Nov“ 23, 1971
`
`Filed March 2, 1970
`
`C. J. DE LANGE
`
`PANEL WALL
`
`3,621,635
`
`2 Sheets-Shoot 1
`
`FIG!
`
`INVENTOR
`CORNELIS J. DELANGE
`c’
`I /)
`
`ATTORNEYS
`
`ALLSTEEL INC.
`Exhibit 1010, Page 1
`
`

`
`NOV‘. 23,,
`
`Filed March 2, 1970
`
`Q J_ DE LANGE
`PANEL WALL
`
`3,621,635
`
`2 Sheets-Sheet 2
`
`W
`
`a
`
`\c on Q ‘5 “\c' u
`
`a a G D o a =1 a
`
`FIGB
`
`BY
`
`INVENTOR
`CORNELIS J. DE LANGE
`M/ 5% /
`
`ATTORNEYS
`
`Exhibit 1010, Page 2
`
`
`
`

`
`United States Patent 0
`rice
`
`3,6Zl,635
`Patented Nov. 23, l97l
`
`1
`
`3,621,635
`PANEL WALL
`Cornelis J. de Lange, Farmington, Mich, assignor to
`Cement Enamel Development, Inc., Detroit, Mich.
`Filed Mar. 2, 1970, Ser. No. 15,599
`Int. Cl. E04!) 2/88
`
`US. Cl. 52-235
`
`5 Claims
`
`ABSTRACT OF THE DISCLOSURE
`A monolithic aggregate textured type wall formed of
`large panels made of thin base sheets covered with a
`bonded textured coating, with the panels arranged edge
`to edge upon a support surface and mounted thereon by
`means of panel mounting strips having downwardly ex
`tending ?anges interengaged with horizontally arranged
`I-shaped strips fastened to the support surface; the panel
`mounting strips being secured to the base sheets only by
`mechanical fasteners before coating the sheets, wherein
`the fasteners are covered and concealed by the coating.
`
`15
`
`20
`
`which may be hooked onto the wall support channels
`for spacing adjacent edges of adjacent panels 'and form
`ing a channel therewith which may be ?lled with grout
`or other ?ller material for producing a monolithic wall
`construction.
`The panel mounting strips which may be arranged
`either horizontally or vertically upon the rear face of the
`panel additionally serve to stiffen the panels against
`wind loads and to align the panels in coplanar relation
`ship despite irregularities of the support wall surface and
`further permit rapid assembly by endwise sliding of the
`panels upon the support Wall and disassembly, where de
`sired, by vertical lifting off of the support wall. Further,
`with the construction herein, the panels are spaced a short
`distance in front of the support wall, which may be of any
`sort of material, to not only provide for air circulation
`but also eliminate the need for smoothing or finishing ir
`regularities in the support surface thus making it easy to
`modernize an existing exterior building wall.
`These and other objects and advantages of this inven
`tion will become apparent upon reading the following
`description of which the attached drawings form a part.
`
`DESCRIPTION OF DRAWINGS
`FIG. 1 is a perspective fragmentary view of the abutting
`edges of two adjacent panels and the support means for
`mounting same upon the support surface.
`FIG. 2 is an enlarged cross-sectional view taken in the
`direction of arrows 2~—2. of FIG. 1.
`FIG. 3 is a perspective fragmentary view of a spacer
`strip.
`FIG. 4 is a cross-sectional elevational view taken in the
`direction of arrows 4-4 of FIG. 1..
`FIG. 5 is a view, to reduced scale, of the rear face of
`a single panel.
`'FIG. ‘6 illustrates the rear face of a modi?ed mounting
`means for the panel, and
`FIG. 7 is an enlarged fragmentary perspective view of
`the modi?ed mounting means.
`FIG. 8 is a cross-sectional view taken in the direction
`of arrows 8—8 of FIG. 7.
`
`DETAILED DESCRIPTION
`
`FIG. 1 illustrates a fragment of an exterior panel wall
`10 mounted upon a support surface ill which may be an
`already existing wall formed of blocks, concrete, stone or
`the like or may be a semi-?nished or un?nished wall frame
`work, such as a stud construction.
`The wall is made of a number of large size panels 12
`each formed of a thin, substantially rigid sheet or sub
`strate 13 made of a suitable construction material, such
`as of cement-asbestos sheeting or the like. Covering the
`sheet is an aggregate coating 14 which may be formed of
`small sized stones or pebbles or marble chips or the like
`joined together and bonded to the substrate with a suitable
`resin binder. Such binders and the aggregate coatings are
`conventional and hence no further description thereof is
`given here.
`Secured to the support surface 11 are a number of
`horizontally arranged sheet metal support strips 15 which
`are J-shaped or upwardly opening channel shaped in cross
`section. Such strips may be fastened to the support wall by
`nails or screws 16 or other suitable fastening means.
`Inverted J-shaped panel strips 17 are horizontally ar
`ranged upon the rear faces of each of the panels for
`interengaging with, by hooking over, the support strips
`15. The panel strips 17 are secured to the base sheet or
`substrate only by means of mechanical fasteners such as
`rivets, screws or the like 18 which are applied before the
`substrate is coated with the aggregate coating material.
`
`25
`
`BACKGROUND OF INVENTION
`One method for ?nishing or for modernizing an al
`ready ?nished exterior or interior decorative wall is to
`apply to the wall surface a coating formed of small stones
`or aggregates, such as marble chips and the like, bonded
`together and to the wall surface with a suitable resin
`binder. in the past, such coatings, generally formed of
`the aggregate and binder made up as a paste~like material,
`have been applied to the wall surface by hand, using
`conventional plastering or troweling techniques.
`While this technique produces an excellent surface
`particularly where the support surface is of a rough ma
`terial, such as an old wall surface or an un?nished wall ‘
`surface, the amount of hand l-abor required is substantial,
`thereby making the cost of such coatings relatively high.
`In order to reduce the amount of ?eld labor, attempts
`have been made to form panels comprising a substrate
`or a sheet to which the coating has been applied in a
`factory and thereafter securing the panels upon the sup
`port wall by means of mechanical fasteners. Since such
`panel materials are used primarily for exterior surfaces,
`numerous mechanical fasteners are required in order to
`provide an adequate strength of fastening.
`In this technique, it is generally necessary to drill holes
`through the complete panel for the passageway of screws
`or bolts or the like fasteners and thereafter, vafter the
`panel is mounted, to patch the holes with fresh aggregate
`coating materials. This too is relatively time consuming
`and expensive and in addition, tends to make spots or
`marks on the ?nished wall where the patches have been
`applied.
`Hence, the invention herein relates to forming a panel
`type wall using aggregate coated panels but includes a
`mounting system which eliminates the need for ?eld
`application of fasteners through the panel and which pro
`vides a system wherein the panels may be rapidly assem
`bled with a minimum amount of labor and damage.
`SUMMARY OF INVENTION
`The invention herein contemplates assembling mount~
`ing strips to the panel substrate prior to coating, with
`mechanical fasteners which are thereafter coated and
`concealed by the aggregate coating material, and then
`using corresponding channel strips mounted upon the
`support surface wherein the panels may be rapidly
`mounted upon the support surface by interengaging the
`support strips and channels.
`The invention further contemplates using spacer strips
`
`40
`
`45
`
`50
`
`55
`
`60
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`65
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`70
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`Exhibit 1010, Page 3
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`

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`3,621,635
`to application of the- coatinguand ‘which are covered
`Thus, the strips 17 are assembled to the substrate and
`and concealed by said coating,‘ and an integral, down
`thereafter are completely concealed.
`>
`For assembling the wall, each panel, which preferably
`wardly extending hook-like ?ange ?tted into and sup
`is provided with a number of panel mounting strips 17,
`ported by an adjacent support strip hook for‘ther'eby
`is aligned so that the strips 17 are end to end with the
`
`mounting the panel upon- the supporting surfacef ' and, a thin, narrow’ve'rtical sheet metal spacer ‘strip
`support strips 15 and then the panel is slid horizontally
`along the length of the support strips 15 for ?nal position
`arranged between and abutting‘eacli of the adjacent
`ing. The panels are thus positioned one by one to form the
`vertical edges of adjacent panels near the ‘rear faces
`thereof, the spacer strips each having central struck~
`complete wall.
`-
`Preferably, a spacer strip 20 is arranged between the
`.out, ‘rearwardly an'd downwardly extending‘ hook
`adjacent edges of each adjacent pair of panels. The strip
`lrke- ?anges hooked over and supported by: said‘ sup
`20 (see FIGS. 2 and 3) is formed of a thin piece of sheet
`port strips, and a ?lling material ?lling eachof the
`metal, such as one-half inch wide and one-eighth of an
`spaces formed by the adjacent panel edges and the
`inch thick and is secured to the support strips 15 by means
`of struck out tongues or ?anges 21. Thus, the vertical edges
`of the spacer strip contact the edges of the panels near
`their rear surfaces, as shown in FIG. 1, to de?ne a grouting
`channel which may be ?lled with caulking or grout or
`other ?ller material.
`Since the panel mounting strips 17 are assembled to the
`panel substrate at the factory, they may be accurately
`aligned wherein the only skilled labor required is that of
`mounting and aligning the support wall strips 15. No other
`fastening operations are required in the ?eld.
`
`v10
`
`20
`
`25
`
`spacer strip;
`
`'
`
`1
`
`i
`
`.
`
`whereby the panels are mounted coplanar av short dis
`tance from’ the supporting surface and may .be
`mounted thereon‘ by horizontally and endwise slidably
`intereng‘aging the panel mounting strips with the sup
`port strips, panel by panel,iwith the panels‘ spaced
`by said spacer strips and wherein the panels ‘and
`spacer strips together form a monolithic, aggregate
`type textured wall in appearance.
`,
`-'
`' 2. A_Wall construction as de?ned'in claim 1 said sup
`port strips each being formed of elongated strips "of sheet
`metal bent into an approximately J-shaped in cross-section
`for supporting the panel strip ?anges anywhere along its
`length.
`'
`3. A wall construction as de?ned in claim 1, and said
`panel support strips each being formed of an elongated
`horizontally arranged strip of sheet metal bent along its
`length into an inverted J-shape in cross-section for hook
`ing over the support strip.
`4. A wall construction as de?ned in claim 3, and with
`each of the support strip base portions being formed'by
`the longer vertical leg of the J-shape being fastened to
`said panel base sheet by headed fasteners, such as screws,
`rivets and the like, prior to applying the coating to said
`sheet, with the coating applied over and thereby covering
`the fastener heads for concealing same.
`. 5. A wall construction as de?ned in claim 1 and said
`panel support strips each being formed of an elongated,
`vertically arranged strip forming the base portion thereof,
`with said hook-like ?anges formed by integral struck-out,
`rearwardly and downwardly bent portions of'said base
`portions.
`’
`
`References Cited
`UNITED STATES PATENTS
`6/1931 Corwin ________ _-____ 52P-489
`1,810,597
`7/1935 Whiteside _________ __ 52—486
`2,007,842
`6/1937 Venzie ____________ __ 52-486
`2,082,314
`3/1939, Meeker ___; _______ __ 52.—483
`2,151,221
`2,619,686‘ 12/1952 Dombrowski _______ __ 52—-586
`3,248,836
`5/1966 Monk ____________ __ 52-4235
`
`FRANK L. ABBOTT, Primary Examiner
`R. A. SCHWARTZ, Assistant Examiner
`
`, US. Cl. X.R.
`52-——3 15, 459, 486, 622
`
`MODIFICATION—FIGS. 6—8
`FIGS. 6—8 illustrate a modi?ed form of panel mounting
`strip 30 which is formed in a channel shape, the legs of
`which abut the rear face of the panel 12. The channels
`or strips 30 are fastened to the substrate 13 (see FIG. 7)
`by means of screws 32 or other similar types of mechani
`cal fasteners, such as rivets or the like, prior to applica
`tion of the aggregate coating 14 which thus covers and
`conceals the heads of the fasteners (see FIG. 8).
`The base of the channel 30‘ is provided with struck out
`?anges or tongues 32 for interengaging with the support
`wall 15, for thereby mounting the panels thereon.
`This form of mounting strip is particularly useful where
`extra heavy-duty reinforcing is desirable for the Panels
`particularly in the vertical direction as may be required
`on various construction jobs.
`Having fully described an operative embodiment of
`this invention, I now claim:
`1. An aggregate textured type wall construction, com
`prising:
`a vertical supporting surface having horizontally ar
`ranged, vertically spaced apart support strips secured
`thereto, the support strips each being formed with a
`base portion secured to the surface and an integral,
`upwardly directed flange portion to form, in cross
`section, an upwardly opening hook;
`large size panels aligned edge to edge and arranged
`upon the supporting surface, said panels each being
`formed of a thin, substantially rigid base sheet hav
`ing its outer exposed face covered with a thin coat
`ing of an aggregate type material bonded thereto;
`a number of panel mounting‘ strips, arranged upon the
`rear faces of each of the panels, and each having
`a base portion fastened only to said base sheet by 60
`mechanical fastening means which are applied prior
`
`30
`
`40
`
`55
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`Exhibit 1010, Page 4