U.S. patent application number 11/098001 was filed with the patent office on 2006-10-05 for prestressed concrete building panel and method of fabricating the same.
Invention is credited to Thomas G. Harmon, Harold G. Messenger.
Application Number | 20060218870 11/098001 |
Document ID | / |
Family ID | 37068688 |
Filed Date | 2006-10-05 |
United States Patent
Application |
20060218870 |
Kind Code |
A1 |
Messenger; Harold G. ; et
al. |
October 5, 2006 |
Prestressed concrete building panel and method of fabricating the
same
Abstract
A low density concrete building panel and method of
manufacturing is provided with one or more carbon fiber or steel
reinforcements which may include window and door openings which can
be easily transported and erected at a building site.
Inventors: |
Messenger; Harold G.;
(Rehoboth, MA) ; Harmon; Thomas G.; (St. Louis,
MO) |
Correspondence
Address: |
SHERIDAN ROSS PC
1560 BROADWAY
SUITE 1200
DENVER
CO
80202
US
|
Family ID: |
37068688 |
Appl. No.: |
11/098001 |
Filed: |
April 1, 2005 |
Current U.S.
Class: |
52/414 |
Current CPC
Class: |
B28B 13/022 20130101;
B28B 19/003 20130101; E04C 5/20 20130101; E04C 5/085 20130101; B28B
23/16 20130101; E04C 2/06 20130101; B28B 11/042 20130101; B28B
7/186 20130101; B28B 23/0006 20130101; B28B 7/082 20130101; E04C
5/07 20130101 |
Class at
Publication: |
052/414 |
International
Class: |
E04B 1/18 20060101
E04B001/18 |
Claims
1. A carbon fiber reinforced concrete building panel, comprising:
an inner surface, an outer surface, a first end and a second end,
and a substantially longitudinal axis defined between said first
end and said second end; a tensioned first carbon fiber grid
positioned within an exterior concrete layer between said first end
and said second end; a plurality of foam core panels positioned
substantially adjacent to said exterior concrete layer and defining
a plurality of rib channels between said plurality of foam core
panels which are substantially filled with a concrete material; at
least one carbon fiber shear strip positioned within said plurality
of rib channels and extending into said exterior concrete layer;
and at least one reinforcing bar positioned proximate to said at
least one carbon fiber shear strip and positioned within said
plurality of rib channels.
2. The carbon fiber reinforced concrete building panel of claim 1,
wherein said at least one carbon fiber shear strip is comprised of
an interwoven grid of individual carbon fibers.
3. The carbon fiber reinforced concrete building panel of claim 1,
further comprising at least one lifting anchor interconnected to at
least one of said first end, said second end, and lateral edges
extending therebetween.
4. The carbon fiber reinforced concrete building panel of claim 1,
wherein said plurality of foam core panels is comprised of one
integral foam core panel with a plurality of reinforcing rib
channels positioned therein to receive concrete and reinforcing
materials.
5. The carbon fiber reinforced concrete building panel of claim 1,
further comprising a nailing surface operably interconnected to
said plurality of rib channels which are adapted to receive a nail,
a screw, and other interconnection means.
6. The carbon fiber reinforced concrete building panel of claim 5,
wherein said nailing surface comprises at least one of a foam
material, a wood material and a metal material.
7. The carbon fiber reinforced concrete building panel of claim 1,
further comprising a plurality of spacers positioned between said
plurality of foam core panels which include a support member for
holding a reinforcing bar.
8. The carbon fiber reinforced concrete building panel of claim 1,
further comprising a reinforced section including at least one of a
reinforcing bar and a carbon fiber material positioned around a
window frame or a door frame.
9. The carbon fiber reinforced concrete building panel of claim 1,
wherein said at least one first reinforcing bar is comprised of a
metallic rod having a diameter of at least about 0.25 inches.
10. The carbon fiber reinforced concrete building panel of claim 1,
further comprising a second reinforcing bar which is positioned
proximate to at least one of a plurality of perimeter edges of said
substantially planar concrete panel.
11. The carbon fiber reinforced concrete building panel of claim 1,
further comprises a second carbon fiber sheer strip positioned
proximate to at least one of a plurality of perimeter edges of said
substantially planar concrete panel.
12. The carbon fiber reinforced concrete building panel of claim 1,
further comprising at least one spacer positioned at least
partially around at least one first reinforcing bar, wherein there
is a predetermined amount of separation between said foam core and
said at least one first reinforcing bar.
13. The carbon fiber reinforced building panel of claim 1, wherein
said tensioned first carbon fiber grid has a tension of at least
about 500 lbs.
14. The carbon fiber reinforced building panel of claim 1, wherein
said building panel has a density of no greater than about 20
lbs/ft.sup.2.
15. A method for fabricating a low density concrete building panel,
comprising: a) providing a form having a first end, a second end,
and lateral edges extending therebetween; b) positioning a
plurality of metal strands in said form; c) applying tension to
said plurality of metal strands; d) positioning a first grid of
carbon fiber material in said form; e) applying tension to said
first grid of carbon fiber material; f) pouring a first layer of
concrete material into said form; g) positioning a layer of
insulative material onto said first layer of concrete material,
said insulative material having a plurality of reinforcing rib
channels extending substantially between at least one of said first
end and said second end or said lateral edges; h) positioning a
first reinforcing material in said plurality of rib channels; i)
pouring a second layer of concrete into said plurality of
reinforcing rib channels; j) allowing said first layer and said
second layer of concrete to cure; and k) removing said concrete
building panel from said form, wherein said lightweight concrete
building panel is available for transportation and use.
16. The method of claim 15, further comprising the step of
positioning at least one lifting anchor in at least one of said
plurality of rib channels.
17. The method of claim 15, further comprising positioning a second
reinforced section within said form to define an opening for at
least one of a window, a door, and a utility vault.
18. The method of claim 15, wherein the step of positioning a layer
of insulative material comprises orienting a plurality of
individual foam core panels in a predetermined pattern on said
first layer of concrete.
19. The method of claim 15, further comprising the step of
interconnecting at least some of said individual foam core panels
prior to said step of positioning said individual foam core panels
onto said first layer of concrete material.
20. The method of claim 18, further comprising the step of
positioning a spacer between said plurality of individual foam core
panels, wherein said second layer of concrete has a substantially
uniform thickness between said plurality of individual foam core
panels.
21. The method of claim 15, wherein said layer of insulative
material is comprised of an expanded polystyrene material.
22. The method of claim 21, wherein said spacer further comprises a
support mechanism for holding a reinforcing bar in a predetermined
location.
23. The method of claim 15, further comprising the step of
positioning at least one of a metallic reinforcing bar and a third
grid of carbon fiber along at least a portion of a perimeter edge
of said concrete building panel prior to said step of allowing said
first layer and said second layer of concrete to cure.
24. A method for fabricating a low density concrete building panel
having a window or door opening, comprising: a) providing a casting
form having a first end, a second end, and lateral edges extending
therebetween; b) positioning a negative to a bottom portion of the
casting forms in a predetermined position which defines a window
opening or a door opening; c) positioning a plurality of metal
strands in said form; d) applying tension to said plurality of
metal strands; e) positioning a first grid of carbon fiber material
in said form; f) applying tension to said first grid of carbon
fiber material; g) positioning a framing material on or proximate
to said negative; h) pouring a first layer of concrete material
into said form; i) positioning a layer of foam core onto said first
layer of concrete material, said layer of foam core having a
plurality of reinforcing rib channels extending substantially
between at least one of said first end and said second end or
between said lateral edges; j) positioning a first reinforcing
material in said plurality of reinforcing rib channels; k) pouring
a second layer of concrete into said plurality of rib channels; l)
allowing said first layer and said second layer of concrete to
cure; and m) removing said concrete building panel from said form,
wherein said lightweight concrete building panel is available for
transportation and use.
25. The method of claim 24, wherein said framing material is
comprised of wood.
26. The method of claim 24, wherein at least about 500 lbs. of
tension is applied to said first grid of carbon fiber material.
27. The method of claim 24, further comprising trimming any excess
carbon fiber from the window opening or door opening.
28. The method of claim 24, wherein at least about 500 lbs. of
tension is applied to said plurality of metal strands.
29. The method of claim 24, wherein said positioning a layer of
foam comprises placing a plurality of individual foam panels on
said first layer of concrete in a predetermined pattern.
30. The method of claim 24, wherein positioning a first reinforcing
material in said plurality of reinforcing rib channels comprises
positioning a metallic reinforcing rod on a bracket which is
operatively interconnected to at least one of aid plurality of
individual foam panels.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to building components, and
more specifically composite lightweight building panels which can
be interconnected to build structures such as modular buildings or
applied as cladding to building frames.
BACKGROUND OF THE INVENTION
[0002] Due to the high cost of traditional concrete components and
the extensive transportation and labor costs associated therein,
there is a significant need in the construction industry to provide
a lightweight, precast, composite building panel which may be
transported to a building site and assembled to provide a structure
with superior strength and insulative properties. Previous attempts
to provide these types of materials have failed due to the
extensive transportation costs, low insulative values and thermal
conductivity associated with prefabricated concrete wire reinforced
products. Further, due to the brittle nature of concrete, many of
these types of building panels become cracked and damaged during
transportation.
[0003] More specifically, the relatively large weight per square
foot of prior art fabricated building panels has resulted in high
expenses arising not only from the amount of materials needed for
fabrication, but also the cost of transporting and erecting the
modules. Module weight also placed effective limits on the height
of structures, such as stacked modules, e.g. due to limitations on
the total weight carried by the foundations, footings and lowermost
modules. Furthermore, there is substantial fabrication labor
expense that can arise from efforts needed to design reinforcement,
and the materials and labor costs involved in providing and placing
reinforcement materials. Accordingly, it would be useful to provide
a system for modular construction which is relatively light, can be
readily stacked to heights greater than in previous configurations
and, preferably, inexpensive to design and manufacture.
[0004] Further, in many situations panels or modules are situated
in locations where it is desirable to have openings therethrough to
accommodate doorways, windows, cables, pipes and the like. In some
previous approaches, panels were required to be specially designed
and cast so as to include any necessary openings, requiring careful
planning and design and increasing costs due to the special,
non-standard configuration of such panels. In other approaches,
panels were cast without such openings and the openings were formed
after casting, e.g. by sawing or similar procedures. Such
post-casting procedures as cutting, particularly through the thick
and/or steel-reinforced panels as described above, is a relatively
labor-intensive and expensive process. In many processes for
creating openings, there was a relatively high potential for
cracking or splitting of a panel or module. Accordingly, it would
be useful to provide panels and modules which can be post-fitted
with openings such as doors and windows in desired locations and
with a reduced potential for cracking or splitting.
[0005] One further problem associated with metallic wire materials
used in conjunction with concrete is the varying rates of expansion
and contraction. Thus with extreme heating and cooling the metallic
wire tends to separate from the concrete, thus creating cracks,
exposure to moisture and the eventual degradation of both the
concrete and wire reinforcement.
[0006] One example of a composite building panel which attempts to
solve these problems with modular panel construction is described
in U.S. Pat. No. 6,202,375 to Kleinschmidt (the '375 patent). In
this invention, a building system is provided which utilizes an
insulative core with an interior and exterior sheet of concrete and
which is held together with a metallic wire mesh positioned on both
sides of an insulative core. The wire mesh is embedded in concrete,
and held together by a plurality of metallic wires extending
through said insulative core at a right angle to the longitudinal
plane of the insulative core and concrete panels. Although
providing an advantage over homogenous concrete panels, the
composite panel disclosed in the '375 patent does not provide the
necessary strength and flexure properties required during
transportation and high wind applications. Further, the metallic
wire mesh materials are susceptible to corrosion when exposed to
water during fabrication, and have poor insulative qualities due to
the high heat transfer qualities of metallic wire. Thus, the panels
disclosed in the '375 patent may eventually fail when various
stresses are applied to the building panel during transportation,
assembly or subsequent use. Furthermore, these panels have poor
insulative qualities in cold climates due to the high heat transfer
associated with the metallic wires.
[0007] Accordingly, there is a significant need in the construction
and building industry to provide a composite building panel which
may be used in modular construction and which is lightweight,
provides superior strength and has high insulative values. Further,
a method of making these types of building panels is needed which
is inexpensive, utilizes commonly known manufacturing equipment,
and which can be used to mass produce building panels for use in
the modular construction of warehouses, low cost permanent housing,
hotels, and other buildings.
SUMMARY OF THE INVENTION
[0008] It is thus one aspect of the present invention to provide a
composite wall panel which has superior strength, high insulating
properties, is lightweight for transportation and stacking purposes
and is cost effective to manufacture. Thus, in one embodiment of
the present invention, a substantially planar insulative core with
interior and exterior surfaces is positioned adjacent an exterior
concrete face which is reinforced with a carbon fiber grid. A
plurality of reinforcing ribs are positioned substantially adjacent
the insulative core and are operably interconnected to the exterior
face with a plurality of carbon fiber strands. Preferably, the
carbon fiber mesh grid is comprised of a plurality of first carbon
fiber strands extending in a first direction which are operably
interconnected to a plurality of second carbon fiber strands
oriented in a second direction. Preferably, the carbon fiber mesh
grids are embedded within the reinforcing ribs and exterior
concrete face. Further, in one embodiment the carbon fiber grid in
the exterior concrete face is tensioned during fabrication and
prior to the concrete curing to provide enhanced strength to the
finished product. In a preferred embodiment, a fastener friendly
nailing strip is positioned on an interior surface of the wall
panel opposite each of the reinforcing ribs for the attachment of
drywall, paneling, and other interior trim materials.
[0009] It is another aspect of the present invention to provide a
spacer which controls the separation of the insulative panels
during fabrication to assure that the reinforcing ribs have a
uniform thickness. In one embodiment, these spacers have spikes
that are driven into the insulative panels, and preferably also
include a retention device to support one or more reinforcing
bars.
[0010] It is another aspect of the present invention to provide a
composite wall panel which can be easily modified to accept any
number of exterior textures, surfaces or cladding materials for use
in a plurality of applications. Thus, the present invention is
capable of being finished with a brick surface, stucco, siding and
any other type of exterior surface. In one embodiment of the
present invention, a paraffin protective covering is provided on
the exterior surface for protection of the exterior surface during
manufacturing. The paraffin additionally prevents an excessive bond
between the individual bricks and exterior concrete wall to allow
the removal of a cracked or damaged brick and additionally has been
found to reduce cracking in the bricks due to the differential
shrinkage of the exterior concrete layer and clay brick.
Furthermore, other types of materials such as drywall and other
interior finishes can be applied to the interior concrete panel as
necessary for any given application.
[0011] It is yet another aspect of the present invention to provide
a composite modular wall panel which can be used to quickly and
efficiently construct modular buildings and temporary shelters and
is designed to be completely functional with regard to electrical
wiring and other utilities such as telephone lines, etc. Thus, the
present invention in one embodiment includes at least one utility
line which may be positioned at least partially within the
composite wall panel and which accepts substantially any type of
utility line which may be required in residential or commercial
construction, and which can be quickly interconnected to exterior
service lines. This utility line may be oriented in one or more
directions and positioned either near the interior concrete panel,
exterior concrete panel, or both.
[0012] It is yet another aspect of the present invention to provide
a novel surface configuration of the insulative core which assures
a preferred spacing between the surface of the insulative core and
the carbon fiber grid. This surface configuration is applicable for
a front surface, a rear surface, or both depending on the
application. More specifically, the spacing is designed to provide
a gap between the interior and/or the exterior surface of the
insulative core and the carbon fiber grids to assure that concrete
or other facing materials become positioned between the surface of
the insulative core and the carbon fiber grid. This improved and
consistent spacing enhances the strength and durability of the
insulative panel when interconnected to the facing material, carbon
fiber grids and transverse fibers and/or steel prestressing
strands.
[0013] In one embodiment of the present invention the insulative
core may have an interior and/or an exterior surface which is
undulating, i.e., wavy alternative embodiments may have channels or
protruding rails, spacer "buttons", a "waffleboard" configuration,
or other shapes which create a preferred spacing between the
surface-of the insulative material and the fiber grids. Preferably,
the spacing apparatus, channels, rails or other spacers are
integrally molded with the insulative core to reduce labor and
expenses. Alternatively, these spacing apparatus may be
interconnected to the insulative foam after manufacturing, and may
be attached with adhesives, screws, nails, staples or other
interconnection means well known by one skilled in the art.
[0014] It is a further aspect of the present invention to provide a
lightweight, durable building panel which utilizes concrete and
expanded polystyrene materials, along with a unique geometry of
carbon fiber, steel reinforcing rods, and wire mesh to create a
building panel with superior strength and durability. The building
may utilize one or more reinforcing materials such as carbon fiber,
wire mesh or steel reinforcing bars positioned along 1) a perimeter
edge; 2) an interior portion within the perimeter edge; or 3) both
along the perimeter edges and within a predetermined interior
portion of the building panel. Thus, in one embodiment of the
present invention a lightweight, durable concrete building panel is
provided, comprising:
[0015] a concrete building panel comprising an inner surface, an
outer surface, a first end and a second end, and a substantially
longitudinal axis defined between said first end and said second
end;
[0016] a tensioned first carbon fiber grid positioned within said
substantially planar concrete panel between said first end and said
second end and positioned proximate to said outer surface in an
exterior concrete layer;
[0017] a plurality of foam core sections positioned on said
exterior concrete layer and defining a plurality of reinforcing rib
channels between said plurality of foam core sections which are
substantially filled with a concrete material;
[0018] at least one carbon fiber shear strip positioned within said
plurality of reinforcing rib channels and extending into said
exterior concrete layer; and
[0019] at least one reinforcing bar positioned proximate to said at
least one carbon fiber shear strip and positioned within said
plurality of reinforcing rib channels.
[0020] In a preferred embodiment of the present invention, the
insulative core is comprised of a plurality of individual
insulative panels. The seam of the insulative panels preferably has
a cut-out portion which is used to support reinforcing materials
such as rebar, carbon fiber or other material.
[0021] It is a further aspect of the present invention to provide a
method of fabricating an insulative concrete building panel in a
controlled manufacturing facility which is cost effective, utilizes
commonly known building materials and produces a superior product.
It is a further aspect of the present invention to provide a
manufacturing process which can be custom tailored to produce a
building panel with custom sizes, allows modifications for windows
and doors, and which utilizes a variety of commonly known materials
without significantly altering the fabrication protocol.
[0022] Thus, in another aspect of the present invention, a method
for fabricating low density, durable concrete building panel is
provided, comprising:
[0023] a) providing a casting form having a first end, a second
end, and lateral edges extending therebetween;
[0024] b) positioning a first grid of carbon fiber material into
said concrete material;
[0025] c) applying tension to said first grid of carbon fiber
material;
[0026] d) positioning a plurality of reinforcing strands in said
casting form;
[0027] e) applying tension to said plurality of reinforcing
strands;
[0028] f) pouring a first layer of concrete material into a lower
portion of said form;
[0029] g) positioning a layer of low density insulative material
onto said first layer of concrete material, said low density
insulative material having a plurality of reinforcing rib sections
extending substantially between said first end and said second end,
said reinforced rib sections comprising: [0030] 1) a second grid of
carbon fiber extending substantially between said first end and
said second end of said low density insulative material; [0031] 2)
at least one metallic reinforcing bar positioned proximate to said
second grid of carbon fiber and extending between said front end
and said second end of said foam core;
[0032] h) pouring a second layer of concrete within said plurality
of reinforced rib sections;
[0033] i) allowing said first layer and said second layer of
concrete to cure; and
[0034] j) removing said concrete building panel from said form,
wherein said lightweight concrete building panel is available for
transportation and use.
[0035] It is a further aspect of the present invention to provide a
novel manufacturing method wherein one or more "negatives" are
positioned within the casting form prior to pouring the exterior
layer of concrete. The negatives create a void of concrete in a
predetermined opening such as a window or door, and which can be
repeatedly used in numerous castings of wall panels. In one
embodiment the "negative" is a rubber plastic mat that is laser
oriented to a proper position. Weights or magnets or both may be
utilized to prevent inadvertent movement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a front perspective view of one embodiment of a
casting table with form liner used for fabricating a precast
concrete wall panel;
[0037] FIG. 2 is a front perspective view of the embodiment shown
in FIG. 1, and further depicting the placement of a window
negative;
[0038] FIG. 3 is a front perspective view of the embodiment shown
in FIG. 1, and showing the placement of a tensioned carbon fiber
grid material and tensioned metallic strands;
[0039] FIG. 4 is a front perspective view of the invention shown in
FIG. 1, and further depicting the placement of a V-Buck locator
frame placed over the carbon fiber material;
[0040] FIG. 5 is a front perspective view of the embodiment shown
in FIG. 1, and further depicting the dispensing of a predetermined
volume of concrete into the casting table;
[0041] FIG. 6 is a front perspective view of the embodiment shown
in FIG. 1 showing the concrete positioned in the casting table
being vibrated;
[0042] FIG. 7 is a front perspective view of the casting table
shown in FIG. 1 with the V-Buck frame placed around a window
opening;
[0043] FIG. 8 is a front perspective view of the casting table
shown in FIG. 1 and further depicting the positioning of high
density foam strips and reinforcing material around the window
opening and perimeter edges of the casting table;
[0044] FIG. 9 is a front perspective view of the embodiment shown
in FIG. 1, and further depicting the placement of foam billets on
top of the first concrete layer;
[0045] FIG. 10 is a front perspective view of the embodiment shown
in FIG. 1 and further depicting in detail the positioning of the
foam billets and the brackets used therein;
[0046] FIG. 10A is a detailed cross-sectional view of one portion
of the embodiment shown in FIG. 10;
[0047] FIG. 10B is a detailed cross-sectional view of a rebar
support bracket positioned between two foam billets;
[0048] FIG. 10C is an alternative embodiment of the bracket shown
in FIG. 10B, and an associated plastic foam block spacer;
[0049] FIG. 10D is a cross-sectional elevation view showing
additional detail of the casting table lateral edge and retention
magnet;
[0050] FIG. 10E is a tension bar bracket shown penetrated into two
individual foam blocks;
[0051] FIG. 10F is a top plan view of the bracket shown in FIG.
10E;
[0052] FIG. 10G is an alternative embodiment of the tension bar
bracket shown in FIG. 10E;
[0053] FIG. 10H is a top plan view of the tension bar bracket shown
in FIG. 10G;
[0054] FIG. 11 is a front perspective view of the casting table
shown in FIG. 1, and further depicting the casting table filled
with a second layer of concrete within the reinforcing ribs between
the foam panel;
[0055] FIG. 11A is an cross-sectional elevation view of one
embodiment of a lift anchor positioned within a reinforcing
rib;
[0056] FIG. 12 is a front perspective view of the casting table
shown in FIG. 1 and further depicting the interconnection of
exterior nailers 46 which are interconnected to the reinforcing
ribs 14;
[0057] FIG. 12A depicts detailed cross-sectional elevation views of
two exterior nailer designs, and including tension bar brackets,
rebar, carbon fiber, etc.;
[0058] FIG. 13 is a front perspective view of the embodiment shown
in FIG. 1, and depicting the lateral side forms removed from the
casting table;
[0059] FIG. 14 shows the embodiment shown in FIG. 1 with the
casting table being hydraulically tilted for removal purposes;
[0060] FIG. 15 depicts the lifting of the precast table completed
and removed from the casting table;
[0061] FIG. 16 shows a plurality of prefabricated concrete panels
being positioned on a panel support rack; and
[0062] FIG. 17 depicts a cross-sectional partial front elevation
view of one embodiment of a residential wall panel section.
DETAILED DESCRIPTION
[0063] In one aspect of the present invention, a method of
manufacturing a low density concrete composite building panel 2 is
provided herein. These insulated concrete panels can withstand 150
MPG wind loads and tornado driven projectiles, yet are extremely
light weight to transport and erect with an average density of
approximately 18 lbs/Ft..sup.2 (PSF). The exterior finishes of the
wall panels can incorporate clapboard, paneled brick, stucco and
plain concrete for field finishing. The interior stud surfaces are
fastener friendly with 2 inch wide screw strips that run top to
bottom as well as along all perimeters. Further, a "negative-liner"
casting system is provided to offer a menu of rough opening sizes
that can be custom tailored for the needs of the consumer.
[0064] The manufacturing process is generally initiated by
providing a casting table 8 having a first end and a second end
with lateral edges extending therebetween, the form providing a
shell for receiving the concrete materials and other components. If
window or door openings are required, a negative is laser-located
and positioned within the casting table. A concrete block or other
weight or magnets may further be used to prevent movement of the
negative. A first grid of reinforcing materials is then positioned
into the casting table. Preferably, the first grid of reinforcing
materials comprises a carbon fiber grid which may be put under
tension between about 1000-5000 lbs. Once the carbon fiber grid is
tensioned, a predetermined amount of concrete material is placed in
the casting table. The concrete may be vibrated to remove air and
improve the uniform density. Further, one or more tensioned wire
cables or metallic bars may be positioned in the casting table
prior to the introduction of the concrete, and which are generally
oriented in a longitudinal direction of the building panel 2. After
the concrete is cured any excess carbon fiber grid and metal
reinforcing strands are cut and trimmed from the perimeter edges of
the building panel 2. Next, a layer of insulative core 4 is
positioned on the interior surface of the concrete material. In a
preferred embodiment of the present invention, the insulative core
4 is comprised of a plurality of individual insulative form billets
4 which have been cut to the preferred dimensions of the composite
building panel form. Further, at predetermined widths and on the
exterior edges of the composite building panel, a reinforcing strip
48 is provided which may include a second grid of reinforcing
materials such as carbon fiber, and which extends substantially
between the first and second end of the insulative core 4.
Alternatively, rebar or other reinforcing materials may be
positioned around the perimeter edge of the building panel 2, and
along any window/door openings for increased strength and
performance.
[0065] Referring now to the drawings, FIG. 1 is a front perspective
view of one embodiment of the present invention, and which
generally depicts a novel composite building panel casting table 8.
More specifically, FIG. 1 depicts a front perspective view of a
casting table 8 used in the manufacturing of a fabricated concrete
building panel, and which generally includes a casting table first
end rail 54, a casting table second end rail 56, and lateral edges
84 positioned therebetween. In one embodiment, the lateral edges 84
of the casting table 8 may be selectively positioned with the use
of magnets 82 on the bottom surface of the lateral edges 84.
[0066] FIG. 2 depicts a laser positioning a "negative" in the
casting table 8. The negative 10 in one embodiment is a rubber mat
with a plurality of ribs on channels which are positioned on a
lower portion to engage the form liner on the bottom portion of the
casting table 8. By positioning the negative 10 in a preferred
location, an opening is provided for a window, door, or other
access opening as required based on the building specification.
Although not shown in FIG. 2, after the placement of the negative
10, a concrete weight or other dense material can be positioned on
top of the negative to prevent the negative from inadvertently
moving and either before or after positioning the carbon fiber grid
material 6.
[0067] Referring now to FIG. 3, after positioning of the
negative(s) 10, a carbon fiber grid is stretched along the
longitudinal axis of the casting table 8. Alternatively, the carbon
fiber grid material 6 could be stretched in a direction which is
substantially normal to the longitudinal direction of the casting
table. After the carbon fiber material 6 has been positioned over
the negative 10, in a preferred embodiment the carbon fiber grid
material is placed into tension between about 1000-5000 lbs. As
futher shown in FIG. 3, a plurality of tensioned steel cables or
wires are also positioned within the casting table, and are
preferably put under tension between about 500-5000 lbs. In one
embodiment, the tensioned strands are 1/4"in diameter, although
other sizes between approximately 1/8 to 2.0 inches could be used
depending on the application and size of the building panel.
[0068] Referring now to FIG. 4, after tension has been placed on
the carbon fiber grid material 6 and the tensioned wire 12, a
V-Buck locator frame 26 is positioned on top of the negative, as
well as any high density weights to restrict movement. The V-Buck
locator frame 26 is positioned on top of the negative 10 to provide
support for the reinforced window/door frame 42. As appreciated by
one skilled in the art, the V-Buck locator frame and negative can
be any particular size or dimension depending on the design
criteria required therein.
[0069] Referring now to FIG. 5, after positioning of the V-Buck
locator frame 26 over the window or door frame, concrete is
dispensed into the casting table 8 by a concrete dispenser 30. The
exact volume of concrete required for any given casting is
preferably determined by a CAD program or other computer method to
assure there is not unnecessary waste, and that there is a
sufficient volumetric requirement of concrete based on the size and
thickness of the building panel.
[0070] Referring now to FIG. 6, after the concrete is positioned in
place, the casting table is preferably vibrated for a predetermined
period of time to help improve the density of the concrete by
removing air bubbles and/or concrete voids and to help position the
concrete material.
[0071] Referring now to FIGS. 7 and 8, after the concrete has been
vibrated, the V-Buck 26 is placed around the reinforced window/door
frame 42 and V-Buck locator frame, and is generally comprised of a
wood material which allows the window frame to be interconnected to
the building panel 2 after the building panel wall is erected. As
shown in FIG. 8, after the V-Buck 26 has been positioned around the
reinforced window/door frame 42, high density foam strips and
reinforcing materials are added around the window opening 42 and
perimeter edges of the building panel 2 to provide additional
reinforcement. As shown from the detailed cross-sectional elevation
view in FIG. 8, the reinforcing materials may include tensioned
wire/bar 12, carbon fiber sheer grid 80, or combinations
thereof.
[0072] Referring now to FIG. 9, after the positioning of the
perimeter reinforcing materials around the window/door openings and
the perimeter of the casting table, a plurality of foam billets 4
are positioned in the casting table on top of the concrete layer.
The foam billets 4 in this embodiment are shown as individual
pieces, although as appreciated by one skilled in the art a single
uniform piece of foam may be used which has individual channels
positioned therein to achieve the same purpose.
[0073] Referring now to FIGS. 10-10D, additional detail is provided
for the positioning of the foam billets 4 within the casting table
8, and the use of unique tension bar brackets 18 which are used to
both provide spacing between the individual foam billets 4, and to
support one or more reinforcing tension bars 12. More specifically,
and referring now to FIG. 10A, a detailed cross-sectional view of
the casting table 8 is shown herein, and which includes a casting
table lateral rail 84 which is held in position with a magnet 82.
The magnet 82 allows the casting table lateral rail to be moved to
any position depending on the size of the form required for the
individual application. As shown in FIG. 10A, one specific type of
tension bar bracket 18 is utilized which supports a reinforcing
tension bar 12 and which further includes tension bar bracket
spikes 32 which are driven into the foam billet 4 for support
purposes. Referring now to FIGS. 10B and 10C, alternative
embodiments of various tension bar brackets 18 are shown which
support the tension wires/bar 12. As further shown, the carbon
fiber sheer grid 80 is positioned into the exterior concrete layer
16 to provide additional structural support to the area positioned
between the foam billets 4 when they are subsequently filled with
concrete. Referring now to FIGS. 10E and 10F, cross sectional front
elevation views of the tension bar brackets 18 used in one
embodiment of the present invention are provided herein. More
specifically, the tension bar bracket 18 includes one or more
tension bar bracket spikes 32 which allow the tension bar brackets
18 to be driven into the individual foam billets and to provide
spacing and for structural support to hold the tension bar 12. FIG.
l0F is a top plan view of the embodiment shown in 10E, and
providing additional detail and dimensions. Referring now to FIGS.
10G and 10H, cross sectional front elevation views and plan views
of alternative tension bar brackets 18 are further provided herein
in detail to show the various dimensions and geometric
configuration. Generally, the tension bar brackets 18 provided
herein are made of plastic or fiberglass materials, but
alternatively can be made of any other materials commonly known in
the art.
[0074] Referring now to FIGS. 11 and 11A, detail is provided of a
specific rib with a lift loop or cable 40 being positioned therein
in a lift loop pocket, and which is subsequently used to pick up
the composite building panel 2 after fabrication, and allows the
hidden lift loop 40 to be cut off after transportation and
erection. As shown in the FIG. 11A, the lift loop 40 is positioned
within the rib and concrete rib layer 14, and which is positioned
in a lift loop pocket during fabrication. Preferably the lift loop
40 is comprised of high grade aircraft cable, but obviously other
suitable materials could be used for the same purpose.
[0075] Referring now to FIGS. 12 and 12A, additional detail is
provided which shows the concrete ribs 14 filled with concrete, and
the use of exterior nailers 46 which are interconnected to the
concrete ribs 14 and which are used for the interior finishing of
the composite building panel 2 within a given residential or
commercial structure. More specifically, the exterior nailers 46
are comprised of a foam material, in conjunction with a metallic
aluminum cover sheet or wood and which are adapted for use with
nails, screws, or other attachment hardware used in the finishing
of the interior surface of the wall. Referring now to FIG. 13, the
manufacturing process is shown wherein the side forms of the
casting table 8 are removed, while the remainder of the building
panel 2 is still positioned on the casting table. Referring now to
FIG. 14, the panel table is hydraulically tilted with casting table
hydraulic lift 48 and which elevates the building panel 2 to expose
one or more lifting anchors 40.
[0076] Referring now to FIGS. 15-16, the individual building panels
are shown being lifted with a lifting cable 50 which are
interconnected to the lifting anchor loops 40 and are subsequently
put on a panel support rack 52 for transportation.
[0077] Referring now to FIG. 17, a cross-sectional front elevation
view of one embodiment of the present invention of a building panel
2 is provided herein. More specifically, the building panel 2 is
comprised of a carbon fiber grid material 6 which is positioned in
an exterior concrete layer 16. The exterior concrete layer is
interconnected to a concrete rib 14 by means of a carbon fiber
sheer grid 80 which is further positioned proximate to a tension
wire 12. In-between each of the concrete ribs 14 are individual
foam billets 4 which are generally comprised of reground EPS foam
with a density of between about 0.25-1.25 PCF, and with a thickness
of approximately 3 to 7 inches. As shown interconnected to the
individual concrete ribs 14, an exterior nailer 46 is depicted
which is operably interconnected to the concrete ribs 14 by means
of nailer anchor pins 86. Furthermore, a 20 gauge galvanized
aluminum strip is positioned on top of the foam material and which
is user friendly for attaching hardware such as screws, nails, and
bolts. During interior construction of the building, additional
insulation materials can be positioned along the EPS foam, as well
as sufficient spacing being provided for electrical outlet boxes,
wiring, water pipe positioning, and other utilities commonly used
in construction. Following the positioning of these materials, the
interior portion of the wall panel 2 can be finished with drywall,
paneling and other traditional construction materials.
[0078] One example of a carbon fiber grid ribbon 30 which may be
used in the present invention is the "MeC-GRID.TM." carbon fiber
material which is manufactured by Hexcel Clark-Schwebel and as
described in U.S. Pat. No. 6,236,629, which is incorporated herein
by reference. The interior and exterior carbon grid tape is
comprised generally of looped or crossed weft and warped strands,
that run substantially perpendicular to each other and are machine
placed on several main tape "stabilizing strands" that run parallel
to the running/rolling direction of the tape.
[0079] With regard to the concrete utilized in various embodiments
of the present application, a low density concrete such as
Cret-o-Lite.TM., which is manufactured by Advanced Materials
Company of Hamburg, N.Y., may be used. This is an air dried
cellular concrete which is nailable, drillable, screwable, sawable
and very fire resistant.
[0080] In one embodiment, the exterior concrete layer 16 may be
comprised of a dense concrete material to resist moisture
penetration and in one embodiment VISCO CRETE.TM. is utilized which
enables the high slumped short pot life liquification of concrete
to enable the concrete to be placed in narrow wall cavities with
minimum vibration and thus create a high density, substantially
impermeable concrete layer. VISCO-CRETE.TM. is manufactured by the
Sika Corporation, located in Lyndhurst, N.J. The exterior concrete
layer 16 is preferably about 3/4 to 2 inches thick, and more
preferably about 1.75 inches thick. This concrete layer has a
compression strength of approximately 5000 psi after 28 days of
curing, and is thus extremely weather resistant.
[0081] In one embodiment of the present invention, a vapor barrier
material may be positioned next to or on to the exterior surface of
the insulative core 4, or alternatively on the interior surface of
the insulative foam core 4. The vapor barrier 12 impedes the
penetration of moisture and thus protects the foam core from harsh
environmental conditions caused by temperature changes. Preferably,
the vapor barrier 12 is comprised of a plastic sheet material, or
other substantially impermeable materials that may be applied to
the insulative core 4 during manufacturing of the foam core, or
alternatively applied after manufacturing and prior to positioning
of the insulative foam core 4.
[0082] To assist in the understanding of the present invention, the
following is a list of the components identified in the drawings
and the numbering associated therewith: TABLE-US-00001 # Component
2 Composite building panel 4 Insulative foam billets 6 Carbon fiber
grid material 8 Casting table 10 Casting negative 12 Tension
wire/bar 14 Concrete reinforcing ribs 16 Exterior concrete layer 18
Tension bar bracket 20 Utility conduit 22 Exterior cladding 24
Carbon fiber roll 26 V-Buck locator frame 28 Spacer 30 Concrete
dispenser 32 Tension bar bracket spikes 34 Recessed pocket 36
Reinforcing bar 38 Wire mesh 40 Lifting anchor/loop 42 Reinforced
window/door frame 44 Lifting anchor reinforcing mesh material 46
Exterior nailers 48 Casting table hydraulic lift 50 Lifting cable
52 Panel support rack 54 Casting table first end rail 56 Casting
table second end rail 58 Casting table lower surface 60 Building
panel first end 62 Building panel second end 64 Building panel
exterior surface 66 Building panel interior surface 68 Negative
retention weight 70 High density foam strips 80 Carbon fiber shear
grid 82 Casting table magnet 84 Casting table lateral rail 86
Nailer anchor pins
[0083] The foregoing description of the present invention has been
presented for purposes of illustration and description.
Furthermore, the description is not intended to limit the invention
to the form disclosed herein. Consequently, variations and
modifications commenced here with the above teachings and the skill
or knowledge of the relevant art are within the scope in the
present invention. The embodiments described herein above are
further extended to explain best modes known for practicing the
invention and to enable others skilled in the art to utilize the
invention in such, or other, embodiments or various modifications
required by the particular applications or uses of present
invention. It is intended that the dependent claims be construed to
include all possible embodiments to the extent permitted by the
prior art.
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