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US 5,715,637 AGranted
Prefabricated composite building panel with improved fire retardancy
AssigneePan-Brick, Inc.
InventorsLarry C. Hesterman, Rolf C. Holzkaemper
Life of this patent
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AssigneePan-Brick, Inc.
InventorsLarry C. Hesterman, Rolf C. Holzkaemper
Estimating the term…
A prefabricated composite panel of the type comprising a supporting plywood board, a foamed sheet of polyurethane and a covering layer on the front face of the polyurethane comprising a plurality of brick slices with an aggregate in the spaces between the brick slices which is bonded into the front face of the foam is improved in its fire retardancy by providing a plurality of vertical support metal strips on the inside face of the brick slices at spaced positions across the width of the panel. Each metal strip includes a hanger element at the top which engages over a portion of the foam and a plurality of punched tabs each of which engages under a respective one of the brick slices. The support strips prevent sagging of the brick slices when heat is applied to the front face of the panel since that sagging can allow the heat to penetrate cracks in the covering aggregate. The fire retardancy is further improved by the addition of gypsum to the aggregate which reduces the temperature by releasing water molecules. A yet further improvement provides a reinforcing element in the form of expanded metal embedded in the foam sheet behind those ones of the brick slices which project outwardly at the sides beyond the end of the board.
A prefabricated composite building panel for attachment to a vertical wall of a building comprising a rigid sheet of cellular polymeric material having an outer face for facing outwardly of the wall and an inner face for facing inwardly of the wall, a plurality of rigid facing elements embedded in the outer face of the sheet so as to define an outermost surface of the panel, the facing elements being attached to the outer face in a pattern defining spaces between at least some of the facing elements and adjacent ones of the facing elements, a covering layer on the outer face of the sheet in the spaces and mechanical support means engaging the sheet and formed from a rigid material different from the cellular polymeric material and engaging a plurality of the facing elements to provide mechanical support of the facing elements to resist downward sagging of the facing elements on the sheet.
A prefabricated composite building panel for attachment to a vertical wall of a building comprising a rigid sheet of cellular polymeric material having an outer face for facing outwardly of the wall and an inner face for facing inwardly of the wall, a plurality of rigid facing elements embedded in the outer face of the sheet so as to define an outermost surface of the panel, the facing elements being attached to the outer face in a pattern defining spaces between at least some of the facing elements and adjacent ones of the facing elements, and a covering layer on the outer face of the sheet in the spaces wherein the covering layer is formed from an aggregate monolithically foamed into the outer face, the aggregate including a weather resistant particulate material and a heat dissipating material comprising gypsum.
A prefabricated composite building panel for attachment to a vertical wall of a building comprising a rigid sheet of cellular polymeric material having an outer face for facing outwardly of the wall and an inner face for facing inwardly of the wall, a plurality of rigid facing elements embedded in the outer face of the sheet so as to define an outermost surface of the panel, the facing elements being attached to the outer face in a pattern defining spaces between at least some of the facing elements and adjacent ones of the facing elements, a covering layer on the outer face of the sheet in the spaces, the facing elements comprising rectangular bodies arranged in a staggered pattern with spaces therebetween, the pattern being arranged such that at each end of the panel there are a plurality of the facing elements each of which has a portion thereof projecting from and exposed at the end of the sheet, each of said elements having a portion of the sheet behind the element, and reinforcement means formed from a material different from the cellular polymeric material and embedded within the sheet and extending into the portion of the sheet behind the element.
A prefabricated composite building panel for attachment to a vertical wall of a building comprising a rigid sheet of cellular polymeric material formed by a foaming process and having an outer face for facing outwardly of the wall and an inner face for facing inwardly of the wall, a plurality of rigid facing elements embedded in the outer face of the sheet during the foaming process so as to define an outermost surface of the panel, the facing elements being attached to the outer face in a pattern defining spaces between at least some of the facing elements and adjacent ones of the facing elements, a coveting layer on the outer face of the sheet in the spaces, the coveting layer being formed from an aggregate monolithically integrated into the outer face of the sheet, a coating of a spray adhesive disposed over particles of the aggregate and onto the adjacent ones of the facing elements, wherein the sheet is integrated with the coating and the aggregate to form a monolithic integral structure.
Dependencies are inferred from the claim text.