Method of forming a composite panel

Abstract

A method of forming a composite panel with a facade comprising a planar arrangement of thin discrete facers on a body of structural backing material. The method comprises the steps of providing a horizontal casting bed, providing a plurality of facers each with a chamfer at a corner between side and rear walls. Arranging the plurality of facers in abutting relationship atop the casting bed and in a selected pattern in a face down planar configuration so that the chamfers on the facers open upwardly and define narrow elongated sealant channels at joints between contiguous facers. Depositing a sealant in the channels and pouring concrete as a structural backing material atop the facers, the rear surfaces of the facers and the concrete adhering to form a composite panel.

1 . A method of forming a composite panel with a facade comprising a planar arrangement of thin facers on a body of structural backing material; said method comprising the steps of providing a substantially flat casting bed, providing a plurality of facers each with a recess along at least a major portion of a corner extending along and between its side and rear walls, arranging the plurality of individual facers in abutting relationship atop the casting bed and in a selected geometric pattern in a face-down planar configuration so that recesses on the facers open rearwardly and define narrow elongated channels at joints between contiguous facers, casting structural material behind the facers to both conform to and adhere to the rear surfaces thereof and form a composite panel, the structural material forming a seal with the walls of the recesses at joints between the facers.  
     
     
         2 . A method of forming a composite panel as set forth in    claim 1    wherein the facers have a rectangular configuration, and wherein the rear corners thereof are chamfered along each rear end wall comer and at least one rear-side wall corner.  
     
     
         3 . A method of forming a composite panel as set forth in    claim 2    wherein each chamfer has a flat angularly inclined surface extending between adjacent side and rear facer surfaces.  
     
     
         4 . A method of forming a composite panel or set forth in    claim 1    including the step of depositing a sealant in the channels between facers.  
     
     
         5 . A method of forming a composite panel as set forth in    claim 4    wherein fine particulate material is used as a sealant.  
     
     
         6 . A method of forming a composite panel as set forth in    claim 5    wherein the fine particulate material is sand.  
     
     
         7 . A method of forming a composite panel as set forth in    claim 6    wherein the sand is deposited on the rear surfaces of the facers and swept into the sealant channels with the rear surfaces of the facers swept clean.  
     
     
         8 . A method of forming a composite panel as set forth in    claim 4    wherein the sealant takes the form of a hardenable liquid material deposited in the sealant channels and then allowed to at least partially harden so as to prevent the structural material from flowing through the joints between the facers during casting.  
     
     
         9 . A method of forming a composite panel as set forth in    claim 1    wherein a fine particulate material is employed in providing a deformable casting bed.  
     
     
         10 . A method of forming a composite panel as set forth in    claim 4    wherein the fine particulate material is sand.  
     
     
         11 . A method of forming a composite panel as set forth in    claim 1    wherein a compressible foam plastic material is employed in providing the casting bed.  
     
     
         12 . A method of forming a composite panel as set for the in    claim 1    including providing a plurality of clips and ribs on the backs of facers and installing the clips in interconnecting relationship with ribs on contiguous facers to force the facers into firm engagement and prevent concrete leakage therebetween during casting of the structural material.  
     
     
         13 . A method of forming a composite panel as set forth in    claim 12    where some of the clips are installed in interconnecting relationship on ribs of contiguous facers arranged in end-to-end relationship and others are installed on ribs of contiguous facers arranged in side-by-side relationship.  
     
     
         14 . A method of forming a composite panel as set forth in    claim 13    wherein dove-tailed ribs are provided and wherein the spring clips are provided each with a generally dove-tail configuration in cross-section and with short opposing side legs defining an opening for receiving a dove-tailed rib, the legs of each clip being inwardly inclined toward the mouth of the clip opening, and wherein the clips are snapped into interconnecting positions on the ribs in movement of the clips relative to the ribs, the clips receiving the ribs and being thus mounted in embracing relationship with the ribs.  
     
     
         15 . A method of forming a composite panel as set forth in    claim 14    wherein the clips are provided with vertical through openings for downward entry of the structural material during casting.  
     
     
         16 . A method of forming a composite panel as set forth in    claim 15    including the step of spreading and engaging the legs of each clip with a rib and then releasing and thus connecting the same in embracing relationship with the rib.  
     
     
         17 . A method of forming a composite panel as set forth in    claim 16    and including the steps of providing a tool for conveniently manually spreading and releasing the legs of a clip and thus efficiently snapping the clips into embracing positions on the ribs.  
     
     
         18 . A method of forming a composite panel as set forth in    claim 1    wherein a retarder is applied to the front surfaces of the facers.  
     
     
         19 . A method of forming a composite panel as set forth in    claim 1    wherein an “anti bonding agent” is applied to the front surfaces of the facers.  
     
     
         20 . A method of forming a composite panel as set forth in    claim 1    wherein Self Compacting Concrete is employed as structural backing material.  
     
     
         21 . A method of forming a composite panel as set forth in    claim 1    wherein the facers are provided with integral rearwardly and upwardly projecting connecting means which are embedded in the structural backing material after casting to provide for enhanced structural integrity of the panel.  
     
     
         22 . A method of forming a composite panel as set forth in    claim 21    wherein the connecting means take the form of a series of ribs integral with the bodies of the facers.  
     
     
         23 . A method of forming a composite panel as set forth in    claim 22    wherein the ribs on the facers take a generally dove-tail configuration viewed in cross-section with complementary generally dove-tailed spaces therebetween for enhanced strength of connection with the structural backing material.  
     
     
         24 . A method of forming a composite panel as set forth in    claim 23    wherein a plurality of anchors are provided and installed each with a flexible base portion adapted to snap into engagement with at least one rib and each with a body portion projecting therefrom so as to be embedded in structural material during casting.  
     
     
         25 . A method of forming a composite panel as set forth in    claim 24    wherein the anchors each have base portions adapted to snap into engagement in dove-tailed grooves between adjacent ribs.  
     
     
         26 . A method of forming a composite panel as set forth in    claim 23    wherein a plurality of supports for reinforcing members are provided and mounted on the backs of the facers.  
     
     
         27 . A method of forming a composite panel as set forth in    claim 23    wherein the supports are spring mounted on one or more ribs.  
     
     
         28 . A method of forming a composite panel as set forth in    claim 23    wherein the supports have base portions adapted to slide in an endwise direction into dove-tail inter-rib grooves.  
     
     
         29 . A method of forming a composite panel as set forth in    claim 23    wherein each support takes a chair-like configuration with an upper reinforcing member mounting portion and depending flexible legs adapted to be compressed inwardly toward each other with lower end portions engaging adjacent ribs.  
     
     
         30 . A method of forming a composite panel as set forth in    claim 29    wherein each support mounting portion has at least one open groove for receiving and supporting a portion of a reinforcing bar.  
     
     
         31 . A method of forming a composite panel as set forth in    claim 30    wherein each support mounting portion has two right angularly arranged open grooves for receiving and supporting a portion of a reinforcing bar.  
     
     
         32 . A method of forming a composite panel as set forth in    claim 30    wherein each support mounting portion has two pairs of right angularly arranged open grooves for receiving and supporting a portion of a reinforcing bar, each pair of grooves comprising of at least three (3) aligned grooves.  
     
     
         33 . A method of forming a composite panel as set forth in    claim 30    wherein each support mounting portion has two pairs of right angularly arranged open grooves for receiving and supporting a portion of a reinforcing bar, one pair of grooves comprising three (3) aligned grooves and the other comprising five (5) aligned grooves.  
     
     
         34 . A method of forming a composite panel as set forth in    claim 30   , wherein the structural material takes the form of concrete.  
     
     
         35 . A method of forming a composite tilt-up wall with a facade comprising a planar arrangement of thin decorative rectangular facers on a body of concrete structural backing material; said method comprising the steps of providing a flat substantially horizontal casting bed of sand, providing a plurality of facers each with chamfers along at least the corners between end and rear walls and at least one side and rear wall, arranging the individual facers in abutting relationship atop the casting bed and in a selected geometric pattern in a face-down planar configuration so that the chamfers on the facers open upwardly and define narrow elongated sealant channels between contiguous facers, depositing sand on the rear surfaces of the facers and in the channels therebetween, sweeping the sand from the rear surfaces of the facers, casting concrete atop the facers to adhere to the rear surfaces thereof and to form a composite wall, and tilting the wall to an upright position.  
     
     
         36 . A method of forming a composite panel as set forth in    claim 1    wherein an insulating panel is embedded within the structural backing material with a first portion of the latter between the panel and the facers and a second portion on an opposite side of the panel.  
     
     
         37 . A method of forming a composite panel as set forth in    claim 36    wherein a plurality of connectors are embedded in the insulating panel and extend in opposite directions into both the first and second portions of the structural backing material.