Architectural panel

Abstract: There is provided an architectural panel, wherein a projection (3b) or projections are formed on the back of a bed (3) of an architectural panel used as a fence, a gate or a wall of a building, and a groove (3d) or holes (3a) are formed on the back of the bed (3). The projection or the projections (4c) of one face member (4) is fitted in the groove (4d) or the holes (4f) of another face member (4) which makes a pair with the former face member (4). This prevents the projection (4c) from being broken during transportation or the like.

Description: The present invention relates to architectural panels for building a fence, a gate or a building wall. A conventional fence is built by fixing and stacking concrete blocks side by side and one on another with readymixed concrete. It is however difficult to build fences having various appearances with such stacked blocks. To provide fences with various appearances, the structure as disclosed in, for example, Japanese Examined Utility Model Publication No. 22042/1994 may be employed. According to the structure disclosed in the publication, a groove is formed in the bed or underlying structural member such as a block, a projection or a weir-shaped projection is formed in the back of the face member, such as a tile, and the projection of the face member is fitted in and adhered to the groove of the bed, so that the face member is attached to the bed. With the projection of the face member fitted in the groove of the bed, however, the projection of the face member may be broken during transportation. Particularly, to form a groove in the bed, constituted of an existing concrete block, by a concrete cutter, the groove should be made narrow (generally, about 3 mm). This requires that the projection should also be formed narrow, so that the projection becomes easier to break. Further, if a projection is formed in a brittle face member, it is easily broken when fitted in the groove in the bed. Similar problems arise when face members are attached to beds to construct the facing of a gate or the wall of a building. NL-A 7 016 713 discloses an architectural panel constructed by a coupling structure of two pairs of connected bodies and connectors. There is provided a facing member with a plurality of smaller protrusions for fitting the facing member to an underlying structural member. FR-A-1 578 821 discloses a similar multiple protrusion arrangement. NL-A 7 016 713 as well as FR-A-1 578 821 do not disclose the use of synthesized resin foam material and do not refer to the transportation of facing members and underlying structural members. Accordingly, it is a primary object of the present invention to provide architectural panels, which are structured in such a way that face members, which are to be attached to beds or underlying strucural members to build the face of a gate or the wall of a building, permit the fence or gate to have various appearances, and that projections formed on the face members are unlikely to be broken during transportation or the like. It is another object of this invention to provide an architectural panel which has an improved appearance and has an enhanced strength. It is a different object of this invention to provide an architectural panel which has an improved appearance and has an enhanced strength. It is a further object of this invention to provide an architectural panel which is easy to transport and handle, can relatively permit a size error between its groove and projection, and can facilitate temporal tacking at the time of construction. It is a still further object of this invention to provide an architectural panel whose bed is supported on a support and is not therefore shifted. Other objects of the present invention will become readily apparent from the following detailed description. According to the present invention there is provided an architectural panel as set out in claim 1 or 2. Preferred embodiments of the present invention are subject matters of dependent claims 3 to 5. There is provided an architectural panel having a face member to be fitted to a bed or underlying structural member of a fence, a gate or a wall of a building, the face member having a projection or projections formed on a back thereof and a groove or holes formed on the back thereof in such a way that the projection or projections of the face member are fitted in a groove or holes of another face member which makes a pair with the former face member. It is preferable that the face member has a base made of a foam member and a mixture of an incombustible powdery material and an incombustible adhesive is coated on the surface of the base of the face member to provide a stony finish. It is also preferable that the bed or underlying structural member is made of a synthetic resin foam member. A through hole may be formed in the bed or underlying strucutral member and a support of a fence may be made of an aluminium alloy extruded shape, whereby the through hole is fitted over the support to attach the bed to the support. Further, holes may be formed in the top and bottom of the bed or underlying structural member and vertically adjoining beds may be coupled by a coupling member fitted in the holes in the adjoining beds. The face member of this invention is attached to the bed by fitting the projection or groove provided on the back of the face member in or on the groove or projection of the bed and adhering those projection and groove. At the time of transportation or storage, the projection and groove or holes of one face member are fitted in and on the groove or holes and projection of another face member so that those projections are protected between two face members. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1A is a perspective view exemplifying a face member according to the present invention; Fig. 1B is a side view showing two face members of this example combined together; Fig. 2 is a perspective view showing one embodiment of this invention as adapted for a fence; Fig. 3 is a perspective view showing one example of a bed according to this invention; Fig. 4 is a vertical cross-sectional view of an architectural panel according to this embodiment; Fig. 5 is a perspective view showing another example of the bed and bed coupling means; Fig. 6 is a vertical cross-sectional view showing one example of a fence which uses the bed and coupling means of this invention; Fig. 7 is a perspective view showing this invention as adapted for a gate post; Fig. 8 is a vertical cross-sectional view showing this invention as adapted for the wall of a building; Fig. 9A is a perspective view showing another example of a face member according to this invention; and Fig. 9B is a cross-sectional view showing two face members shown in Fig. 9A connected together. In Fig. 2, reference numeral "1" denotes a support made of an aluminum alloy extruded shape whose bottom end is buried in a concrete sill 2, reference numeral "3" denotes the bed of a fence, and reference numeral "4" denotes a face member. The bed 3 of this example is made of a synthetic foam member, and has a through hole 3a in the up and down direction, a projection 3b at the bottom and a recess 3c at the top. A groove 3d for attachment to the face member 4 is formed horizontally in one side of the bed 3 (it may be formed on both sides). As shown in Figs. 1A and 4, the face member 4 has a base 4a and a top layer 4b. The base 4a is made of a synthetic resin foam member, and the top layer 4b is formed by a dried uniform coat of a mixture of an incombustible powdery material, such as sand or gravel, and an incombustible, weather-resistive synthetic resin adhesive. Accordingly, the top layer 4b has a stony finish. A projection (weir-shaped projection) 4c having substantially the same height as the depth of the groove 3d formed in the bed 3 is formed horizontally on the back of the face member 4. A groove 4d is formed in the back of the face member 4, in parallel to and adjacent to the projection 4c. The groove 4d has substantially the same depth as the height of the projection 4c and is slightly wider than the projection 4c. In building this fence, first, the through hole 3a of the bed 3 is fitted on the support 1 secured to the sill 2, as shown in Figs. 2 and 4. Next, the projection 3b at the bottom of an upwardly adjoining bed 3 is fitted in the recess 3c at the top of the lower bed 3 so that both beds 3 are properly positioned and placed one on the other. Then, the projection 4c of the face member 4 is fitted and adhered into the groove 3d of the surface of the bed 3 by an adhesive 5. Fig. 2 shows the face member 4 adhered only to a part of the bed 3. In this example, a total of six face members 4 are attached to a single bed 3, in two rows horizontally with three face members 4 arranged in the vertical direction in each row. The correlation between the quantities of the bed 3 and the face members 4 may however be changed in various ways; for example, a single face member 4 may be attached to a single bed 3. In adhering the face member 4 to the bed 3 by the adhesive 5, the groove 4d in the face member 4 holds the adhesive 5, thus preventing the downward flow of the adhesive 5. The top of the support 1 may be designed to protrude above the bed 3, so that another member, such as coping or mesh fence, can be attached to the protruding portion to build a fence. The face members 4 are joined with the projections 4c protected therebetween by fitting the projection 4c of one face member 4 into the groove 4d of the mating face member 4, as shown in Fig. 1B. Accordingly, the projections 4c are protected and prevented from being broken during transportation. Sand, gravel or the like are adhered on the top layer 4b of the face member 4 by an adhesive, yielding the stony-finished face member 4, and the bed 3 is covered with those face members 4 so that the face members 4, though being light, have an increased strength. The bed 3 and the face member 4, if made of a foam member to reduce their weights as in this embodiment, facilitate the construction and transportation of the architectural panel. Further, even if the bed 3 is broken down and falls on a pedestrian at the time of an earthquake, the pedestrian is less likely to be injured. In the example shown in Figs. 5 and 6, a coupling member 6 of a foam member, which becomes thinner toward the top and bottom ends to have a tapered shape, is fitted in the through holes of vertically adjoining beds 3 to connect those beds 3. The beds 3 are joined in this manner to build a fence. The through hole 3a has tapered top and bottom ends 3e to match with the taper shape of the coupling member 6. This example has such an advantage that the support 1 should not necessarily be provided so that a fence is built easily and at a low cost. In this example, one side or the other side of the through hole 3a or the coupling member 6 may be designed to have a polygonal or elliptical cross section. In the example shown in Figs. 5 and 6, the projection 4c of the face member 4 is fitted in the groove 3d provided in the bed 3 and the groove 4d of the face member 4 is fitted and adhered onto a projection 3f provided on the bed 3 by the adhesive 5, thereby enhancing the bonding strength of the face member 4. With the projection 3f provided on the bed 3, the fitting of this projection 3f into the groove 4d may serve to position the face member 4 or enhance the coupling strength, while the projection 4c of the face member 4 may be loosely fitted in the groove 3d of the bed 3. Fig. 7 shows an example wherein a gate is built. In building this gate, first, a support 7 made of an aluminum alloy extruded section is secured to the sill 2. A bed 8 made of a foam member is attached to the support 7 by fitting its hole 8a over the support 7. Then, the projection 4c of the face member 4 is fitted in a groove 8b provided in the outer surface of the bed 8 and is secured to the groove 8b by an adhesive. In this example, the beds 8 are fitted over the support 7 one on another, facilitating the construction, and the beds 8 are supported by the support 7 to be prevented from being shifted. Further, the built gate has an enhanced strength. Fig. 8 shows an example in which the wall of a building is constructed by the panels of this invention. In this example, a bed 11 made of a foam member or the like is attached to a stud 9 by a securing member 10 or an adhesive and the projection 4c of the face member 4 is fitted and secured in a groove 11a of the bed 11 by the adhesive 5 so that the bed 11 and the face member 4 are attached together. Fig. 9A shows another example of the face member embodying this invention, and Fig. 9B shows two face members of this type combined. In this embodiment, a plurality of projections 4e are formed side by side at the back of the face member 4, and holes 4f equal in number to the projections 4e are provided at the same intervals as the projections 4e. At the time of transportation or storage, the projections 4e and holes 4f of one face member are fitted in and on the holes 4f and projections of another face member so that the face members are attached, back to back, to each other. The projections 4e are fitted in the grooves 3d, 8b or 11a or the holes so that the face member 4 is attached to the bed 3, 8 or 11. In this embodiment, grooves may be provided in place of the holes 4f. The shapes of the projection 4e and the hole 4f may be altered in various other forms as long as both can be fitted together. As another example, a groove or holes may be formed in a concrete block already placed in position so that the projections 4c, 4e of the face member 4 can be securely fitted in that groove. The face members 4 of this invention may be attached to such existing concrete blocks to build a fence. The specific shapes of the bed 3 and the face member 4 and the attachment therebetween are not limited to the illustrated ones and may be modified in various other forms. For example, two or more projections 4c may be provided in the face member 4 and two or more grooves 4d may be formed in the face member 4. The ends of the beds 3 may be butted against each other at right angles or in an inclined manner.

Claims: Architectural panel comprising a plurality of face members (4), an underlying structural member (3) and an adhesive (5) for securing said face members (4) to said underlying structural member (3); each said face member (4) has a base (4a) made of a synthesized resin foam and a mixture of an incombustible powdery material and an incombustible adhesive is coated on a front surface of said base (4a) of said face member (4) to provide a stony finish; each said face member (4) has a linearly extending projection (4c) and a linearly extending groove (4d) formed along a back surface thereof, said projection (4c) and groove (4d) lying parallel to each other entirely across said face member (4); each said groove (4d) has substantially the same depth from said back surface as the height of said projection (4c) from said back surface and a width wider than a width of said projection (4c); the arrangement allowing two face members to be joined back-to-back with interlocking projections (4c) and grooves (4d) to protect said projections and grooves during transporation or storage; said underlying structural member (3) has grooves (3d) formed along a front surface thereof; each said face member (4) is fixed to said underlying structural member (3) by fitting said projection (4c) at said back surface thereof into one of said grooves (3d) formed in said front surface of said underlying structural member (3); and said adhesive (5) is applied to said grooves (3d) of said underlying structural member (3) and said face members (4) such that said underlying structural member (3) and said face members (4) are secured to one another with said back surface of said face members (4) abutting said front surface of said underlying structural member (3) and said groove (4d) of said face member (4) holds said adhesive (5). Architectural panel comprising a plurality of face members (4), an underlying structural member (3) and an adhesive (5) for securing said face members (4) to said underlying structural member (3); each said face member (4) has a base (4a) made of a synthesized resin foam and a mixture of an incombustible powdery material and an incombustible adhesive is coated on a front surface of said base (4a) of said face member (4) to provide a stony finish; each said face member (4) has projections (4e) and holes (4f) formed on respectively in a back surface thereof; each said hole (4f) has substantially the same depth from said back surface as the height of said projection (4e) from said back surface and a width wider than a width of said projection (4e); the arrangement allowing two face members to be joined back-to-back with interlocking projections (4e) and holes (4f) to protect said projections and holes during transporation or storage; said underlying structural member (3) has grooves (3d) formed along a front surface thereof; each said face member (4) is fixed to said underlying structural member (3) by fitting said projection (4e) at said back surface thereof into one of said grooves (3d) formed in said front surface of said underlying structural member (3); and said adhesive (5) is applied to said grooves (3d) of said underlying structural member (3) and said face members (4) such that said underlying structural member (3) and said face members (4) are secured to one another with said back surface of said face members (4) abutting said front surface of said underlying structural member (3) and said hole (4f) of said face member (4) holds said adhesive (5). Architectural panel according to claim 1 or 2, wherein said underlying structural member (3) is made of a synthetic resin foam member. Architectural panel according to any preceding claim, wherein a through-hole (3a) is formed in said underlying structural member (3) and a support (1) of a fence is made of an aluminum alloy extruded shape, whereby said through-hole (3a) is fitted over said support (1) to attach said underlying structural member (3) to said support (1). Architectural panel according to any preceding claim, wherein holes (3a) are formed in a top and bottom of said underlying structural member (3) and vertically adjoining underlying structural members (3) are coupled by a coupling member (6) fitted in said adjoining holes (3a) in said underlying structural members (3).

Inventors: ISHII MIKIO, MORI SHIGERU, ISHII, MIKIO, MORI, SHIGERU
Applicants: TOYO EXTERIOR CO LTD, TOYO EXTERIOR CO., LTD.
Application year: 1995
Main classification: E04F13
IPC codes: E04H17, E04C2, E04F13