U.S. patent application number 11/773911 was filed with the patent office on 2008-05-08 for lightweight concrete wall panel with metallic studs.
This patent application is currently assigned to OLDCASTLE PRECAST, INC.. Invention is credited to Thuan Bui, Thomas G. Harmon, Harold G. Messenger.
Application Number | 20080104913 11/773911 |
Document ID | / |
Family ID | 38895475 |
Filed Date | 2008-05-08 |
United States Patent
Application |
20080104913 |
Kind Code |
A1 |
Messenger; Harold G. ; et
al. |
May 8, 2008 |
Lightweight Concrete Wall Panel With Metallic Studs
Abstract
A wall panel is provided that is comprised of a plurality of
spaced foam insulative blocks. Between each block is a metal stud
that spans the height of the wall panel and provides sufficient
strength to counteract any compressive loads the wall panel may
encounter. The presence of the insulation panels provides large
surface areas for the receipt of a thin layer of cementious or
gypsum based material that is adapted to receive nails and be
easily cut. In addition, the decreased weight of the exterior wall
allows for the omission of reinforcing internal structure within
the exterior wall which is found in the prior art, thereby
providing a lightweight and easy to fabricate wall.
Inventors: |
Messenger; Harold G.;
(Rehoboth, MA) ; Bui; Thuan; (Philadelphia,
PA) ; Harmon; Thomas G.; (St. Louis, MO) |
Correspondence
Address: |
SHERIDAN ROSS PC
1560 BROADWAY, SUITE 1200
DENVER
CO
80202
US
|
Assignee: |
OLDCASTLE PRECAST, INC.
Littleton
CO
|
Family ID: |
38895475 |
Appl. No.: |
11/773911 |
Filed: |
July 5, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60806598 |
Jul 5, 2006 |
|
|
|
Current U.S.
Class: |
52/309.9 |
Current CPC
Class: |
E04C 2/384 20130101;
E04C 2/288 20130101 |
Class at
Publication: |
52/309.9 |
International
Class: |
E04C 2/06 20060101
E04C002/06 |
Claims
1. A wall panel with metallic studs comprising: an exterior layer
comprised of at least one of a cementious or gypsum based material;
a plurality of generally parallel spaced foam blocks positioned on
said layer of cementious or gypsum based material, each foam block
having an upper end, a lower end and two lateral sides extending
therebetween, wherein one lateral side further comprises a lip
extending therefrom that defines a space between adjacent foam
blocks; a plurality of metallic framing members each with an upper
end and a lower end, at least one said plurality of metallic
framing members positioned within the space between the adjacent
foam blocks; and a fastening device interconnecting said metallic
framing members to said exterior layer.
2. The wall panel of claim 1 wherein said wall panel is adapted to
be cut with a hand saw.
3. The wall panel of claim 1 wherein said plurality of foam blocks
are adhered to said plurality of frame members to increase bonding
strength.
4. The wall panel of claim 1 wherein said plurality of foam blocks
include a passageway therethrough and said plurality of frame
members include apertures that are adapted to receive utility
wiring or plumbing.
5. The wall panel of claim 1, further comprising a first channel
interconnected to said upper ends of said plurality of spaced
metallic framing members.
6. The wall panel of claim 1, wherein said fastening device is
comprised of a stamped flat metal member coated with nylon and is
adapted for attachment to said plurality of frame members with at
least one of screws, rivets, welds and adhesives.
7. The wall panel of claim 1, further comprising a bonding agent
positioned between said layer of cementious or gypsum material and
said foam blocks.
8. The wall panel of claim 1, further comprising a second channel
interconnected to said lower ends of said plurality of spaced
framing members.
9. The wall panel of claim 1, further comprising at least one bore
formed through at least a portion of at least one of the framing
members and at least one of the foam blocks opposite from the
exterior layer for aiding in the bonding of a second exterior layer
comprised of at least one of a cementious or gypsum based
material.
10. The wall panel of claim 1, wherein the exterior layer comprises
concrete.
11. The wall panel of claim 1, wherein the exterior layer comprises
SHEETCRETE.TM. by Oldcastle Precast, Inc.
12. The wall panel of claim 1, wherein the exterior layer comprises
glasscrete.
13. A low density wall panel, comprising: a first exterior layer
comprised of at least one of a cementious or gypsum based material;
a foam block positioned on the first exterior layer, the foam block
having a front surface and a rear surface, the front surface being
in contact with the first exterior layer; a plurality of studs
embedded in the foam block, wherein each stud includes first and
second portions, the first portion being adjacent the front surface
of the foam block and the second portion being generally opposite
the first portion; and at least one fastener extending into the
foam block and the first exterior layer.
14. The wall panel of claim 13, wherein at least one bore is formed
through the foam block and the second portion of at least one of
the plurality of studs for aiding in the bonding of a second layer
of at least one of a cementious or gypsum based material to the
foam block opposite from the first exterior layer.
15. The wall panel of claim 13, wherein the front surface of the
foam block includes at least one cutout for aiding in the bonding
of the first exterior layer to the foam block.
16. The wall panel of claim 15, wherein the cutout includes a
dovetail-shaped cutout.
17. The wall panel of claim 13, wherein the fastener includes a
head, an abutment portion, and a protruding portion; wherein when
the protruding portion is mounted in the foam block, the abutment
portion contacts the front surface of the foam block and the head
is mounted in the exterior layer.
18. The wall panel of claim 17, wherein the protruding portion is
threaded.
19. The wall panel of claim 13, wherein the fastener includes a
head and a protruding portion; wherein when the protruding portion
is mounted in the foam block, the head is mounted in the exterior
layer.
20. The wall panel of claim 19, wherein the protruding portion is
threaded.
Description
[0001] This application claims benefit of U.S. Provisional
Application Ser. No. 60/806,598, filed Jul. 5, 2006, the entire
disclosure of which is hereby incorporated by reference.
[0002] This application is also related to pending U.S. patent
application Ser. No. 11/122,792, filed May 4, 2005, which is a
continuation-in-part of pending U.S. patent application Ser. No.
11/096,705, filed Apr. 1, 2005, which is a continuation-in-part of
pending U.S. patent application Ser. No. 10/772,148, filed Feb. 3,
2004, now U.S. Pat. No. 7,100,336, which is a continuation-in-part
of pending U.S. patent application Ser. No. 10/423,286, filed Apr.
24, 2003, now U.S. Pat. No. 6,898,908, 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. In
addition, this application is related to U.S. patent application
Ser. No. 11/121,267, filed May 2, 2005, to U.S. Provisional Patent
Application Ser. No. 60/697,169, filed Jul. 6, 2005, and to U.S.
Provisional Patent Application Ser. No. 60/741,487, filed Dec. 2,
2005 and Provisional Patent Application Ser. No. 60/744,736, filed
Apr. 12, 2006. This application incorporates all of the
applications and issued patents listed above by reference in their
entirety herein.
FIELD OF THE INVENTION
[0003] 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
[0004] 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.
[0005] The relatively large weight per square foot of building
panels of the prior art has resulted in increased expenses arising
not only from the amount of materials needed for fabrication, but
also the cost of transporting and erecting the modules. Building
panel 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 integrating 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.
[0006] In many situations, wall panels are situated in locations
where it is desirable to have openings to accommodate cables, pipes
and the like. In some previous approaches, wall panels were cast so
as to include any necessary openings that require careful planning
and design, thus increasing costs. In other approaches, wall panels
were cast without such openings and the required openings were
formed after casting, e.g. by sawing, drilling, or similar
procedures. Such post-casting procedures, for example cutting
through thick and/or steel-reinforced panels are labor-intensive
and expensive. Further, in many processes for creating openings,
there is a relatively high potential for cracking or splitting of
the wall panel. Accordingly, it would be useful to provide wall
panels wherein passageways for fluid, air, and/or electrical
conduits may be cost effectively integrated in desired locations
with a reduced potential for cracking or splitting.
[0007] Many types of tilt-up pre-fabricated wall panels have been
employed in the past. More specifically, wall panels of the prior
art are generally lightweight, durable, and can be manufactured
with readily available material. However, the wall panels of the
prior art usually employ a thickened exterior wall of concrete that
is internally supported by a framework of metal, i.e. "re-bar". The
thickness of the exterior wall and the presence of metallic
reinforcement makes the wall panel difficult to modify during
construction. It should be noted that previous attempts to
fabricate thin shell wall panels have resulted in walls with
reduced load carrying capacity, but for most low level residential
structures the load carrying capability of thin shelled wall panels
may be adequate.
[0008] Additionally, the exterior walls of buildings often include
various types of siding that can be mounted directly to the
building structure (i.e. framing). The siding protects the
buildings from rain, wind, snow, etc. which in turn can cause
damage to the framing and other elements of the building. For
instance, a building may include wood siding, plastic siding, metal
siding, or composite siding, etc. However, the siding, while meant
to protect the interior of the building from the elements, is often
itself susceptible to deterioration from the elements. For
instance, a common type of siding is corrugated metal siding
because of the wide array of design options it provides. This
corrugated metal siding, however, is susceptible to rusting which
can present an unsightly appearance along with allowing moisture
and wind to penetrate into the interior of the building. While
using galvanized steel or other rust resistance metals can help
prevent rust from forming, these are often not perfect solutions.
Additionally, in the case of corrugated metal siding mounted to the
building structure, the insulation located between the metal siding
and the building structure is often compressed therebetween,
thereby reducing the R-value of the insulation. Accordingly, it
would be useful to provide an aesthetically pleasing lightweight
facade that can be mounted to the siding of a building and which is
capable of preventing moisture and other natural elements from
penetrating the interior building structures. Further, it would be
useful to provide a lightweight facade that maintains or enhances
the insulative properties of the wall.
[0009] Accordingly, there is a significant need in the construction
and building industry to provide a selectively alterable composite
building wall panels 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.
SUMMARY OF THE INVENTION
[0010] It is one aspect of the present invention to provide a
lightweight wall panel. More specifically, embodiments of the
present invention are comprised of a plurality of lightweight foam
insulative blocks separated by metal studs. The metal studs provide
sufficient compressive strength to the wall panel. In addition, a
layer of lightweight concrete is employed on one side of the
insulative foam blocks to provide a surface that is resistant to
heat, cold, wind, water and other natural conditions. The wall
panel as provided herein is contemplated to become an exterior of a
building. However, one skilled in the art will appreciate that the
wall panel as disclosed herein is ideal for interior walls of a
building. The insulative foam blocks provide thermal isolation
between the metal components of the wall and the concrete
components of the wall. In addition, the insulation provides an
excellent barrier from the outside elements. Further, the
insulation panels in accordance with embodiments of the present
invention provide added structural support for the thin layer of
concrete, which allows for the omission of reinforcing bar
structures that are generally embedded in the concrete wall panels
of the prior art. More specifically, in the past, thicker external
walls were required to provide sufficient structural support. Since
wall panels as described herein employ insulation panels that carry
some of the load, a reinforcing bar substructure is not required.
That is, by utilizing foam blocks positioned between the metallic
studs, a great degree of surface area is provided for which a thin
concrete layer can bond, thereby allowing the omission of the
reinforcing bar structure generally embedded in the wall structure
and which allows for thinner, lighter wall section.
[0011] As briefly mentioned above, the exterior wall of embodiments
of the present invention is made of high performance or lightweight
concrete. For example, the concrete may be comprised partially of
sand expanded perlite or the like for aggregate with polyvinyl
acelate (PVA) fiber embedded therein. Concrete of this type allows
for the incorporation of fasteners, such as nails and screws and
allows the wall panel to be cut like wood, which translates to
flexibility in the construction of residential buildings. It is
also another aspect of the present invention that the concrete
layer be easily modified to accept any number of interior and
exterior textures, surfaces or cladding materials. More
specifically, the present invention is capable of being finished
with stucco, siding, brick, drywall or other type of interior or
exterior surface finish. More importantly, exterior claddings of
bricks or stones for example, may be employed into the casting when
the wall panel is being fabricated thereby yielding a finished
exterior facade. Additionally, the exterior layer may comprise
SHEETCRETE.TM. by Oldcastle Precast, Inc." or glasscrete as an
alternative material to concrete.
[0012] It is another aspect of the present invention to provide
wall panels that can be employed to quickly and efficiently
construct modular buildings and temporary shelters and is designed
to be completely functional with regard to electrical wiring or
other utilities such as telephone lines, etc. Thus embodiments of
the present invention include at least one utility conduit that is
positioned at least partially within the wall panel for the receipt
of substantially any type of utility line which may be required in
residential or commercial construction. Utility conduits integrated
into the wall panels may be oriented in one or more directions are
generally positioned in the insulation panels near the interior
surface of the wall panel.
[0013] It is yet another aspect of the present invention to provide
a finished interior wall. As will be appreciated by one skilled in
the art, portions of the metallic studs that are situated away from
the concrete exterior wall may be used to accept dry wall, or wood
strips that are used to interconnect dry wall or other types of
interior surface material. Additionally, a layer of dens armor,
traditional gypsum, drywall, or other building material may be
placed in the fixture during fabrication to yield a wall panel with
a completed interior wall. Preferably, a layer of "sheet crete" or
other gypsum or cementious material as disclosed in U.S.
provisional patent application 60/741,487, entitled "Lightweight
Structural Concrete With Properties Similar to Wood" may be
employed to form the interior faces of the wall panel. Therefore,
since the exterior of the wall panel is substantially comprised of
concrete based materials or metallic materials, 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 interior and exterior
walls or the insulative foam itself. In addition, the use of
insulation provides a wall panel that is insulated, and one
embodiment having an enhanced resistance to heat flow (R-value).
Further, with proper treatment of the concrete, the wall panel is
substantially water resistant.
[0014] Further, it is another aspect of the present invention that
the wall panel will have sufficient rigidity and structural
strength to allow for the interconnection of hardware such as
screws, bolts, etc. Without requiring the location of a stud. Thus
cabinets, pictures and other interior items may be hung directly
from hardware penetrating the wall panel.
[0015] It is still yet another aspect of the present invention to
provide a wall panel that has a substantially joint free internal
surface. As briefly alluded to above, embodiments of the present
invention utilize a concrete like internal surface thereby yielding
an internal wall having substantially no joints. Thus the wall
panel is provided that does not require further post direction
finishing to prepare drywall, for example. Further, previous wall
panels similar to those described herein may have included wood
strips or other surfaces for drywall nails, a feature no longer
required. However, one skilled in the art will appreciate that wood
or other materials may be integrated in the wall to provide an
interface for wood framing if so desired.
[0016] It is another aspect of the present invention to provide a
wall panel that is easy to construct. More specifically, wall
panels of the prior art generally require the use of clips that are
permanently attached to the metal studs that interface with the
layer of concrete. Since the concrete layer of embodiments of the
present invention is substantially thinner than those previously
used, fewer clips are required because the majority of structural
support of the concrete wall panel is provided by the insulation
foam blocks. Thus embodiments of the present invention utilize a
plurality of clips interconnected to the metal studs along the
height thereof. During fabrication, the clips are inserted into the
still wet concrete wherein curing of the concrete permanently
affixes the exterior wall onto the metal studs. Nylon cladding is
used on the clips in one embodiment to minimize the heat transfer
between the concrete wall and the metal stud. Since the clips are a
secondary attachment mechanism, fewer clips are needed to
interconnect the exterior wall to the metal studs. This unique
modification reduces the number of thermal transmission points
between the concrete and metal frame, thus improving the thermal
efficiency of the wall panel.
[0017] In order to ensure that the concrete wall is affixed firmly
to the metallic studs, a bonding material may additionally be used.
The bonding of the insulation panels to the exterior wall also
provides additional structural support of the exterior wall. Some
embodiments of the present invention thus employ a primer coat onto
the exterior wall after it is initially placed. This primer coat
may be PVA or acrylic resin. Preferably, the bonding coat is
cementious that includes portland cement, flyash and super
plasticizer. Alternatively, and emulsion polymer or a moisture
cured urethane may be used to ensure fast and easy application.
Generally, these materials are applied to the exterior wall by a
roller or a spray. Bonding may be used on all surfaces of the metal
stud as well to ensure that the sides of the insulation panel are
affixed securely thereto. Finally, the clips may be coated with
some sort of bonding material to enhance their interconnection with
the exterior wall.
[0018] According to yet another aspect of the present invention, a
lightweight wall panel is provided that provides a building facade
for the exterior of a building. More specifically, wall panels of
some embodiments of the present invention include a lightweight
foam insulative block with embedded studs. The studs provide
compressive strength to the wall panel. In one variation, the studs
comprise metal studs. However, ordinary artisans will realize that
other materials, such as composite materials or plastic for
instance, can be utilized to construct the studs. In addition, a
layer of lightweight concrete (see discussion of concrete supra) is
employed on one side of the insulative foam block to provide a
surface that is resistant to heat, cold, wind, water and other
natural conditions. Further, multiple wall panels can be connected
together in an end-to-end relationship to provide a facade of a
desired width for a building. More specifically, one end of a wall
panel may be provided with a cutout allowing a portion of a stud to
protrude therefrom. Additionally, one end of an adjacent wall panel
may be provided with a bracket protruding therefrom. Thereafter,
the bracket may be connected to protruding portion of the stud so
as to mount the wall panels together in an end-to-end relationship.
Ordinary artisans will realize that the bracket can be connected to
the protruding portion of the stud in multiple ways, including, but
not limited to, welding, riveting, a threaded connection, etc.
While the wall panel as provided herein is contemplated to become
an exterior of a building, one skilled in the art will appreciate
that the wall panel as disclosed herein is ideal for interior walls
of a building.
[0019] According to yet another aspect of the present invention, a
lightweight wall panel is provided that includes a foam block with
a plurality of embedded studs for providing compressive strength to
the panel. The studs are preferably C-shaped metal studs that
substantially extend from a front surface to a back surface of the
foam block. However, ordinary artisans will realize that studs of
various other shapes and materials or studs that do not extend the
entire length of the foam block can be utilized. After the foam
block is formed with reinforcement therein, it is placed on top of
a not yet cured layer of lightweight concrete in order to form the
lightweight wall panel. In one variation, various types of
fasteners can be inserted into the foam block and into the stud
(via a threaded connection, interference fit, etc) so that the foam
block can be placed on top of the uncured concrete or other
exterior layer wherein the fasteners are inserted into the uncured
concrete or other exterior layer. Thereafter, once the exterior
layer fully cures, the foam block will be more rigidly connected to
the exterior layer due to its mechanical bond with the fasteners.
Additionally, if desired, a second layer of concrete or other
material can be placed or otherwise formed on the side of the foam
block opposite from the first layer of concrete or other material.
To aid in the bonding strength of the foam block to the second
layer, bores can be formed through the foam block and a portion of
the studs. Thereafter, as the second layer of concrete or other
material is placed on top of the foam block, a portion of the
concrete or other material will flow into the bores. As a result,
after cure, a more rigid connection between the foam block and the
second layer will exist. One of ordinary skill will understand that
additional bores can be formed through the foam block and not
through the studs for flowing of the uncured second layer.
Embodiments of the present invention thus include foam blocks and
studs with bores along with the aforementioned fasteners that
provide a more robust and durable wall panel.
[0020] It will be appreciated that shipping the wall panels of the
present invention from the factory to the job site will be enhanced
because of the low weight of the wall panels. Building erection at
the job site will be enhanced for similar reasons. For instance,
buildings can be retrofitted by mounting the lightweight wall
panels of the present invention directly onto the exterior of the
building or by removing exterior layers of the building and then
mounting the wall panels of the present invention onto desired
sections of the building.
[0021] Moreover, those of ordinary skill in the art will recognize
that the concrete may include color additives to provide for a wall
of a desired appearance. Also, methods known in the art can be used
to create the impression of bricks or other shapes in the layer of
concrete or other material.
[0022] Thus, in one embodiment of the present invention, a low
density concrete wall panel is provided, comprising:
[0023] an exterior layer comprised of at least one of a cementious
or gypsum based material;
[0024] a plurality of generally parallel spaced foam blocks
positioned on said layer of cementious or gypsum based material,
each foam block having an upper end, a lower end and two lateral
sides extending therebetween wherein one lateral side further
comprises a lip extending therefrom that defines a space between
adjacent foam blocks;
[0025] a plurality of metallic framing members each with an upper
end and a lower end, at least one framing member of the plurality
thereof positioned within the space between adjacent foam
blocks;
[0026] a first channel interconnected to said upper ends of said
plurality of spaced metallic framing members; and
[0027] a second channel interconnected to said lower ends of said
plurality of spaced framing members.
[0028] Further, in another embodiment of the present invention, a
low density wall panel is provided, comprising:
[0029] a first exterior layer comprised of at least one of a
cementious or gypsum based material;
[0030] a foam block positioned on the first exterior layer, the
foam block having a front surface and a rear surface, the front
surface being in contact with the first exterior layer;
[0031] a plurality of studs embedded in the foam block, wherein
each stud includes first and second portions, the first portion
being adjacent the front surface of the foam block and the second
portion being generally opposite the first portion; and
[0032] at least one fastener extending into the foam block and the
first exterior layer.
[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 wall panel of one
embodiment of the present invention;
[0036] FIG. 2 is a top perspective view of a foam insulation block
of one embodiment of the present invention;
[0037] FIG. 3 is a top perspective view of a metal frame employed
in embodiments of the present invention;
[0038] FIG. 4 is a partial detailed perspective view of the
embodiment shown in FIG. 1;
[0039] FIG. 5 is a partial bottom plan view of the embodiment of
the present invention shown in FIG. 1;
[0040] FIG. 6 is a variation of the embodiment of FIG. 1
illustrating a series of bores to aid in attachment of a second
layer of concrete or other material;
[0041] FIG. 7 is a top plan view of a wall panel of another
embodiment of the present invention;
[0042] FIG. 8 is a partial top plan view illustrating the
end-to-end interconnection of two wall panels according to another
embodiment of the present invention;
[0043] FIG. 9 is a partial top plan view of a wall panel of another
embodiment of the present invention.
[0044] To assist in interpreting the drawings, the following table
is herein which identifies the various components of the present
invention and the numbering associated therewith:
TABLE-US-00001 # Component 2 Wall panel 6 Metal stud 10 Foam block
14 Upper surface 18 Lower surface 22 Lateral surface 26 Interior
surface 34 Lip 38 Exterior wall 46 Channel 50 Upper edge 54 Lower
edge 58 Passage 62 Stud aperture 64 Channel apertures 68 Frame
system 72 Clip 76 Adhesive 80 Bores 102 Wall panel 106 Stud 107
First portion 108 Second portion 110 Foam block 114 Front surface
118 Rear surface 119 First end 120 Second end 122 First fastener
126 Protruding portion 130 Head portion 134 Cutout 138 Bracket 139
Protruding portion 140 Aperture 142 Second fastener 143 Aperture
146 Exterior wall 150 Overlapping region 154 Fasteners 158 Washer
202 Wall panel 206 Stud 207 First portion 208 Second portion 209
Aperture 210 Foam block 214 Front surface 218 Rear surface 222
First fastener 226 Head 230 Abutting portion 234 Protruding portion
238 Second fastener 242 Head 246 Protruding portion 250 Third
fastener 254 Bridge portion 258 Legs 262 Bore 266 Bore 270 Exterior
layer 274 Second layer 278 Cutout
[0045] 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
[0046] Referring now to FIGS. 1-5, a lightweight wall panel 2 is
provided that includes a plurality of metal studs 6 that receive
foam insulation blocks 10 positioned therebetween. The foam blocks
10 used in the present invention are generally rectangular with an
upper surface 14, a lower surface 18 and two lateral side surfaces
22. In addition, an interior 26 and exterior surface 30 is
provided. Further, at least one lateral side surface has a lip 34
depending therefrom that generally extends the exterior surface 30.
The lip 34 is adapted to receive the metallic stud 6 and separates
the metallic stud 6 from a layer of lightweight concrete material
38 that is affixed to the exterior surface 30 of the foam block.
Wall panels 2 as contemplated herein also may include insulative
strips 42 adjacent to a lower surface 18 and an upper surface 14 of
the foam blocks 10 that provide a location for the interconnection
of a channel 46 that also interconnects to upper 50 and lower 54
edges of the metallic studs 6. The channel 46 provides a location
wherein air, utility, or fluid conduits may be situated. Further,
it is also contemplated that some foam blocks 10 of the wall panel
2 may include at least one passage 58 for the receipt of conduits
for receiving electrical wiring, piping, etc. as well. In order to
allow the conduits to traverse the entire width of the wall panel,
one skilled in the art will appreciate that apertures 62 may also
be included into the metal studs 6.
[0047] Referring now to FIG. 1 the wall panel 2 of one embodiment
of the present invention is provided herein. The wall panel 2 is
comprised generally of an exterior wall 38 of a lightweight
concrete material. After the concrete material is placed, a
plurality of foam blocks 10 are positioned thereon. As the exterior
wall 38 cures, the foam blocks 10 will adhere thereto. To enhance
adherence of the foam blocks to the exterior wall, dovetails or
other shaped cutouts may be made into the surface of the foam block
in any location and in any direction that contacts the exterior
wall 38. Such cutouts will allow a portion of the exterior wall 38
to flow into the cutout before the exterior wall 38 is fully cured
thus increasing the aforementioned adherence once the exterior wall
38 is fully cured. Other methods of securing the interior
components of the wall will be described below. In addition, the
foam blocks 10 may include a lip 34 that receives the metal studs 6
that effectively separate the foam blocks 10. The metal studs 6 may
be comprised of a c-channel or a solid piece of metal depending on
the required strength of the wall panel 2. In the illustrated
embodiment, the upper surface and the lower surface of the foam
blocks 10 do not entirely match the height of the exterior wall 38
thereby providing a gap that separates the foam blocks 10 from a
metal channel 46 that spans between the ends of the metal studs 6.
In addition, foam strips 42 are added adjacent to the upper surface
and the lower surface 54 of the foam blocks 10 that receive a
portion of the channel 46 and the metal studs 6. These measures are
taken such that the metal stud 6 is separated from the exterior
wall concrete material 38 which is important because each material
has different expansion rates wherein quicker expansion of the
metallic material may cause cracking of the exterior wall 38.
Exterior walls 38 of embodiments of the present invention are
created of a lightweight concrete. However, as alluded to above,
one skilled in the art will appreciate the other materials, such as
dry wall, SHEETCRETE.TM. by Oldcastle Precast, Inc., glasscrete, or
other similar materials may be utilized without departing from the
scope of the invention. The metal studs 6 may also include stud
apertures 62 that provide access to passages 58 built into the foam
block 10. A plurality of passages 58 may further be aligned to
incorporate conduit through the width of the wall panel 10. In
addition, the channel 46, which is positioned at the top edge and
the bottom edge of the wall may be used for conduit as well.
Further, if c-channels are utilized for the metallic studs, an air
space is also provided that is useful for the transition of conduit
therethrough. The channel may also have apertures 64 that allow
access to the space provided by the metallic studs 6.
[0048] Referring now to FIG. 2, the foam block 10 of one embodiment
of the present invention is provided. More specifically, the foam
block 10 includes the upper surface 14, the lower surface 18 and
two lateral surfaces 22 extending therebetween. In addition, an
interior surface 26 and an exterior surface 30 is provided. A lip
34 extends from at least one lateral surface 22 that provides a
location for the positioning of the metal stud. This lip 34
performs a double function by providing the required spacing
between two adjacent foam blocks 10 and providing a pad that
receives the metal stud so that it does not contact the concrete
exterior surface limiting undesirable heat transfer. The foam
blocks 10 of some embodiments of the present invention include at
least one passage 58 forwarded therethrough for the receipt of
conduit. Although the passage 58 in FIG. 2 is shown to extend
horizontally, one skilled in the art will appreciate that any shape
or angulation or orientation of the passage 58 may be used without
departing from the scope of the invention.
[0049] Referring now to FIG. 3, a frame system 68 of one embodiment
of the present invention is shown. More specifically, the frame
system 68 is comprised of a plurality of spaced metal studs 6
wherein the upper edge 50 and lower edge 54 thereof are
interconnected to a channel 46. In addition, to ensure that the
metal studs 6 are firmly interconnected to the concrete exterior
wall, a plurality of clips 72 are provided that are interconnected
to the metal studs 6. The clips 72 are preferably coated with nylon
or other insulative material thereby limiting the amount of heat
transferred between the metal studs 6 and the concrete wall. In
addition, since the insulation panels provide additional structural
support to the exterior concrete wall, the amount of clips 72
required in many embodiments of the present invention are
significantly reduced, thus further ensuring that some thermal
expansion issues are alleviated. One skilled in the art will
appreciate that the channel 46 may be affixed to the metal studs 6
in any way previously used in the art, such as welding, riveting,
screwing, nailing, bonding, to name a few.
[0050] Referring now to FIG. 4, a cut away view of one embodiment
of the present invention is shown. Upon review of this figure, one
skilled in the art will appreciate the method of manufacture of
wall panels 2 as contemplated herein. More specifically, initially
a layer of lightweight concrete 38 is placed then in a form,
preferably to a depth of about 11/2 to 1 inch in thickness. Next, a
plurality of foam blocks 10 are located in the form wherein the
lips 34 of the foam blocks 10 are abutted against the adjacent foam
blocks 10 to provide a space for the receipt of metal studs 6. The
metal studs 6, which may include the clips 72 interconnected
thereto, is then placed on the lip 34 wherein the metal clip 72
includes a portion that penetrates into the still wet and uncured
concrete 38 or other wall material. In addition, the clip 72 is of
such a thickness that it can fit easily between any gap provided
between the metal stud 6 and the foam block 10 situated next to the
metal stud 6. Prior to placing the metal studs 6, a foam strip is
placed adjacent to the upper and lower surfaces 18 of the foam
block 10 over an exposed section of lightweight concrete 38. This
small overlap allows the channel 46 to be interconnected to the
edges 54 of the metal studs 6 that provide a space between the
upper and lower surfaces 18 of the foam block 10 and the channel
46. The channels 46 provide an excellent location for the
positioning of wiring, piping, etc. And to provide an insulative
air barrier.
[0051] Referring now to FIG. 5, a front elevation view of one
embodiment of the present invention is shown. This figure
illustrates the spacing of the metal stud 6 with respect to the
layer of lightweight concrete 38. It also shows that when a
C-shaped metallic stud 6 is used, an air barrier and channel is
provided that provides a location for conduits. Embodiments of the
present invention may use adhesives 76 to secure portions of the
metal stud 6 onto the foam blocks 10 that are situated adjacent
thereto. In addition, as one skilled in the art will appreciate,
adhesives may be employed onto the layer of concrete 38 prior to
placing the foam blocks 10 thereon thereby ensuring a tighter
bond.
[0052] With reference to FIG. 6, a variation of the embodiment of
FIG. 1 is shown whereby a second layer of concrete or other
material can effectively be placed onto the foam block opposite
from the first layer of concrete or other material. To aid in the
attachment of the second layer to the wall panel, bores 80 are
formed through a portion of the studs and into the foam block. As
the second layer is being placed, a portion of the second layer
will flow into the bores 80. Thereafter, once the second layer
fully cures, the second layer will be more effectively bonded to
the wall panel due to the second layer curing within the bores 80
of the foam block and the studs.
[0053] Referring now to FIG. 7 and according to another embodiment
of the present invention, a lightweight wall panel 102 is provided
that includes a foam insulation block 110 with a plurality of studs
106 embedded therein. The foam block includes a front surface 114,
a rear surface 118, a first end 119, a second end 120, and a
length, and can comprise any number of materials including, but not
limited to, expanded polystyrene (EPS), expanded polystyrene (XPS),
polyurethane, etc.
[0054] Each stud 106 is metal and includes first and second
portions 107, 108 that are respectively situated near the front and
rear surfaces 114, 118 of the foam block. In the illustrated
embodiment, each stud 106 comprises a z-shaped channel. However,
ordinary artisans will recognize that other shapes such as c-shaped
channels or other shaped channels can be utilized depending on the
required strength of the wall panel 102. While each stud will
preferably extend from the top to the bottom of the foam block 110,
multiple studs can be utilized from the top to the bottom of the
foam block instead of a just a single stud 106. Further, the studs
106 are preferably equally spaced along the length of the foam
block. However, ordinary artisans will recognize that other
spacings between studs may be required depending upon the desired
design requirements. Further, at least one first fastener 122 is
mounted to the front surface 114 of the foam block and the first
portion 107 of the stud 106. The first fastener 122 is mounted to
the front surface 114 and the first portion 107 via a threaded
connection, an interference fit, etc. Each first fastener 122
includes a portion 126 that protrudes from the front surface 114 of
the foam block 110. The first fastener 122 may comprise a screw,
bolt, nail, etc., among others, and may further include a head
portion 130 for reasons that will be described below.
[0055] With continued reference to FIG. 7, each wall panel 102 also
includes an exterior wall 146 constructed of, for instance, a
lightweight concrete material. However, one skilled in the art will
appreciate that other lightweight materials such as SHEETCRETE.TM.
by Oldcastle Precast, Inc. and glasscrete can also be utilized.
Each exterior wall 146 is mounted on the front surface 114 of the
wall panel 102. As will be described more fully below, before the
material of the exterior wall 146 is fully cured, the protruding
portion 126 of each first fastener 122 is pressed into the exterior
wall 142 until the front surface 114 of the foam block 110 abuts
the exterior wall 146. It will be appreciated that a cutout or
cutouts, such as but not limited to, dovetail cutouts, can be
provided on the front surface 214 of the foam block to interact
with the concrete or other material. These cutouts can be provided
in any location and in any direction along the front surface of the
foam block. Thereafter, once the concrete has fully cured around
the protruding portion 126 of each first fastener 122, and within
the cutout(s), the exterior wall 146 will be rigidly mounted to the
front surface 114 of the foam block 110. Moreover, if a head
portion 130 is provided on the first fastener 122, additional
rigidity can be provided between the exterior wall 146 and the foam
block 110 due to the concrete curing around the head portion
130.
[0056] Referring now to FIG. 8, an end-to-end interconnection
between two of the wall panels 102 of one embodiment is shown. More
specifically, a cutout 134 is formed on the first end 119 of the
foam block 110 of a first wall panel 102 thus exposing the second
portion 108 of a stud 106. The second portion 108 of the stud 106
may be provided with an aperture 143 for receiving a second
fastener 142 as will be described below. The second end 120 of a
second wall panel 102 includes a bracket 138 with a portion 139
protruding from the second end 120 mounted adjacent to the second
portion 108 of a stud 106. One skilled in the art will appreciate
that the bracket 138 can be mounted to the second end 120 in
various ways, such as by curing the foam around the bracket, a
threaded connection, gluing, etc. Additionally, the bracket 138 may
include an aperture 140 for reasons that will be described
below.
[0057] In operation, two wall panels 102 are interconnected in an
end-to-end relationship by initially placing the first end 119 of a
first wall panel 102 adjacent to the second end 120 of a second
wall panel 102 such that the protruding portion 139 is located in
the cutout 134. Thereafter, the aperture 143 of the second portion
108 of the stud 106 of the first wall panel 102 and the aperture
140 of the bracket 138 of the second wall panel 102 are aligned and
a second fastener 143 is inserted therethrough to rigidly
interconnect the first and second wall panels 102. Preferably, the
second fastener 143 is threaded such that after the fastener 143 is
placed through the apertures 143, 140, the fastener 143 is threaded
into the siding of a building thus mounting the wall panels to the
building. However, ordinary artisans will appreciate that various
other interconnection schemes can be used such as nailing,
riveting, welding, etc. Further, although only a single bracket,
second fastener, etc. have been shown, it will be appreciated that
multiple brackets, second fasteners, etc. can be used to provide a
desired rigidity between the panels themselves and/or desired
rigidity between the panels and the exterior of a building.
Moreover, while the first and second wall panels 102 are shown to
be in a collinear arrangement in FIG. 8, it is contemplated that
the first and second wall panels 102 could be interconnected such
that the first wall panel is arranged at an angle to the second
wall panel.
[0058] With respect to FIG. 8a, a variation of the end-to-end
interconnection between two adjacent wall panels 102 is shown. More
specifically, the second portion 108 of a stud 106 protrudes from a
first wall panel 102 adjacent the first end 119 of first wall panel
102. The second portion 108 of a stud 106 protrudes from a second
wall panel 102 adjacent the second end 120 of the second wall panel
102. In operation, the second portions 108 of the studs 106 of the
first and second wall panels are brought into contact at an
overlapping region 150. Thereafter, the second portions are rigidly
connected at the overlapping region 150 by any method known in the
art, such as, but not limited to, welding, a threaded connection,
clamping, etc.
[0059] With respect to FIG. 8b, another variation of the end-to-end
interconnection between two adjacent wall panels 102 is shown. More
specifically, the second portion 108 of a stud 106 protrudes from a
first wall panel 102 adjacent the first end 119 of first wall panel
102. The second portion 108 of a stud 106 protrudes from a second
wall panel 102 adjacent the second end 120 of the second wall panel
102. In operation, the second portions 108 of the studs 106 of the
first and second wall panels are brought into contact at an
overlapping region 150. Thereafter, a bracket 138 is provided for
providing additional support to the overlapping region 150.
Finally, fasteners 154 are provided for rigidly interconnecting the
second portions 108 of the studs and the bracket 138. To further
provide for a robust connection, a washer 158 can be provided to
fill in any gaps that exist between the bracket 138 and the second
portions 108 of the studs 106 as shown in FIG. 8b. It will be
appreciated that while the aforementioned connection arrangements
have been illustrated to rigidly interconnect two adjacent wall
panels 102, others known to ordinary artisans are contemplated as
being within the scope of the present invention.
[0060] A method of a manufacturing the wall panel of FIGS. 7 and 8
will now be described. Initially, a mold is provided for curing of
the foam blocks. After a plurality of studs are placed in the mold
at desired locations, a foam solution is introduced into the mold
and allowed to cool and/or cure. After curing, the foam block is
removed and if desired, cut into appropriate lengths. Once the foam
block has been produced, a form for producing an exterior wall 146
is provided on-site or prefabricated of a shape and size
corresponding to the foam block. After the concrete or other
material has been placed into the form but before the concrete has
completely cured, the protruding portion 126 of each first fastener
122 of the foam block 110 is pressed into the concrete or other
material until the front surface 114 of the foam block 110 abuts
the concrete or other material and the concrete or other material
flows into in provided cutouts on the front surface 114.
Thereafter, once the concrete or other material has fully cured
around the protruding portion 126 of each first fastener 122 and
within the cutouts, the exterior wall 146 will be rigidly mounted
to the front surface 114 of the foam block 110. As previously
described, if a head portion 130 is provided on the first fastener
122, additional rigidity can be provided between the exterior wall
146 and the foam block 110 due to the concrete curing around the
head portion 130.
[0061] Referring now to FIG. 9 and according to another embodiment
of the present invention, a lightweight wall panel 202 is provided
that includes a foam insulation block 210 with a plurality of studs
206 embedded therein. The foam block includes front and rear
surfaces 114, 118 and can comprise any number of materials
including, but not limited to, expanded polystyrene (EPS), expanded
polystyrene (XPS), polyurethane, etc. Each stud 206 is metal and
includes first and second portions 207, 208 that are respectively
situated near the front and rear surfaces 214, 218 of the foam
block. In the illustrated embodiment, each stud 206 comprises a
c-shaped channel. However, ordinary artisans will recognize that
other shapes such as z-shaped channels or other shaped channels can
be utilized depending on the required strength of the wall panel
202. While each stud 206 will generally extend from the top to the
bottom of the foam block 210, ordinary artisans will appreciate
that multiple studs can be utilized from the top to the bottom of
the foam block instead of a just a single stud 206. Further, the
studs 206 are preferably equally spaced along the length of the
foam block. However, it is recognized that other spacings between
studs may be required depending upon the desired design
requirements.
[0062] Further, at least one first fastener 222 is mounted to the
front surface 214 of the foam block 210 as well the first portion
207 of one of the studs 206. Each first fastener 222 includes a
head 226, an abutment portion 230, and a protruding portion 234.
The protruding portion 234 is inserted into front surface 214 and
aperture 209 of first portion 207 until the abutment portion 234
abuts the front surface 214. It is appreciated that the first
fastener 222 can be mounted to the front surface 214 and first
portion 207 via a threaded connection, an interference fit,
etc.
[0063] It is contemplated that fasteners of varied shapes can be
provided. For instance, at least one second fastener 238 is mounted
to the front surface 214 of the foam block 210 as well as the first
portion 207 of another one of the studs 206. Each second fastener
238 includes a head 242 and a protruding portion 246. The
protruding portion 246 is inserted into front surface 214 and
aperture 209 of first portion 207 such that the head 242 remains
separated from the front surface. As ordinary artisans will
recognize, the second fastener 238 can be mounted to the front
surface 214 and first portion 207 via a threaded connection, an
interference fit, etc. Also, at least one third fastener 250 is
mounted to the front surface 214 of the foam block 210 as well as
the first portion 207 of another one of the studs 206. Each third
fastener 250 includes a bridge portion 254 and a pair of legs 258.
The legs 258 are inserted into front surface 214 and apertures 209
of first portion 207 such that the bridge portion 254 remains
separated from the front surface.
[0064] With continued reference to FIG. 9, each wall panel 202 also
includes an exterior wall 270 constructed of, for instance, a
lightweight concrete material. However, ordinary artisans will
realize that other lightweight materials such as SHEETCRETE.TM. by
Oldcastle Precast, Inc. and glasscrete can also be utilized. Before
the material of the exterior wall 270 is fully cured, the head
portion 226, head portion 242 and bridge portion 254 of first,
second and third fasteners 222, 238, 250 respectively are pressed
into the exterior wall 270 until the front surface 214 of the foam
block 210 abuts the exterior wall 270. Also, the front surface 214
of the foam block is provided with a cutout 278, such as a
dovetail-shaped cutout, to interact with the concrete or other
material. It will be appreciated that more than one cutout can be
provided, and also that the cutout(s) can be provided any location
and in any direction along the front surface of the foam block.
Thereafter, once the concrete or other material has fully cured
around the head portion 226, head portion 242 and bridge portion
254, and within the cutout 278, the exterior wall 270 will be
rigidly mounted to the front surface 214 of the foam block 210.
[0065] Moreover, if desired, a second layer of concrete or other
material 274 can be provided on the foam block 210 opposite from
the exterior wall 270. To aid in the bonding strength of the foam
block to the second layer, bores 262, 266 can be formed through the
foam block and a portion of the studs. Thereafter, as the second
layer of concrete or other material 274 is placed on top of the
foam block, a portion of the concrete or other material will flow
into the bores 262, 266. As a result, once the concrete or other
material has fully cured, a more rigid connection between the foam
block and the second layer will exist. One of ordinary skill will
understand that additional bores can be formed through the foam
block and not through the studs for flowing of the uncured second
layer.
[0066] The method of manufacturing the wall panel of FIG. 9 is
similar to the method of manufacturing the wall panel of FIG. 7 and
8.
[0067] One of ordinary skill in the art will appreciate how many of
the aforementioned features are interchangeable with the various
embodiments described. For instance, any of the aforementioned
fasteners can be utilized in any of the embodiments to aid in
bonding of the foam block to the concrete or other material.
Further, only a single type of the aforementioned fasteners can be
used throughout the wall panel if desired. Additionally, dovetails,
bores or other cutouts can be formed in any locations and in any
directions in the foam block and the studs to allow for flowing of
the concrete or other material into the dovetails, bores or other
cutouts. This increases the bonding strength between the foam block
and the concrete or other material as well as enhances the crack
resistance of the wall panel. Moreover, second layers of concrete
or other material can be formed on the wall panels opposite from
the first exterior layer or concrete or other material depending
upon a user's specific design requirements.
[0068] 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.
* * * * *