U.S. patent application number 11/456057 was filed with the patent office on 2007-06-28 for method and apparatus for fabricating a low density wall panel with interior surface finished.
Invention is credited to Harold G. Messenger, Thomas Rotondo.
Application Number | 20070144093 11/456057 |
Document ID | / |
Family ID | 38191977 |
Filed Date | 2007-06-28 |
United States Patent
Application |
20070144093 |
Kind Code |
A1 |
Messenger; Harold G. ; et
al. |
June 28, 2007 |
Method and apparatus for fabricating a low density wall panel with
interior surface finished
Abstract
A fabricated low density concrete foundation/wall panel is
provided with a plurality of insulation panels and reinforcing ribs
to improve strength and reduce the density of the wall panel. The
wall panels are easily placed and interconnected together to
quickly provide a foundation adapted to support the main walls of a
home, for example. The fabricated wall panels in one embodiment
generally includes an inner wall sheathing that is interconnected
to the load-supporting segments of the wall panel during
fabrication.
Inventors: |
Messenger; Harold G.;
(Rehoboth, MA) ; Rotondo; Thomas; (Harwinton,
CT) |
Correspondence
Address: |
SHERIDAN ROSS PC
1560 BROADWAY
SUITE 1200
DENVER
CO
80202
US
|
Family ID: |
38191977 |
Appl. No.: |
11/456057 |
Filed: |
July 6, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60697169 |
Jul 6, 2005 |
|
|
|
60744736 |
Apr 12, 2006 |
|
|
|
Current U.S.
Class: |
52/309.12 ;
52/309.17 |
Current CPC
Class: |
E04C 2/382 20130101;
E04C 2/288 20130101; E04C 2/044 20130101; E02D 27/02 20130101 |
Class at
Publication: |
052/309.12 ;
052/309.17 |
International
Class: |
E04C 1/00 20060101
E04C001/00 |
Claims
1. A low density, concrete wall panel having a first end, a second
end and laterals edges extending therebetween, comprising: a
concrete exterior face wall extending between said first end and
said second end; a plurality of foam panels positioned adjacent to
said concrete exterior face wall, said plurality of foam panels
operably spaced to define a reinforcing rib between each of said
foam panels which is filled with concrete; at least one reinforcing
rod positioned within each of said reinforcing ribs; and an
interior sheathing material interconnected to said plurality of
foam panels on a side opposite said exterior face wall.
2. The low density wall panel of claim 1, further comprising a
reinforcing rib extending around a perimeter edge of said wall
panel, said reinforcing rib comprised of concrete and a metal
reinforcement material.
3. The low density wall panel of claim 1, further comprising a
plurality of utility channels extending at least partially between
said first end and said second end which are adapted to receive
electrical wiring, piping or other utilities.
4. The low density wall panel of claim 1, further comprising a
lifting lug interconnected to at least one of said first end and
said second end.
5. The low density wall panel of claim 1, wherein said perimeter
edges are comprised of concrete extending from said exterior face
wall to said interior face wall.
6. A method for fabricating a low density concrete building panel,
comprising the steps of: a) providing a casting form having a first
end, a second end, and lateral edges extending therebetween; b)
positioning a flexible plastic material within the confines of the
form; c) interconnecting at least one foam core panel to an
interior face building material; d) positioning the at least one
foam core panel and said interior face building material within
said form on said flexible plastic material, wherein a channel is
formed between two of said foam core panels; e) positioning at
least one reinforcing bar in said channel; f) providing a layer of
concrete within said chapels and on an upper surface of said at
least one foam core panel; g) curing said concrete; and h) removing
said lightweight, concrete building panel from said form.
7. The method of claim 6, further comprising the step of
positioning an interior frame within said casting form prior to
said providing a layer of concrete, wherein an opening for a window
or a door is provided.
8. The method of claim 6, further comprising the step of
positioning at least one lift anchor within said concrete building
panel to facilitate the removal of said lightweight building panel
from said casting form.
9. The method of claim 6, wherein said foam core is comprised of at
least one of an expanded polystyrene material, an extruded
polypropylene and a polyisocyanurate material.
10. The method of claim 6, further comprising the step of
reinforcing at least one of a plurality of perimeter edges of said
concrete building panel with at least one of a metallic reinforcing
bar and a carbon fiber material.
11. The method of claim 6, further comprising the step of vibrating
said first concrete material, wherein a density of said first
concrete material is increased.
12. The method of claim 6, wherein interconnection of said at least
one foam core panel and said interior face building material is
accomplished within the casting form.
13. The method of claim 12, where said interior face building
material is poured within said casting form during fabrication of
the low density building panel.
14. A low density fabricated concrete wall panel, comprising an
upper end, a lower end and lateral edges extending between,
comprising: an interior sheathing material positioned substantially
between said upper end, said lower end and said lateral edges; a
plurality of foam panels positioned adjacent to said interior
sheathing material and oriented to define a space between said at
least two of said plurality of foam panels between said upper end
and said lower end; a cavity extending within at least one of said
plurality of foam panels between said upper end and said lower end,
said cavity adapted to receive a utility; a concrete material
positioned on an exterior surface of said plurality of foam panels
to define an exterior face and within said space between said at
least two of said plurality of foam panels to define a reinforcing
rib.
15. The low density wall panel of claim 14, wherein said sheathing
material is comprised at least partially of a gypsum material.
16. The low density wall panel of claim 14, wherein said plurality
of foam panels are comprised of at least one of an expanded
polystyrene material, an extruded polypropylene and a
polyisocyanurate material.
17. The low density wall panel of claim 14, further comprising a
metallic rod positioned within said space and formed between said
at least two of said plurality of foam panels.
18. The low density wall panel of claim 14, Further comprising a
lift anchor positioned along a perimeter edge to facilitate lifting
the low density wall panel.
Description
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. Nos. 60/697,169 and 60/744,736, filed Jul.
6, 2005 and Apr. 12, 2006, respectively, which are incorporated by
reference in their entireties herein. This application is also
related to pending U.S. patent application Ser. No. 11/096,705,
which is a continuation-in-part of pending U.S. patent application
Ser. No. 10/772,148, filed Feb. 3, 2004, which is a
continuation-in-part of pending U.S. patent application Ser. No.
10/423,286, filed Apr. 24, 2003, which is a continuation-in-part of
U.S. patent application Ser. No. 10/150,465, now U.S. Pat. No.
6,729,090, filed May 17, 2002, which is a continuation-in-part of
U.S. patent application Ser. No. 10/093,292, now U.S. Pat. No.
6,701,683, filed Mar. 6, 2002, each of the pending applications or
issued patents being incorporated by reference in their entirety
herein.
FIELD OF THE INVENTION
[0002] The present invention relates to building components, and
more specifically low density concrete wall panels that are
manufactured in a controlled environment and can be selectively
interconnected on-site to fabricate modular buildings.
BACKGROUND OF THE INVENTION
[0003] Due to the high cost of traditional concrete components and
the expensive transportation and labor costs associated therewith,
there is a significant need in the construction industry to provide
lightweight, precast, composite building panels that have superior
strength and insulative properties. Previous attempts to provide
these types of building panels have failed due to the expensive
transportation costs and less than ideal insulative and thermal
conductivity properties associated with prefabricated concrete
wire-reinforced products. Further, due to the brittle nature of
concrete, many of the previously used building panels are prone to
cracks and other damage during transportation.
[0004] The relatively large weight per square foot of building
panels of the prior art 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 places effective limits on the height of structures, such as
stacked modules e.g., due to load limitations of the building
foundations, footings and/or lowermost modules. Furthermore, there
is substantial fabrication labor expense that can arise from
design, material, and labor costs associated with providing and
placing reinforcement materials. Accordingly, it would be useful to
provide a wall panel system for modular construction that is
relatively light, can be readily stacked to increased heights and,
preferably, inexpensive to design, manufacture, transport and
erect.
[0005] 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, thus 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 such 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 is a relatively high potential for
cracking or splitting of the panel or module. Accordingly, it would
be useful to provide panels and modules wherein openings such as
doors and windows may be integrated in desired locations with a
reduced potential for cracking or splitting.
[0006] One other problem associated with metallic wire or bar
materials used in conjunction with concrete is the varying rates of
expansion and contraction. Thus, with extreme heating and cooling
the embedded metallic materials tend to separate from the concrete,
thus creating cracks which may lead to exposure to moisture and the
eventual degradation of both the concrete and wire reinforcement
due to corrosion.
[0007] One example of a composite building panel that attempts to
resolve the aforementioned problems inherent in modular panel
construction of the prior art is described in U.S. Pat. No.
6,202,375 to Kleinschmidt (the '375 patent), which is incorporated
by reference in its entirety herein. In this invention, a building
system is provided that 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 the 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 stiffness
properties required during transportation and in high wind
environments. 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
properties of metallic wire. Thus, the panels disclosed in the '375
patent may be more susceptible to failure when exposed to stresses
during transportation, assembly or subsequent use.
[0008] In addition, attempts have been made to employ improved
building materials that incorporate carbon fiber. For example, in
U.S. Pat. No. 6,230,465 to Messenger, et al., which is incorporated
herein in its entirety by reference, discloses concrete with a
carbon fiber and steel reinforced precast frame. Unfortunately, the
insulative properties of this invention are relatively poor due to
the physical nature of the concrete and steel. Further, the
excessive weight of the panels and inherent problems associated
with transportation, stacking, etc. are present. Previously known
prefabricated building panels have also not been found to have
sufficient tensile and compressive strength when utilizing only
concrete insulative foam materials or wire mesh. Thus, there is a
significant need for a lightweight concrete building panel that has
increased tensile and compressive strength, and which utilizes one
or more commonly known building materials to achieve this
purpose.
[0009] Furthermore, there is a need for a precast concrete
foundation wall system that can be directly positioned on a
prepared soil gravel or sand surface and interconnected to one or
more foundation walls. After interconnection, a concrete floor can
be poured which is operatively interconnected to the foundation
walls and provides additional support.
[0010] Accordingly, there is a significant need in the construction
and building industry to provide composite building panel walls and
foundation walls that may be used in modular construction that are
lightweight, that provide superior strength and that have high
insulative values. Further, a method of making these types of
building panels is needed that 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. Finally there is a significant need for a precast
foundation wall system that can be positioned on a prepared soil or
gravel surface and operably interconnected to a poured concrete
floor without utilizing onsite forms or other expensive building
techniques.
SUMMARY OF THE INVENTION
[0011] It is one aspect of the present invention to provide a
composite wall panel that has superior strength, high insulating
properties, is lightweight for transportation and stacking purposes
and is cost effective to manufacture. As used herein the term
foundation wall panel, wall panel, foundation/wall panel all refer
to a manufactured, low density wall comprised at least partially of
concrete and which can be utilized as a foundation wall or any
other wall in a commercial or residential structure. Thus, in one
embodiment of the present invention, a substantially planar
insulative core with interior and exterior surfaces is positioned
between concrete panels that are reinforced with carbon fiber grids
positioned substantially adjacent to the insulative core. In a
preferred embodiment of the present invention, the interior layer
of concrete is comprised of a low-density concrete. Furthermore, as
used herein, insulative core may comprise any type of material that
is thermally efficient and has a low heat transfer coefficient.
These materials may include, but are not limited to,
Styrofoam.RTM.-type materials such as expanded polystyrenes,
extruded polystyrenes, extruded polypropylene, polyisocyanurate,
combinations thereof and other materials, including wood materials,
rubbers, and other materials well known in the construction
industry.
[0012] It is a further aspect of the present invention to provide a
lightweight, composite concrete wall panel that is adapted to be
selectively interconnected to a structural steel frame. Thus, in
one embodiment of the present invention attachment hardware is
selectively positioned within the wall panel during fabrication
that is used to quickly and efficiently interconnect the panel to a
structural frame.
[0013] It is another aspect of the present invention to provide a
low density concrete wall panel that has sufficient compressive
strength to allow a second building panel to be stacked in a
vertical relationship, on which can support a vertical load in the
form of a floor truss or other structural member. Alternately, it
is another related aspect of the present invention to provide a
composite lightweight wall panel that can be utilized in a corner
adjacent to a second wall panel, or aligned horizontally with a
plurality of wall panels in a side by side relationship.
[0014] It is still yet another aspect of the present invention to
provide a composite wall panel that can be easily modified to
accept any number of interior textures, surfaces or cladding
materials for use in a plurality of applications. Thus, the present
invention is capable of being finished with a stucco, siding,
brick, drywall other type of interior or exterior surface.
[0015] It is yet another aspect of the present invention to provide
a composite modular wall panel that 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 is 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 is
generally positioned near the interior surface of the foundation
wall panel.
[0016] It is yet another aspect of the present invention to provide
a novel configuration of the insulative core that assures a
preferred spacing between the insulative core and the reinforcing
ribs. More specifically, the spacing is designed to provide a gap
between the insulative core panels to assure that concrete carbon
fiber stirrups and/or metallic reinforcing bars are properly
positioned between the insulative core panels. This improved and
consistent spacing enhances the strength and durability of the
panel
[0017] It is still yet another aspect of the present invention to
provide an insulated concrete wall panel that is comprised of a
exterior face wall with a plurality of reinforcing ribs emanating
therefrom. The space between the ribs receives foam insulation,
thereby increasing the insulative properties of the wall panel and
reducing the overall density of the wall panel. The exterior face
in one embodiment of the invention is additionally strengthened
with at least one carbon fiber grid that generally extends
horizontally therethrough. During fabrication, the carbon fiber
band is preferably tensioned between about 500-3000 lbs. so that
once released the carbon fiber band will retract somewhat, thus
placing the hardening concrete in a compressed state. The wall
panel may also include a footer positioned adjacent to a top edge
and a bearing pad positioned at a bottom edge. The footer provides
a location for the placement of main building walls and the bearing
pad is designed to increase the footprint of the wall panel on a
soil or pea stone, and which subsequently becomes operably
interconnected to the concrete floor surface.
[0018] It is still yet another aspect of the present invention to
provide an insulative panel that is quickly manufactured and
durable. More specifically, one embodiment of the present invention
is manufactured in an exterior face up configuration. As used
herein, "face up" configuration refers to the exterior surface of
the foundation wall panel being in an uppermost portion of the
casting form during fabrication. This configuration allows for the
efficient placement of the insulative foam panels, reinforcing
strands and carbon fiber grid material. Alternatively, a panel of
Dens-Armor, traditional gypsum, drywall, or other building material
may be placed in the fixture initially and the remaining members of
the wall placed thereon to yield a wall panel with a completed
interior wall. Since the wall panel is substantially comprised of a
concrete base material, the finished product is fire resistant,
substantially maintenance free, mold resistant, insect proof, wind
resistant and projectile resistant. To increase the fire and smoke
resistance of the panel, a fire and smoke resistant surface may be
affixed to the insulative foam. In addition, the use of insulation
in-between the ribs provides a foundation wall panel that is
insulated, in one embodiment having an R factor of about 20 or
more. Further, with proper treatment of the concrete, the
foundation wall panel is substantially water resistant.
[0019] Thus, in one embodiment of the present invention, a low
density concrete wall panel is provided, comprising:
[0020] a concrete exterior face wall extending between said first
end and said second end;
[0021] a plurality of foam panels positioned adjacent to said
concrete exterior face wall, said plurality of foam panels operably
spaced to define a reinforcing rib between each of said foam panels
which is filled with concrete;
[0022] at least one reinforcing rod positioned within each of said
reinforcing ribs; and
[0023] an interior sheathing material interconnected to said
plurality of foam panels on a side opposite said exterior face
wall.
[0024] Alternatively, it is another aspect of the present invention
to provide a method of manufacturing a low density, concrete
building wall wherein the interior face material is poured during
the manufacturing process. More specifically, rather than
interconnecting one or more foam panels to an interior face
material such as Dens-Armor or drywall sheets, the gypsum or other
interior face material may first be poured within the casting form,
and preferably on a plastic sheeting material. Once the gypsum or
other material has been poured, the foam panels can be positioned
on top of the interior face material, and the concrete subsequently
poured within the channels and around the perimeter edges of the
building panel as previously described. That it is another aspect
of the present invention to provide a method of manufacturing a low
density concrete foundation/wall panel, comprising:
[0025] a) providing a casting form having a first end, a second
end, and lateral edges extending therebetween;
[0026] b) positioning a flexible plastic material within the
confines of the form;
[0027] c) interconnecting at least one foam core panel to an
interior face building material;
[0028] d) positioning the at least one foam core panel and said
interior face building material within said form on said flexible
plastic material, wherein a channel is formed between two of said
foam core panels;
[0029] e) positioning at least one reinforcing bar in said
channel;
[0030] f) providing a layer of concrete within said channels and on
an upper surface of said at least one foam core panel;
[0031] g) curing said concrete; and
[0032] h) removing said lightweight, concrete building panel from
said form.
[0033] The Summary of the Invention is neither intended nor should
it be construed as being representative of the full extent and
scope of the present invention. The present invention is set forth
in various levels of detail in the Summary of the Invention as well
as in the attached drawings and the Detailed Description of the
Invention and no limitation as to the scope of the present
invention is intended by either the inclusion or non-inclusion of
elements, components, etc. in this Summary of the Invention.
Additional aspects of the present invention will become more
readily apparent from the Detail Description, particularly when
taken together with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] The accompanying drawings, which are incorporated in and
constitute a part of the specification, illustrate embodiments of
the invention and together with the general description of the
invention given above and the detailed description of the drawings
given below, serve to explain the principles of these
inventions.
[0035] FIG. 1 is a top perspective view of a structure employing
wall panels of one embodiment of the present invention, wherein an
inner wall is removed for clarity;
[0036] FIG. 2 is a partial top perspective view of a structure
employing wall panels of one embodiment of the present
invention;
[0037] FIG. 3 are top sectional views of a wall panel and portions
thereof;
[0038] FIG. 4 is a front elevation view of a wall panel of one
embodiment of the present invention;
[0039] FIG. 5 is a top plan view of the wall panel shown in FIG.
4;
[0040] FIG. 6 is a right cross sectional view of the wall panel of
one embodiment of the present invention;
[0041] FIG. 7 is a perspective view of a wall panel assembly
emphasizing the wall/floor interface;
[0042] FIG. 8 is a top plan view of the wall panel of one
embodiment of the present invention showing lifting hardware;
[0043] FIG. 9 is a perspective view of a fixture for making one
embodiment of the present invention;
[0044] FIG. 10 is a cross-sectional view of the wall panels of the
present invention shown employed in a structure;
[0045] FIG. 11 is a perspective view of the prior art method of
constructing a foundation/wall panel of one embodiment of the
present invention;
[0046] FIG. 12 is a perspective view of a novel method of
constructing a foundation/wall panel; and
[0047] FIG. 13 is a perspective view depicting foam panels and the
interior surface material being positioned within a casting
form.
[0048] It should be understood that the drawings are not
necessarily to scale. In certain instances, details that are not
necessary for an understanding of the invention or that render
other details difficult to perceive may have been omitted. It
should be understood, of course, that the invention is not
necessarily limited to the particular embodiments illustrated
herein.
DETAILED DESCRIPTION
[0049] Referring now to FIGS. 1-13, various embodiments of the
present apparatus and method for making the same is provided
herein. More specifically, FIG. 1 depicts a construction
installation sight identifying an excavation and a foundation wall
positioned in place for the placement of a structure such as a
single family home. As shown in the photograph, the foundation
walls have been installed and secured together similar to a poured
foundation, the novelty being that all of the foundation walls have
been precast in a manufacturing facility, delivered on location and
erected with a crane or other similar means. Furthermore, the
foundation and/or wall panels of the present invention utilize a
low density foam material positioned between a plurality of ribs
made out of concrete, and which may additionally include steel
reinforcing bars for structural support. As further shown in these
foundation walls, windows or other openings may be provided as
necessary. Furthermore, and not shown in this particular drawing, a
method for manufacturing a foundation or wall panel is provided,
wherein an interior wall surface of sheet rock or gypsum board,
siding, or other building materials may be provided during the
manufacturing process, thus eliminating the additional time and
expense of installing drywall or other materials after the walls
are erected. In one embodiment, a material known as Dens-Armor.RTM.
is utilized, which is coated glass backed gypsum panel manufactured
by Georgia Pacific Corporation of Atlanta, Ga.
[0050] Referring now to FIG. 2, a cut-away sectional view of a
plurality of assembled foundation walls of the present invention
are provided herein. More specifically, the foundation wall is
shown leveled and positioned on a minimum six inch thick base of
one-half inch pea stone or other similar base material which is
compacted and level after excavation at the building site. Drainage
is provided by a perforated PVC pipe or other means well known in
the art and is positioned within the pea gravel. Further, a
polyethylene film may be provided under the basement floor slab to
create a substantially impermeable barrier between the concrete and
pea gravel. Once the site is properly leveled, the plurality of
foundation wall panels may be positioned on the pea gravel for
proper interconnection.
[0051] As shown in the drawing, in one embodiment a recessed joint
fastener which utilizes a bolt or other attachment hardware is
utilized to properly interconnect the joints. Furthermore, a gasket
or other sealing means may be positioned within the joint to
provide a waterproof seal between the two wall panels at the
juncture of the joints and, to assure there is no penetration from
exterior moisture. In one embodiment, the gasket may be a bentonite
material, a polyethylene material, rubber, caulking compound or
other sealing materials well known in the art. As additionally
shown in FIG. 2, external "corbels" may be manufactured within the
wall panel to provide a support for brick materials as necessary
depending on the exterior finish of the building. Furthermore,
windows, bulk heads, doors and other features can be provided to
provide access from the basement or other location. Furthermore,
and as shown in the drawing, the wall panels may be installed on
location with the use of recessed erection lift lugs. Furthermore,
threaded inserts for the attachment of the sill on the top of the
foundation wall panel may be provided during manufacturing to allow
for further erection of the building. Additionally, recessed
vertical utility voids may be provided within the foam panels
during the manufacturing of the low density foundation/wall panel
to provide access points for utilities such as electrical wiring,
water, hot water heating, etc.
[0052] Referring now to FIGS. 3A and 3B, a cross-sectional view of
one foundation/wall panel of the present invention is provided
herein. More specifically, a 45.degree. corner is provided on a
wall panel for use generally in a corner location. As depicted the
wall panel further includes foam panels with a three inch spacing
therebetween which is filled during the manufacturing process with
concrete and rebar or other reinforcing materials. The exterior
wall outer surface may additionally include rebar, carbon fiber, or
other materials for strengthening and structural integrity.
Furthermore, as shown in FIGS. 3A and 3B, the interior wall surface
is manufactured with the use of Dens-Armor, drywall, or other
interior construction materials which are generally interconnected
to the foam panels during the manufacturing of the wall panel, and
prior to the concrete being poured.
[0053] Referring now to FIG. 3C-3J, a variety of cross-sectional
elevation and plan views are provided herein and which provide
additional detail to various embodiments of the present invention.
For example, FIG. 3C shows an upper portion of a wall panel, which
further includes 1/2 inch diameter plastic inserts placed at 24
inch centers which are utilized for attaching the sill plate on top
of the wall panel. Furthermore, the positioning of the foam panels,
the plywood material, and/or the Dens-Armor material is shown
positioned on the interior surface of the panel. As further
depicted in FIG. 3C-3G, reference is made to a PT plywood material
used in combination with a Dens-Armor sheathing material. As
referenced herein, the 1/2''.times.48''.times.6'' plywood material
is utilized either along a lower portion of the wall panel or an
upper portion of the wall panel, and is generally used as a
fastener friendly strip for interconnecting interior trim materials
such as baseboard.
[0054] Referring now to FIG. 3E, the positioning of the EPS foam
panels with respect to the Dens-Armor sheeting materials is
provided herein, and with regard to the concrete which is
positioned between the EPS foam panels during manufacturing to
provide a structural rib. More specifically, in one embodiment of
the present invention the foam panels are first glued or otherwise
attached to the interior face sheathing material, which is
positioned into the bottom portion of a casting form. Prior to
positioning the foam panels and interior face sheathing materials
in the form, it is preferable to utilize a plastic or other
flexible material to position on the steel forms to prevent rust or
other discoloration from showing on the exterior surface of the
interior sheathing material. The sheathing panels are then abutted
next to each other, at which time in a preferable embodiment a 3
inch by 1/2 inch EPS foam strip or other material is positioned
over the joint to assure that concrete when poured does not
permeate between the seam of the sheathing material during
manufacturing. Referring now to FIG. 3F-3G, additional details are
provided of the connection inserts which are shown placed in the
gypsum wall sheathing near the bottom of the panel, and also with
respect to the lower portion of the wall panel.
[0055] Referring now to FIG. 3H, detail is provided wherein a floor
joist is shown positioned on top of a foundation wall panel, which
is bolted to a sill on the upper portion of the foundation/wall
panel for interconnection purposes. As additionally shown in FIG.
3H, 1.5 inch straps may be used for interconnection purposes of the
floor joists, and positioned at 32 inch centers. FIG. 3I depicts
lifters in the upper portion of the foundation and/or wall panel
which are used for transporting and lifting the wall panels, while
the positioning of rebar or other structural materials are shown in
FIG. 3J in a drawing depicting the lower portion of the wall
panel.
[0056] Referring now to FIGS. 4-5, additional detailed drawings are
shown of a typical foundation/wall panel. As shown in this drawing,
the positioning of the rebar within the channels between the low
density foam materials is shown herein, along with a cut-out
wherein a window may be provided during the forming process. In one
embodiment of the present invention, it is anticipated that the
window frame can actually be positioned within a cut-out in the
sheathing material during the formation of the foundation wall, and
during which time the window is positioned while the concrete is
poured in place. Alternatively, a void or cut-out can be formed and
positioned in place of the window, the concrete poured, and the
window inserted after the installation of the building panel. As
shown in FIG. 5, greater detail is provided with regard to the
positioning of the rebar, the foam panels, and the plastic inserts
and lifters used for interconnecting the sill, and the bolt anchors
respectively.
[0057] Referring now to FIG. 6, a side elevation photograph of one
wall/foundation panel of the present invention is provided herein
and which depicts additional detail. More specifically, the
exterior concrete wall portion is shown, which is immediately
positioned adjacent to the EPS foam material, which in turn is
interconnected to the Dens-Armor or other sheathing material.
[0058] Referring now to FIG. 7, additional details are provided
showing a typical joint between the interior sheathing material.
More specifically, after construction of the wall panel, the joint
between the Dens-Armor, sheet rock, or other material has a slight
seam which is easily taped and finished once the foundation/wall
panels are erected and positioned in place. Furthermore, a concrete
basement floor or other material can be poured after the erection
of the walls. Additionally, a wood strip or other similar material
can be utilized at the lower or uppermost portion of the Dens-Armor
or other interior wall surface, and which is utilized for
interconnecting interior trim to the foundation/wall panel.
[0059] Referring now to FIG. 8, a photograph is provided showing
additional detail of the foundation/wall panel of the present
invention. More specifically, the Dens-Armor, drywall or other
interior sheathing material is shown positioned against the upper
portion of the foundation wall, and which includes a utility access
for positioning utility wires, piping, or other utility access.
Furthermore, a lift lug is shown which is used for transporting and
erecting the foundation/wall panel, as well as a sill insert which
is used for interconnecting the sill plate on top of the foundation
wall.
[0060] Referring now to FIG. 9, a front perspective view of a
corner portion of a casting form used for manufacturing a wall
panel is provided herein. More specifically, a 45.degree. mitered
corner is utilized for creating a 90.degree. corner between two
wall panels. As appreciated by one skilled in the art, this angle
an be modified depending on the geometry of the building site.
Furthermore, the plastic sill insert is shown which will be
embedded within the concrete and allows for the interconnection of
the sill, while a lift lug is shown positioned for allowing for the
transportation, erection and positioning of the foundation wall at
the building site. As provided herein, steel or other metal
materials are generally utilized for the forms and other molds
during the manufacturing of the wall panels, although other
materials known in the art could also be used.
[0061] Referring now to FIG. 10, a cross sectional front elevation
view of one embodiment of the present invention is provided herein.
More specifically, a foundation wall panel is shown on a lower
portion of the drawing, which is interconnected by the use of a
threaded rod through a sleeve to a stem deck floor or other
flooring material. Furthermore, a manufactured wall panel is shown
operably interconnected to an upper portion of the stem deck floor,
and wherein a portion of the threaded rod extends from the
foundation wall panel through the stem deck floor, and through a
lower portion of the wall panel for interconnection purposes. As
further shown in FIG. 10, the wall panel includes a wall board
finish made out of Dens-Armor, drywall, or other building materials
and which is interconnected to the foundation wall panel during
manufacturing. Furthermore, the same interior wall board finish may
be utilized on the foundation wall as well. As additionally shown
in FIG. 10, a brick shelf or corbel may be manufactured integral to
the foundation wall, and which provides a ledge or other support
mechanism for supporting bricks, or other veneered materials.
[0062] Referring now to FIGS. 11-12, photographs depicting the
manufacturing of a foundation panel of the present invention is
provided herein. More specifically, FIG. 11 depicts the prior art
method of manufacturing the building panel, while FIGS. 12 and 13
depict a new method of manufacturing. With respect to FIG. 11, the
foam panels were previously required to be held down within the
bottom portion of the casting form, with a plurality of wood or
metallic hold downs. Not utilizing the hold downs allows the foam
panels to float once the concrete is poured, thus creating
inconsistencies within the wall panel and a potential loss of
structural integrity. Furthermore, in the prior art method shown in
FIG. 11, no interior sheathing or other surface was provided below
the panels, and an interior drywall or other material would be
installed after the wall panel was erected.
[0063] Referring now to FIG. 12, and depicting a novel method of
manufacturing, the foam panels in one embodiment are first glued or
otherwise interconnected to an interior face sheathing material
such as Dens-Armor. Preferably, two of the foam panels are glued to
the sheathing material, and including a three inch void between the
foam panels for the positioning of one or more pieces of
reinforcing material for structural support and to provide a
channel to create a reinforcing rib which is filled with concrete.
Once the foam panels and interconnected interior sheathing
materials are placed adjacent one another, a three inch foam strip
or other material may be positioned on top of the seam created
between the sheets of interior sheathing materials, thus preventing
the concrete from leaking between the seams. Once the rebar and
other structural support materials have been placed within the
structural ribs, the concrete is poured on top of the foam panels
and within the structural ribs. The excess concrete on the exterior
wall portion of the reinforced wall is skimmed off, and corbels or
other distinct exterior shapes can be created within the form as
necessary.
[0064] Referring now to FIG. 13, a photograph is provided showing
the installation of the foam panels within the casting form. More
specifically, two foam panels are shown glued to an exterior face
material such as Dens-Armor or drywall. The plurality of foam
panels are then laid on a plastic liner or other materials to
prevent rust or other contamination from contacting the interior
face material or sheathing. As the exterior face sheathing
materials are laid side by side, a three inch void is created
between each of the foam panels, thus forming the reinforcing ribs.
After each of the foam panels and interconnected interior face
materials are positioned within the casting form, rebar or other
reinforcing materials are positioned within the reinforcing
channels, and preferably along the perimeter edges of the low
density concrete wall panels. Once the reinforcing materials are
positioned within the channels and around the perimeter edges,
concrete is poured within the reinforcing ribs and along the
perimeter edges and on top of the foam panels to create the
exterior face of the low density concrete building panel.
[0065] In an alternative embodiment of the present invention, it is
anticipated that gypsum, drywall materials or other building
materials could actually be poured into the casting form as opposed
to interconnecting the exterior sheathing materials to the foam
panels. Once the interior sheathing material is poured into the
casting form, the foam panels can be positioned on top of the
interior sheathing material, the rebar positioned within the
channels created by the foam panels, and the concrete subsequently
poured. Thus, in this embodiment the step of interconnecting the
foam panels to a rigid interior face material would be
eliminated.
[0066] In another aspect of the invention not identified in FIG.
13, once the foam panels and interconnected internal sheathing
materials are laid down within the casting form, a 3 inch foam
material or tape can be positioned on top of the seams created
between the interior face sheathing materials. By positioning the
foam or tape on top of the seams, concrete is substantially
prevented from permeating through the seams and disfiguring the
interior face of the wall panel. After the wall panel is erected on
the building site, the seams created between each of the Dens-Armor
or other interior face material can subsequently be taped and
textured to create a smooth finish similar to traditional drywall
or gypsum board.
[0067] As generally provided in the drawings and photographs,
foundation/wall panels are shown in a variety of embodiments. More
specifically, foundation wall panels may be formed in a variety of
shapes and sizes depending on the application and design criteria.
In addition, the foundation wall panels may be arranged such that
they are interconnectable, or have a bend integrated therein, such
that a plurality of angled walls are provided by one panel.
Further, it should be understood by one skilled in the art that a
plurality of apertures 46 may be integrated into the wall panel(s)
2 so that conduits for electrical lines, sewage lines and/or water
lines may be accommodated.
[0068] In addition, reinforcing bars preferably span substantially
the entire height of the foundation wall panel 2. More
specifically, one embodiment of the present invention includes
reinforcing bars that are integrated into the reinforcing ribs of
the panel from the plate to the shoe, i.e. lateral edge to lateral
edge, providing additional strength and rigidity.
[0069] Other embodiments of the present invention include
reinforcing bars integrated horizontally between a first and second
end of the wall panel. One skilled in the art will appreciate that
the horizontal reinforcing bars and the longitudinal reinforcing
bars may be interconnected to increase strength and rigidity. In
addition, carbon fiber may be added to the ribs, the shoe, and/or
the plate, in conjunction with steel reinforcing bars or alone, to
increase the wall panel strength. Further, foundation/wall panels
as contemplated by the present invention may also include lifters
and inserts that receive a lifting device to facilitate
transportation and erection of the foundation wall panels 2.
[0070] Furthermore, an interconnection scheme employed in certain
embodiments of the present invention is shown. More specifically,
one embodiment of the foundation wall panels may be interconnected
via a bolt or other attachment hardware. Preferably, the foundation
wall panels include an angled outer edge that engages a matching
angled edge of an adjacent foundation wall panel. These edges are
similar to that of miter joints as known in the art. Bolt pockets
may also be provided that are located adjacent to the upper edge
and the lower edge of the foundation wall panels for
interconnection. The bolt pockets allow for the insertion of a
fastener, such as a bolt through coincident apertures on each wall
panel. The adjacent foundation wall panels can then be securely
interconnected by a nut or other attachment hardware known in the
art. Alternatively, welding may be utilized to prevent movement of
the two panels. In addition, steel plates may be included, affixed
to either an inner corner or an outer corner of the finished
interconnected joint, to add increased strength thereto. These
plates are interconnected to the foundation wall panels via
fasteners, such as bolts, or alternatively welded.
[0071] As further provided, one method of constructing the
insulative foundation panel is shown and described. Embodiments of
the present invention are constructed with the exterior surface
"face up", which is believed novel. Initially, the insulation
panels are placed in the casting form, wherein the reinforcing ribs
are defined by the spaces between the insulative panels.
Reinforcing bars are then positioned within the space for the
reinforcing ribs. Concrete is then poured into the space. One
skilled in the art will appreciate that additional steps, such as
vibration, may be employed to ensure that the consistency of the
concrete is per specification, and to improve the density of the
concrete. Finally, wood, foam, or metal screw strips may be applied
along the edges of the ribs. Although not shown, the insulative
foundation panel may include a footer and a bearing pad that is
placed when the ribs are formed, and which may be tied into the
face wall with reinforcing bar and stirrups as well. The footer may
subsequently be covered at least partially with concrete when the
concrete floor is poured during installation at the building site,
thus providing additional structural support.
[0072] With regard to the concrete utilized in various embodiments
of the present application, the face wall and associated ribs may
be comprised of a low density concrete such as Cret-o-Lite.TM.,
which is manufactured by Advanced Materials Company of Hamburg,
N.Y. This is an air dried cellular concrete that is nailable,
drillable, screwable, sawable and very fire resistant. In a
preferred embodiment, the face wall is comprised of a dense
concrete material to resist moisture penetration and in one
embodiment is created using VISCO CRETE.TM. or equal product, which
is a chemical that 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 face wall is preferably about 2 inches thick. This concrete
layer has a compression strength of approximately 5000 psi after 28
days of curing.
[0073] Positioned within the ribs is one or more reinforcing bars
"rebar", which are generally manufactured from carbon steel or
other similar metallic materials. Preferably, the reinforcing bar
has a diameter of at least about 0.25 inches, and more preferably
about 0.75-1.50 inches. As appreciated by one skilled in the art,
the reinforcing bars may be any variety of dimensions or lengths
depending on the length and width of the wall panel, and the
strength requirements necessary for any given project.
[0074] 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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