Prefabricated wall panel with interlocking structure

Abstract

A prefabricated wall panel ( 10 ) has a precast body ( 12 ) including at least one decorative design element ( 14 ). In addition, the wall panel includes a mounting element ( 16 ) having a first end ( 18 ) embedded in the precast body and a second end ( 20 ) projecting from the precast body. A interlocking structure ( 36,40 ) is provided along at least two opposing edges of the wall panel to insure proper alignment and interconnection when two or more wall panels are installed together on a support substrate.

1 . A prefabricated wall panel, comprising:
 a precast body including at least one decorative design element;   a mounting element including a first end embedded in said precast body and a second end projecting from said precast body; and   an interlocking structure provided along at least two opposing edges of said prefabricated wall panel to insure proper alignment and interconnection when at least two of said prefabricated wall panels are positioned together to complete a wall.   
     
     
         2 . The wall panel of  claim 1 , further including at least one protrusion in said second end and at least one keying hole in said first end of said mounting element. 
     
     
         3 . The wall panel of  claim 2 , wherein said protrusion has an interior diameter of between approximately 0 and approximately 7.6 centimeters. 
     
     
         4 . The wall panel of  claim 3 , wherein said protrusion has a depth of between approximately 0.30 and approximately 0.6 centimeters. 
     
     
         5 . The wall panel of  claim 4 , further including at least one weep hole in said mounting element. 
     
     
         6 . The wall panel of  claim 5 , wherein said first end of said mounting element extends in a first plane and said second end of said mounting element extends in a second plane wherein said second plane is substantially parallel to said first plane. 
     
     
         7 . The wall panel of  claim 6 , wherein said mounting element further includes a transition section that connects said first end to said second end and transitions between said first and second planes. 
     
     
         8 . The wall panel of  claim 7 , wherein said mounting element is made from a material selected from wood, concrete, cellulose fiberboard, polymer material, composite material, metal, plastic, reinforced plastic, thermoplastic, fiber composite, reinforced wood, steel, corrosion-resistant steel, aluminum, stainless, steel, zinc, copper, and combinations thereof. 
     
     
         9 . The wall panel of  claim 8 , wherein said mounting element is formed as a solid sheet, as a mesh or as a combination thereof. 
     
     
         10 . The wall panel of  claim 1 , wherein said precast body is made from a material selected from a group consisting of concrete, fiber reinforced concrete, gypsum, fiber reinforced gypsum, polymer modified gypsum, other cementitious materials and mixtures thereof. 
     
     
         11 . The wall panel of  claim 10 , wherein said precast body includes reinforcing fibers selected from a group of fibers consisting of glass fibers, carbon fibers, mineral fibers, natural fibers, polymer fibers, E-glass fibers, AR-glass fibers and mixtures thereof. 
     
     
         12 . The wall panel of  claim 1 , wherein said interlocking structure comprises a cooperating tongue and groove arrangement. 
     
     
         13 . The wall panel of  claim 1 , wherein said interlocking structure includes alternating tongues and grooves staggered in two rows. 
     
     
         14 . The wall panel of  claim 1 , wherein said interlocking structure comprises a cooperating hook and slot arrangement. 
     
     
         15 . The wall panel of  claim 1 , wherein said interlocking structure comprises edge grooves and an interconnecting pin received in said grooves. 
     
     
         16 . The wall panel of  claim 1 , wherein said interlocking structure is provided along at least two opposing edges of said precast body. 
     
     
         17 . The wall panel of  claim 16 , wherein said interlocking structure comprises a cooperating tongue and groove arrangement. 
     
     
         18 . The wall panel of  claim 16 , wherein said interlocking structure includes alternating tongues and grooves staggered in two rows. 
     
     
         19 . The wall panel of  claim 16 , wherein said interlocking structure comprises a cooperating hook and slot arrangement. 
     
     
         20 . The wall panel of  claim 16 , wherein said interlocking structure comprises edge grooves and an interconnecting pin received in said grooves. 
     
     
         21 . A wall panel system, comprising:
 a prefabricated wall panel;   a starter strip; and   a trim element;   said wall panel system being characterized by said prefabricated wall panel including;   a precast body including at least one decorative design element;   a mounting element including a first end embedded in said precast body and a second end projecting from said precast body; and   an interlocking structure provided along at least two opposing edges of said prefabricated wall panel to insure proper alignment and interconnection when at least two of said prefabricated wall panels are positioned together to complete a wall.   
     
     
         22 . The wall panel system of  claim 21 , wherein said starter strip includes a securing leg and a channel. 
     
     
         23 . The wall panel system of  claim 22 , wherein said trim element includes a substantially J-shaped body including a mounting leg, a covering leg and a wall panel holding channel.