spaced apart from the lower edge of the first side surface, and
- the mounting element support surface and a portion of the first side surface adjacent the upper edge of the first side surface define a rib that extends along the first side surface and toward the second side surface into the mold cavity, wherein the rib is spaced apart from the bottom surface;
- disposing a mounting element into the mold such that a first portion of the mounting element is disposed in the mold cavity and is embedded in the casting material, and a second portion of the mounting element is disposed on the mounting element support surface outside of the mold cavity, wherein the second portion of the mounting element comprises a weep hole;
- allowing the casting material to set and form the panel, wherein the formed panel comprises a front face formed by the bottom surface of the mold cavity, a first edge surface formed by the first side surface of the mold cavity, and a second edge surface formed by the second side surface of the mold cavity, wherein the first and second edge surfaces are opposite and spaced apart from each other and the front face extends between the first and second edge surface, the first edge surface and the second portion of the mounting element define a groove adjacent a back face of the formed panel, and the groove is formed by the rib;
- wherein the weep hole is configured to allow water to drain from the groove.
Dependencies are inferred from the claim text.