Reinforced architectural panel

Abstract

An architectural panel includes a substantially rectangular prismatic main body cast from lightweight concrete that has first and second major faces which are substantially planar and parallel to one another. First and second reinforcing mesh sheets are disposed substantially parallel to one another, next to the first and second major faces, respectively, and embedded in the main body. Recesses are arrayed in the first major face. Each recess extends through a respective opening in the first mesh sheet.

1 . An architectural panel comprising:
 a main body cast from lightweight concrete;   first and second major faces on the main body which are substantially planar and parallel to one another;   first and second mesh sheets disposed substantially parallel to one another, next to the first and second major faces, respectively, and embedded in the main body, wherein
 edges of each of the first and second mesh sheets are disposed adjacent respective edges of the main body, and 
 the first mesh sheet includes an array of openings; and 
   an array of recesses in the first major face, wherein each recess extends through a respective one of the openings in the first mesh sheet.   
     
     
         2 . The architectural panel of  claim 1  wherein the main body has a substantially rectangular prismatic form and the mesh sheets are rectangular. 
     
     
         3 . The architectural panel of  claim 1  wherein no undercut is provided in the recesses. 
     
     
         4 . The architectural panel of  claim 1  wherein each recess tapers inwardly from a mouth at the first major face to a base. 
     
     
         5 . The architectural panel of  claim 1  wherein each recess comprises a plurality of intersecting flat faces. 
     
     
         6 . The architectural panel of  claim 1  wherein each recess comprises five flat faces. 
     
     
         7 . The architectural panel of  claim 4  wherein the openings in the first mesh are square and each mouth is square. 
     
     
         8 . The architectural panel of  claim 7  wherein each recess includes four tapered faces that extend from the square mouth to a square face at the base. 
     
     
         9 . The architectural panel of  claim 8  wherein the four tapered faces have rotational symmetry about a central axis of each recess that extends substantially orthogonal to the first face. 
     
     
         10 . The architectural panel of  claim 1  wherein the lightweight concrete comprises one of aerated concrete and foamed concrete, and, as aggregate, one chosen from the group consisting of: sintered expanded clay, expanded polystyrene beads, pumice, expanded shale, bottom ash, ceramics. 
     
     
         11 . The architectural panel of  claim 1 , further comprising a plurality of fixtures cast into the main body to provide mounting points, each fixture comprising a plate fixed to a projecting bracket extending substantially perpendicular to the plate, wherein each bracket includes an aperture with an internal screw thread. 
     
     
         12 . The architectural panel of  claim 11  wherein the panel has a thickness and each fixture has a dimension generally the same as the thickness of the panel. 
     
     
         13 . The architectural panel of  claim 11  wherein the fixtures are fixed to the first and second mesh sheets. 
     
     
         14 . The architectural panel of  claim 11  wherein the bracket has a length and substantially all of the length of the bracket is embedded in the concrete. 
     
     
         15 . The architectural panel of  claim 1 , further comprising a backing layer extending over the first major face and keyed into the recesses, the backing layer being formed by casting, after casting the main body. 
     
     
         16 . The architectural panel of  claim 1  further comprising a facing layer of lightweight concrete bonded to the second major face. 
     
     
         17 . An architectural panel of generally rectangular prismatic form comprising:
 a main body cast from lightweight concrete comprising one of aerated concrete and foamed concrete, and, as aggregate, one chosen from the group consisting of: sintered expanded clay, expanded polystyrene beads, pumice, expanded shale, bottom ash, ceramics;   first and second major faces on the main body which are substantially planar and parallel to one another;   first and second rectangular sheets or first and second wire reinforcing mesh sheets embedded in the main body and disposed substantially parallel to one another, next to the first and second major faces, respectively, wherein
 edges of each of the first and second wire reinforcing mesh sheet are disposed adjacent respective edges of the main body, and 
 the first wire reinforcing mesh sheet includes an array of openings; and 
   an array of recesses in the first major face, wherein each recess extends through a respective one of the openings in the first wire reinforcing mesh sheet and tapers inwardly from a relatively large mouth at the first major face to a relatively small base.   
     
     
         18 . The architectural panel of  claim 17 , further comprising a plurality of fixtures embedded in the main body to provide mounting points for the panel, each fixture comprising a plate fixed to a projecting bracket, wherein
 each plate is disposed adjacent the second major face,   each bracket extends substantially perpendicular to the plate,   an axial end of each bracket is disposed adjacent the first major face,
 each bracket includes an aperture extending through the axial end, with an internal screw thread in the aperture and 
 the fixtures are fixed to the first and second wire reinforcing mesh sheets. 
   
     
     
         19 . The architectural panel of  claim 18 , further comprising a backing layer extending over the first major face and keyed into the recesses, the backing layer being formed by casting, after casting the main body. 
     
     
         20 . The architectural panel of  claim 18  further comprising a facing layer of lightweight concrete bonded to the second major face.