Composite lightweight building element and methods of making and using same
OwnerJohn W. Boehninginventor
Life of this patent
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Abstract
A composite lightweight building element comprises a first layer of aggregate based material (7, 8 and 9) extruded, sprayed, molded or cast onto a lightweight base form (1) which becomes an integral part of the element. This element can be manufactured in a panel to emulate common face brick (52), a smooth or chipped surfaced cut stone (60) or a floor tile. Integral with the first and second layers are cooperating dovetail ridges and grooves (4) respectively which serve to provide mechanical locking between the layers and a strengthening to the first layer. Integral with the second layer are male and female interlocking members (6 and 6a) to facilitate installation, to resist air or water infiltration between the panels and to provide mechanical locking between panels.
Claims19
A composite wall facing or floor covering construction element comprising a first layer of aggregate based material having an outer or upper surface which in use forms the exterior surface of said wall facing or floor covering element and an inner or lower surface being in abutment with an outer or upper surface of a second layer, said second layer having a density less than that of said first layer, said second layer extending substantially to the rear of said first layer, wherein said abutting surfaces of said first and second layers include complementary interlocking engaging means comprising one or more male and female members and wherein said first layer is formed by depositing, extruding, casting or pouring said aggregate based material onto said second layer providing a single permanently joined entity, wherein said first aggregate based layer extends to cover around the entire complementary interlocking engaging means and all edges of the element which are visible in use.
A composite wall facing or floor covering construction element comprising a first layer of aggregate based material having an outer or upper surface which in use forms the exterior surface of said wall facing or floor covering element and an inner or lower surface being in abutment with an outer or upper surface of a second layer, said second layer having a density less than that of said first layer, said second layer extending substantially to the rear of said first layer, wherein said abutting surfaces of said first and second layers include complementary interlocking engaging means comprising one or more male and female members, wherein said first layer is formed by depositing, extruding, casting or pouring said aggregate based material onto said second layer providing a single permanently joined entity, wherein said first aggregate based layer extends to cover around the entire complementary interlocking engaging means and all edges of the element which are visible in use, and wherein said second layer is provided with a means of depositing a second color of said aggregate based material of said first layer on one or more sides of the peripheral edges of said first layer.
A composite wall facing or floor covering construction element comprising a first layer of aggregate based material having an outer or upper surface which in use forms the exterior surface of said wall facing or floor covering element and an inner or lower surface being in abutment with an outer or upper surface of a second layer, said second layer having a density less than that of said first layer, said second layer extending substantially to the rear of said first layer, wherein said abutting surfaces of said first and second layers include complementary interlocking engaging means comprising one or more male and female members, wherein said second layer is provided with a means of depositing a second color of said aggregate based material of said first layer on one or more sides of the peripheral edges of said first layer, wherein said first layer is formed by depositing, extruding, casting or pouring said aggregate based material onto said second layer providing a single permanently joined entity, wherein said first aggregate based layer extends to cover around the entire complementary interlocking engaging means and all edges of the element which are visible in use, and wherein said second layer is provided with an interlocking means consisting of male and female members on opposite surfaces which in use engage each other when one element is installed on or beside a previous member.
Dependencies are inferred from the claim text.