U.S. patent application number 12/118691 was filed with the patent office on 2008-11-13 for low density concrete wall panel with reinforced insulation members.
This patent application is currently assigned to OLDCASTLE PRECAST, INC.. Invention is credited to Thuan Bui, Thomas G. Harmon, Harold G. Messenger.
Application Number | 20080276559 12/118691 |
Document ID | / |
Family ID | 39968271 |
Filed Date | 2008-11-13 |
United States Patent
Application |
20080276559 |
Kind Code |
A1 |
Messenger; Harold G. ; et
al. |
November 13, 2008 |
Low Density Concrete Wall Panel With Reinforced Insulation
Members
Abstract
An insulated wall panel is provided that employs a plurality of
spaced insulated members that define cavities within the body of
the wall panel. The insulation panels that form the cavities may be
constructed of a reinforced insulating material, such as expanded
polystyrene. The insulated wall panels may include a reinforcing
mesh, preferably fiberglass coated with PVC embedded within the
body of the EPS foam during fabrication. The strengthened EPS foam
blocks have the advantage of being lightweight and very durable,
thereby reducing handling damage, for example.
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.
Rehoboth
MA
|
Family ID: |
39968271 |
Appl. No.: |
12/118691 |
Filed: |
May 10, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60917454 |
May 11, 2007 |
|
|
|
Current U.S.
Class: |
52/506.01 ;
52/508; 52/745.19 |
Current CPC
Class: |
B29C 44/12 20130101;
B29C 44/1285 20130101; B28B 19/003 20130101; E04B 5/04 20130101;
E04C 2/2885 20130101; B28B 23/0068 20130101; E04B 5/043 20130101;
E04B 5/48 20130101 |
Class at
Publication: |
52/506.01 ;
52/745.19; 52/508 |
International
Class: |
E04B 2/00 20060101
E04B002/00 |
Claims
1. A reinforced foam shell adapted for use with a low density
manufactured concrete wall panel, comprising: a low density foam
core comprising an upper end, a lower end and lateral edges
positioned therebetween and having an exterior surface and an
interior surface to define a predetermined depth; a first and a
second lateral wall extending downwardly from said lateral edges
and extending substantially between said lower end and said upper
end to define a substantially hollow portion positioned within the
confines of the first wall and the second wall core; and a mesh
material positioned within the low density foam material to provide
enhanced strength to the low density core.
2. The reinforced foam shall of claim 1, further comprising a lip
extending around a perimeter edge of said low density foam core
proximate to said interior surface.
3. The reinforced foam shall of claim 2, wherein said lip includes
a least one rib with a cross-sectional profile adapted to support a
reinforcing rod.
4. The reinforced foam shell of claim 12, further comprising at
least one structural rib positioned between said lateral edges of
said foam core within said substantially hollow portion.
5. The reinforced foam shell of claim 4, wherein said at least one
structural rib has a cut-out portion adapted to receive a
utility;
6. The reinforced foam shell of claim 2, wherein the mesh material
comprises at lest one of a polypropylene, a carbon fiber, a
polyethylene, a fiberglass and metal material.
7. The reinforced foam shell of claim 1, further comprising at
least one spacer extending outwardly along said lateral edges,
wherein a defined space is formed between the lateral edges when
one reinforced foam core is positioned adjacent a second reinforced
foam core along the lateral edges.
8. The reinforced foam shell of claim 1, wherein said shell has an
open bottom.
9. The reinforced foam shell of claim 1, further comprising at
least one plurality of plastic nailers positioned proximate to said
upper end and said lower end.
10. The reinforced foam shell of claim 1, wherein said mesh
material extends between said upper end and said lower end.
11. A method of manufacturing a reinforced foam material having a
predetermined shape, comprising: providing a mold with a
predetermined shape; positioning a reinforcing material at a
predetermined location within said mold; injecting a heated foam
material into the mold; and bending said foam material to said
reinforcing material.
12. The method of claim 1, wherein the low density foam material is
comprised of an EPS material.
13. The method of claim 1, wherein said reinforcing material is
placed in tension within the mold.
14. The method of claim 1, wherein said reinforcing material is
comprised of at least one of a fiberglass, a polypropylene, a
polyvinyl chloride, and a carbon fiber material.
15. The method of claim 14, wherein said reinforcing material is a
fiberglass material coated with a polyvinyl chloride material.
16. An insulative wall panel comprising: a concrete exterior face
wall having an upper edge, a lower edge, and lateral edges
therebetween; a plurality of reinforced cavity formers
interconnected to said exterior face wall; and a plurality of ribs
extending from said concrete exterior face wall, wherein said
plurality of ribs are reinforced with a reinforcing rod and are
interconnected to said concrete exterior face wall with a carbon
fiber stirrup.
17. The insulative wall panel of claim 16, further comprising a
footer on said lower edge; and a bearing pad for engagement with a
building foundation interconnected adjacent to said lower edge of
said face wall.
18. The insulative wall panel of claim 16, further including a
carbon fiber stirrup interconnected to said reinforcing rod and
said concrete exterior face wall.
19. The insulative wall panel of claim 16, further comprising a
wood strip interconnected to at least one of said plurality of ribs
and said reinforced cavity formers, said wood strip being oriented
generally parallel to said plurality of ribs.
20. The insulative wall panel of claim 16, wherein said plurality
of reinforced cavity formers include a channel for receipt of a
utility conduit.
Description
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 60/917,454, filed May 11, 2007, the
entire disclosure of which is incorporated by reference herein.
[0002] This application is also related to U.S. Pat. Nos.
6,701,683, 6,729,090 and 6,898,908 and 7,100,336, the entire
disclosures of which are incorporated by reference herein.
[0003] This application is also related to pending U.S. patent
application Ser. Nos. 11/121,267, 11/096,705, 11/122,792 and
11/456,057, the entire disclosures of which are incorporated by
reference herein.
FIELD OF THE INVENTION
[0004] The present invention is generally related to low density
concrete wall panels that employ insulation members that are
internally reinforced.
BACKGROUND OF THE INVENTION
[0005] 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.
[0006] Concrete wall panels are often expansive. The large weight
per square foot ratio of prior art building panels has resulted in
significant expenses arising not only from the amount of materials
needed for fabrication, but also the cost of transporting and
erecting the wall panels. 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, substantial fabrication expenses
often arise from design, material, and labor costs associated with
providing and placing reinforcement materials within a building
panel. 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.
[0007] Furthermore, in many situations prefabricated concrete
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. This step requires careful planning and
design, thus increasing the inherent 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 are relatively labor-intensive and
expensive. 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, and which is cost effective during the
manufacturing process.
[0008] One prior art 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 ("Kleinschmidt"), which is incorporated
by reference in its entirety herein. Kleinschmidt provides a
building system that utilizes an insulative core bounded by
interior and exterior layers of concrete that are held together
with a metallic wire mesh positioned on both sides of the
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 by Kleinschmidt does not provide the necessary strength
and stiffness 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 Kleinschmidt panels are more
susceptible to failure when exposed to stresses during
transportation, assembly or subsequent use.
[0009] Further, previously known prefabricated building panels that
employ only concrete, insulative foam materials and wire mesh have
also not been found to have sufficient tensile and compressive
strength. In addition, the insulating members used in the prior art
are often fragile and are thus prone to damage during
transportation and integration into the concrete wall. More
specifically, insulating members are often fabricated of molten
polystyrene that is either introduced into a mold to form expanded
polystyrene (EPS) foam or extruded to form extruded polystyrene
(XPS) foam that is then cut to the required size. EPS is the
insulative foam most often found in low-density concrete wall
panels, is very brittle and apt to break and is not designed to
resist bending, torsional, tension, or compressive loading. EPS is
often damaged during handling, which may not be evident until
concrete is introduced to a wall form containing the insulation
members. For example, the introduction of heavy, wet concrete will
load the already placed insulation members, thereby possibly
causing a blow-out wherein concrete will infiltrate into a void
provided by the insulating members, which will be more apparent
upon review of the following. Weakened insulation members may also
compromise the structural integrity of the finished concrete wall
panel. It is thus desirable to provide a concrete wall panel within
insulation members that are stronger and more durable and are more
apt to support the weight of concrete during formation.
[0010] Thus, it is a long felt need in the field of concrete wall
panel construction to provide an insulated concrete wall floor or
structural (hereinafter "wall panel") panel that includes
insulation members that are strong and resistant to damage. The
following disclosure describes an improved insulation member for
use in low-density concrete wall panels that is reinforced such
that it resists damage due to handling, is capable of supporting
the weight of concrete during fabrication, and enhances the
strength of the finished wall panel.
SUMMARY OF THE INVENTION
[0011] It is one aspect of the present invention to provide an
insulating member for incorporation into a preformed low-density
concrete panel that forms a void in the finished wall. More
specifically, one embodiment of the present invention employs a
plurality of cavity forming insulation panels that provide a cavity
within the finished wall panel. Thus a lighter wall panel is formed
that is easier to transport due to its decreased weight. The
cavities in the wall panel also provide locations for the
incorporation of conduit for utilities such as electrical, fluid,
air, etc. The dead air within the cavities and the insulative
properties of the insulation members increase the insulation value
of the wall to a level greater than that of a wall made entirely of
concrete. For example, one embodiment of the present invention
possesses an R value of about 5, which is upgradable to 19 by the
addition of insulation into the cavity. The dead air with the
cavities also attenuates noise.
[0012] It is a related aspect of the present invention to provide a
reinforced insulation member. More specifically, embodiments of the
present invention employ a reinforced insulated cavity former. That
is, instead of using large EPS blocks that are often formed in
8'.times.8'.times.30' sections and cutting them into sheets of
4'.times.8'.times.2'' for use in the wall panel, EPS in one
embodiment, is molded with a reinforcing textile mesh made
preferably of fiberglass that is preferably coated with polyvinyl
chloride (PVC). The use of PVC coating is advantageous since it
reacts with the molten EPS during formation to create an enhanced
bond between the reinforcing mesh and the EPS insulation. The
reinforcing mesh may be in the form of strips or sheet, which will
be apparent upon review of the detailed description below. In
operation, reinforcing mesh is placed in the mold at a
predetermined location to yield an insulation member that improves
the strength and rigidity and provides exerted by the concrete
during formation. Another significant benefit is the reduced size
of insulative foam required to achieve the same strength as larger
foam panels, thus significantly decreasing cost.
[0013] As briefly mentioned above, one embodiment of the present
invention possesses enhanced bonding characteristics between the
PVC coated reinforcing mesh or "scrim" and the EPS foam. That is,
the PVC coating and raw polystyrene have approximately the same
melting point. Thus, during molding, the molten EPS will tend to
melt the PVC coating, thereby facilitating a chemical bond between
the polystyrene and the PVC. It is important to note, that the heat
from the EPS does not destroy the PVC bonds (often known as
"beads") that interconnect the individual fiber strands that make
up the reinforcing mesh. More specifically, often the mesh
reinforcement is created not by weaving, but by placing glass
fibers in one direction onto glass fiber oriented in another
direction and by dipping this fiber grid into a hot liquid PVC
bath. The beads that are present at firm crossings hold the
individual fibers together.
[0014] As briefly mentioned above, one advantage of employing
reinforced insulated members is a decrease in cost. More
specifically, costs related to handling, shipping, cutting and
waste disposal of large foam blocks is often an obstacle of the
construction of insulated concrete wall panels. Embodiments of the
present invention reduce the amount of insulated foam by ten times
the amount normally used. That is, due to their increased strength,
an insulating member with a decreased cross-sectional area may be
employed, which reduces the amount of insulation needed. Due to the
shape of the insulated cavity formers, a number of cavity forms
that can be place in shipping containers is also increased which
reduces shipping costs. In addition, since the cavity formers are
reinforced, less damage occurs during handling. Finally, the
enhanced strength of the insulation panels increase the aggregate
strength of the wall panel, which should be apparent to one skilled
in the art. Other advantages of the invention will also be apparent
to one skilled in the art upon review of the following
disclosure.
[0015] Thus it is one aspect of the present invention to provide a
low density manufactured concrete wall panel, comprising: a low
density foam core comprising an upper end, a lower end and lateral
edges positioned therebetween and having an exterior surface and an
interior surface to define a predetermined depth; a first and a
second lateral wall extending downwardly from said lateral edges
and extending substantially between said lower end and said upper
end to define a substantially hollow portion positioned within the
confines of the first wall and the second wall core; and a mesh
material positioned within the lower density foam material to
provide enhanced strength to the low density core.
[0016] It is also an aspect of the present invention to provide a
method of manufacturing a low density wall panel with a reinforced
foam material having a predetermined shape, comprising: providing a
mold with a predetermined shape; positioning a reinforcing material
at a predetermined location within said mold; injecting a foam
material into the mold; and heating the foam material, wherein said
mesh material and said foam bond.
[0017] 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
[0018] 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
embodiments.
[0019] FIG. 1 is a top perspective view of an insulating cavity
former shown in FIG. 1;
[0020] FIG. 2 is a bottom perspective view of the insulating cavity
former shown in FIG. 1;
[0021] FIG. 3 is a top perspective of an insulating cavity former
that employs a plurality of homogeneous spacers;
[0022] FIG. 4 is a bottom perspective of the insulating cavity
former shown in FIG. 3;
[0023] FIG. 5 is a front elevation view of a mold used to form
insulating cavity formers of one embodiment of the present
invention;
[0024] FIG. 6 is a front elevation view of the FIG. 5;
[0025] FIG. 7 is a front elevation view of a form used to fabricate
a low density wall panel of one embodiment of the present
invention;
[0026] FIG. 8 is a front elevation view of the mold shown in FIG. 7
with a plurality of cavity formers positioned therein;
[0027] FIG. 9 is a front elevation view of a complete concrete wall
panel positioned within the mold;
[0028] FIG. 10 is a front elevation view of a plurality of
insulating cavity formers stacked in a nesting configuration for
transport;
[0029] FIG. 11 is a perspective view of a cart with a plurality of
insulating cavity formers positioned over a concrete form;
[0030] FIG. 12 is a perspective view of a single insulating cavity
former of another embodiment of the present invention;
[0031] FIG. 13 is a bottom perspective view of the insulating
cavity former shown in FIG. 12;
[0032] FIG. 14 is a front elevation view of the insulating cavity
former as shown in FIG. 12;
[0033] FIG. 15 is a front elevation view of the insulating cavity
former shown in FIG. 12;
[0034] FIG. 16 is a right elevation view of a mold used to
fabricate the insulating cavity former shown in FIG. 12;
[0035] FIG. 17 is a right elevation view of a mold shown in FIG.
16;
[0036] FIG. 18 is a front elevation view of a form used to
fabricate a low density wall panel;
[0037] FIG. 19 is a front elevation view of a concrete mold having
a plurality of insulative cavity formers positioned therein;
[0038] FIG. 20 is a front elevation view of a complete concrete
wall panel;
[0039] FIG. 21 is a front elevation view of a plurality of nested
cavity formers;
[0040] FIG. 22 is a perspective view of a cart positioned over a
form for dispensing a plurality of cavity formers;
[0041] FIG. 23 is a right elevation view of an insulated cavity
former of another embodiment of the present invention;
[0042] FIG. 24 is a detailed view of FIG. 23;
[0043] FIG. 25 is a top plan view of the insulating cavity former
shown in FIG. 23;
[0044] FIG. 26 is a bottom plan view of the insulating cavity
former shown in FIG. 23;
[0045] FIG. 27 is a perspective view of an insulating cavity former
of another embodiment of the present invention;
[0046] FIG. 28 is a bottom perspective view of the insulating
cavity former shown in FIG. 27;
[0047] FIG. 29 is a detailed view of the insulating cavity former
shown in FIG. 27;
[0048] FIG. 30 is a left elevation view of the insulating cavity
former shown in FIG. 27;
[0049] FIG. 31 is a left elevation view of a plurality of engaged
insulating cavity formers;
[0050] FIG. 32 is a top perspective view of a plurality of engaged
insulating cavity formers; and
[0051] FIG. 33 is a bottom perspective view of a plurality of
engaged insulating cavity formers;
[0052] FIG. 34 is a top perspective view of an insulating cavity
former of another embodiment of the present invention;
[0053] FIG. 35 is a top plan view of the insulating cavity former
shown in FIG. 34;
[0054] FIG. 36 is a cross-sectional left elevation view of the
embodiment shown in FIG. 34;
[0055] FIG. 37 is a front elevation view of the embodiment shown in
FIG. 34;
[0056] FIG. 38 is a detailed view of FIG. 37;
[0057] FIG. 39 is a detailed view of FIG. 37;
[0058] FIG. 40 is a top perspective view of a plurality of engaged
insulating cavity formers; and
[0059] FIG. 41 is a left elevation view of the plurality of engaged
cavity formers shown in FIG. 40;
[0060] FIG. 42 is a top perspective view of an insulating cavity
former of another embodiment of the present invention;
[0061] FIG. 43 is a top plan view of the insulating cavity former
shown in FIG. 42;
[0062] FIG. 44 is a front elevation view of the insulating cavity
former shown in FIG. 42;
[0063] FIG. 45 is a detail view of FIG. 44;
[0064] FIG. 46 is a front elevation view of the insulating cavity
former shown in FIG. 42;
[0065] FIG. 47 is a detail view of FIG. 46;
[0066] FIG. 47A is a detail view of an alternate embodiment of FIG.
46;
[0067] FIG. 47B is a partial top plan view of FIG. 47A;
[0068] FIG. 48 is a detail view of FIG. 46;
[0069] FIG. 49 is a cross sectional view of FIG. 46;
[0070] FIG. 50 is a top perspective view of a plurality of engaged
insulating cavity formers;
[0071] FIG. 51 is a left elevation view of the plurality of engaged
insulating cavity formers shown in FIG. 50;
[0072] FIG. 52 is a top perspective view of an insulating cavity
former of another embodiment of the present invention;
[0073] FIG. 53 is a top plan view of the insulating cavity former
shown in FIG. 52;
[0074] FIG. 54 is a front elevation view of the insulating cavity
former shown in FIG. 52;
[0075] FIG. 55 is a detailed view of FIG. 54;
[0076] FIG. 56 is a front elevation view of the insulating cavity
former shown in FIG. 52;
[0077] FIG. 57 is a detailed view of FIG. 56;
[0078] FIG. 58 is a detailed view of FIG. 56;
[0079] FIG. 59 is a cross sectional view of FIG. 54;
[0080] FIG. 60 is a top perspective view of a plurality of engaged
insulating cavity formers;
[0081] FIG. 61 is a left elevation view of the plurality of
insulating cavity formers shown in FIG. 60;
[0082] FIG. 62 is a perspective view of a shear nail employed by
embodiments of the present invention;
[0083] FIG. 63 is a top perspective view of an insulating cavity
former of another embodiment of the present invention;
[0084] FIG. 64 is a top plan view of the insulating cavity former
shown in FIG. 63;
[0085] FIG. 65 is a front elevation view of the insulating cavity
former shown in FIG. 63;
[0086] FIG. 66 is a detail view of FIG. 65;
[0087] FIG. 67 is a front elevation view of the insulating cavity
former shown in FIG. 63;
[0088] FIG. 68 is a detail view of FIG. 67;
[0089] FIG. 69 is a detail view of FIG. 67;
[0090] FIG. 70 is a cross-sectional view of FIG. 65;
[0091] FIG. 71 is a top perspective view of a plurality of engaged
insulating cavity formers;
[0092] FIG. 72 is a left elevation view of the plurality of engaged
insulating cavity formers shown in FIG. 71;
[0093] FIG. 73 is a top perspective view of an insulating cavity
former of another embodiment of the present invention;
[0094] FIG. 74 is a top plan view of the insulating cavity former
shown in FIG. 73;
[0095] FIG. 75 is a front elevation view of the insulating cavity
former shown in FIG. 73;
[0096] FIG. 76 is a detailed view of FIG. 75;
[0097] FIG. 77 is a front elevation view of the insulating cavity
former shown in FIG. 73;
[0098] FIG. 78 is a detailed view of FIG. 77;
[0099] FIG. 79 is a detailed view of FIG. 77;
[0100] FIG. 80 is a cross sectional view of FIG. 75;
[0101] FIG. 81 is a top perspective view of a plurality of engaged
insulating cavity formers;
[0102] FIG. 82 is a left elevation view of the plurality of
insulating cavity formers shown in FIG. 81; and
[0103] FIG. 83 is a perspective view of a tapered pin employed by
embodiments of the present invention;
[0104] To assist in the understanding of the present invention the
following list of components and associated numbering found in the
drawings is provided herein:
TABLE-US-00001 # Component 2 Wall panel 6 Cavity former 10 Cavity
14 Insulation 18 Reinforcing mesh 22 Mold 26 Planar surface 30 Leg
34 Spacer 38 Rib 42 Aperture 50 Roll 54 Upper mold 58 Lower mold 62
Stud 66 Form 70 Side form 74 Inner wall 78 Protrusion 82 Concrete
86 Reinforcement 90 Cart 94 Ramp 98 Void 102 Upper surface 106
Lower surface 110 End wall 114 Lip 118 Seat 122 Port 126 Recess 130
Groove 134 Gusset 138 Clip 142 Rebar bridge 146 Upper surface 148
Groove 150 Channel 152 Fibrous concrete 156 Slot 160 Shear nail 164
Arm 168 Locator 172 Pin 179 Film
[0105] 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
[0106] Referring now to FIGS. 1-83, a low density wall panel 2 that
generally employs a plurality of insulating cavity formers 6
(hereinafter "cavity former") is shown. Although the term "wall
panel" is used throughout this specification, one skilled in the
art will appreciate that cavity formers 6 as described herein may
be incorporated into foundation wall panels, floors, ceilings, and
any other building component of a structure. Embodiments of the
present invention employ reinforced cavity formers 6 to create
cavities 10 within the preformed concrete wall 2. The cavities 10
in combination with the insulation 14 that is used to form the
cavity formers, decreases heat transfer through the wall panel 2
and greatly reduces the weight of the wall panel 2 such that the
wall panel 2 is cost effective to transport and erect. Preferably,
cavity formers 6 include a reinforcing mesh 18 such as fiberglass.
During fabrication, fiberglass mesh 18 is coated with polyvinyl
chloride (PVC), and is positioned within a mold 22. Thereafter,
molten expanded polystyrene (EPS) is added to the mold 22 to form a
cavity former 2 of a predetermined shape. In one embodiment, the
heat of the molten EPS is approximately the same as the melting
point of the PVC coating of the mesh 18. Thus, during fabrication,
a tight mechanical and/or chemical bond is formed between the EPS
foam and the PVC coated mesh 18, thereby providing a strengthened
cavity former.
[0107] Referring now to FIGS. 1 and 2, a cavity former 6 of one
embodiment of the present invention is provided that is designed to
form a plurality of cavities 10 with a finished wall. The cavity
former 6 is generally comprised of a planar surface 26 with two
legs 30 extending therefrom that define the cavity 10. During
fabrication, reinforcement 18 is added to the EPS foam to increase
the strength and stiffness of the finished cavity former 6.
Although a three piece cavity former 6 is shown herein, one skilled
in the art will appreciate that cavity formers 6 may provide a
single cavity 10 or a plurality thereof depending on the specific
design. The reinforcement 18 may be added to the cavity former 6
via a plurality of strips or a sheet, which will be explained in
further detail below. The legs 30 of the cavity former are
separated by spacers 34 that allow concrete to be placed between
adjacent cavities 10 to form a rib.
[0108] Referring now to FIGS. 3 and 4, another embodiment of a
cavity former 6 is shown that includes spacers 34 with a plurality
of apertures 42 therethrough that provide handles to aid in
transportation of the cavity formers 6. The apertures 42 also have
an added benefit of decreasing the weight of the cavity former 6
which also facilitates transportation. In addition, the apertures
42 allow concrete to traverse from a point adjacent to the planar
surface 26 of the cavity formers 6 to a point under the spacer 34,
thereby allowing for the formation of a continuous concrete rib
through the thickness of the concrete wall, which will be apparent
upon review of the remaining figures.
[0109] Referring now to FIGS. 5 and 6, the mold 22 used to create
cavity formers in one embodiment of the present invention is
provided. In operation, a roll 50 of reinforcing mesh 18, which is
preferably coated with PVC, is positioned between an upper mold 54
and a lower mold 58. The roll 50 may be comprised of a sheet of
reinforcing mesh 18 that extends the entire width of the mold 22 or
a plurality of discreet mesh strips that are positioned at varying
locations within the mold 22. One skilled in the art will
appreciate that the reinforcing mesh 18 possesses any orientation
of fibers, such as random, 0 degrees and 90 degrees, 45 and 45
degrees etc. to provide the desired composite material properties.
Further, it is contemplated that more than one sheet of
reinforcement may be employed. More specifically, it is envisioned
that multiple spaced layers of reinforcement be employed, which may
be oriented relative to each other. The lower mold 58 also includes
locations for the positioning of studs 62 that are to be integrated
into the legs of the cavity formers. The studs 62 are used to help
position and secure the cavity formers when they are introduced to
concrete.
[0110] FIG. 6, which is a right perspective of FIG. 5, illustrates
how the reinforcing mesh 18 can be a continuous sheet that is
positioned between the upper mold 54 and the lower mold 58.
Preferably, the reinforcing mesh is placed under tension during the
fabrication process. This figure also distinctly shows how the mold
22 is adapted to form the planar surface at the top of the cavity
former and the legs that emanate therefrom. The studs 62 are also
succinctly shown positioned in the area that will define the ends
of the legs of the cavity former 6.
[0111] Referring now to FIGS. 7-9, the fabrication of a wall panel
2 is shown and described herein. In operation, a form 66 is
employed that includes side forms 70 extending therefrom. The side
form 70 also includes an inner wall 74 that may include a
protrusion 78. Initially, a layer of concrete 82 is added to the
form. One skilled in the art will appreciate that this initial
layer may be designed to comprise an inner surface of a finished
wall wherein the material placed is adapted to receive fasteners,
such as Sheet-Crete as described in U.S. Patent Application Ser.
No. 60/741,487, which is incorporated by reference herein. That is,
a layer comprised of a mixture that includes fly ash, PVA fibers,
pearlite and blended sands, which is fire resistant, substantially
impermeable and that possesses high flexural strength, may be used.
Reinforcement 86 such as prestressed strands may also be located
within the first layer of concrete. Some embodiments of the present
invention may employ rebar within this first layer of concrete 82
or prestressed composite bands to increase the stiffness and
strength of the finished wall panel.
[0112] With specific reference to FIG. 8, while the initial layer
of concrete 82 is still wet, i.e., not cured, the cavity formers 6
are integrated thereto. More specifically, the cavity formers 6,
which may or may not include studs 62, are placed atop the layer of
concrete 82 that was initially placed in the form 66. If the cavity
formers 6 are included with a plurality of studs 62, the studs 62
would interface with the wet concrete 82, thereby securely
fastening the cavity formers 6 thereto. This figure also
illustrates how the spacers 34 are used to separate individual
cavity formers 6. The spacers 34 may include an interlocking
mechanism that helps maintain their orientation in the form when
concrete is added thereto. In addition, FIG. 8 illustrates that the
protrusion 78 of the side form inner wall 78 is adapted to engage
spacers 34 that extend from a cavity former 6 to position the
cavity formers 6 within the form 66.
[0113] Referring now specifically to FIG. 9, once the cavity
formers 6 are placed within the form 66, a second layer of concrete
82 is added to the form 66. Here, it is easily seen how the
apertures in the spacers 34 allow for concrete 82 to pass beneath
the spacer 34, thereby forming a continuous rib 38 through the
thickness of the finished wall panel 2. It is also shown that
during formation, substantially no concrete 82 enters the cavity 10
provided by a cavity former 6, thus reducing the density of the
wall panel 2. In addition, since the cavity formers 6 are
reinforced, they resist deflection when the second layer of
concrete 82 is added to the form 66. The cavity formers 6 of
various embodiments of the present invention include a roughened
outer surface to enhance the bond between the concrete 82 and the
EPS foam insulation 14. As one skilled in the art will appreciate,
an enhanced bond increases the sheer transfer performance of the
wall panel 2.
[0114] Referring now to FIG. 10, a method of transporting a
plurality of cavity formers 6 is shown. In order to facilitate
transportation of a plurality of cavity formers 6 from the location
where they are fabricated to the location where they will be
integrated into a wall form, the cavity formers 6 of one embodiment
of the present invention are designed to be nested together to
decrease their shipping envelope, thereby potentially decreasing
shipping costs.
[0115] Referring now to FIG. 11, integration of a plurality of
cavity formers 6 onto a manufacturing form 66 is provided. In
operation, once the first layer of concrete 82 is laid in the form,
a cart 90 holding a plurality of stacked cavity formers 6 is
transitioned over the form 66. A ramp 94 may be provided that aids
in positioning the cavity formers 6 on the concrete 82. The ramp 94
may be positioned such that it does not touch the first layer of
concrete 82. This system allows for the plurality of cavity formers
6 to be quickly laid on the wet concrete 82 prior to the addition
of the second layer of concrete to form the wall panel. After the
concrete is poured and sufficiently cured, the forms may be removed
to yield a wall panel, which may then be cut to the preferred
size.
[0116] Referring now to FIGS. 12-15, another embodiment of the
cavity former 6 is provided herein. Here, the cavity former 6 that
defines a single cavity 10 is provided that includes discreet
spacers 34 positioned on the legs 30 thereof. The spacers 34 are
adapted to engage spacers of an adjacent cavity former to provide
the requisite spacing between adjacent cavity formers 6 so that
concrete can flow between adjacent cavity formers to form ribs 38
through the thickness of the concrete wall. With specific reference
to FIG. 14, the cavity formers 6 comprise planar surfaces 26 with
legs 30 that extend therefrom. The legs 30 may also include plastic
studs 62 for interconnection with the wet concrete in the form, as
described above. The cavity former 6 also includes reinforcing mesh
18 within the thickness of the planar surface.
[0117] Referring now to FIGS. 16 and 17, the mold 22 for forming
the embodiments shown in FIGS. 12-15 is shown. This mold 22 is very
similar to that described above, wherein a roll 50 is used to
dispense a sheet of reinforcing mesh 18 between an upper mold 54
and a lower mold 58. The lower mold 58 in this embodiment of the
present invention includes voids 98 that define the spacers after
molding completed. Once the mold halves are closed, the reinforcing
mesh 18 is positioned approximately between the upper surface 102
of the lower mold 58 and the lower surface 106 of the upper mold
54. Thereafter, molten EPS is added to the mold 22, which heats the
PVC coating of the reinforcing mesh 18, thereby enhancing bonding
therebetween. As alluded to above, the surfaces of the mold 22 may
be roughened such that the finished cavity former is adapted to
bond securely with the concrete to increase the sheer performance
of the finished wall panel
[0118] Referring now to FIGS. 18-20, as descried above, a plurality
of cavity formers 6 are added to a form 66 that included a layer of
reinforced concrete 82. Thereafter, a second layer of concrete 82
is added to the form 66, which, in light of the spacers 34, is able
to occupy the space between adjacent legs 30 of adjacent cavity
formers 6 to form ribs 38 that extend through the thickness of the
wall panel 2. The cavity formers 6 are stiffened in this embodiment
of the present invention to resist the weight of the second layer
of concrete 82, thereby providing uniform cavities 10 within the
wall panel 2.
[0119] Referring now to FIG. 21, this embodiment of the present
invention is also adapted to be stacked in a nested fashion,
thereby decreasing the shipping envelope of a plurality of cavity
formers 6.
[0120] Referring now to FIG. 22, a cart 90 with a ramp 94 is shown
that supports a plurality of cavity formers 6. The cavity formers 6
are placed on a form 66 that contains a first layer of concrete 82.
After a wall panel is formed, it may be cut to size depending on
the building requirements.
[0121] Referring now to FIGS. 23-33, yet another embodiment of a
cavity former 6 is provided. More specifically, this embodiment of
a cavity former 6 is very similar to those described above that
include a planar surface 26 with legs 30 extending therefrom.
However, this embodiment of a cavity former 6 includes end walls
110 that help prevent concrete from infiltrating the cavity 10
provided by the cavity former 6. This embodiment of the present
invention also includes a lip 114 that extends from the legs 30 end
walls 110 that provides a location for a seat 118 for the receipt
of reinforcing members, such as rebar that will be situated within
the ribs, for example, of the finished wall panel. The lip 114 also
provides a spacing function such that the lip of adjacent cavity
formers 6 touch, thereby setting the width of the rib that will be
formed in the wall. The lip 114 that spans at least a portion of
the leg 30 of the cavity former 6 may also be included with a
plurality of rebar seats 118 for securing the reinforcing bar. A
plurality of ports 122 may be provided within the legs 30 that are
generally plugged. Further, the cavity former 6 may include a
groove 148, which may have a plurality of seats 118, for receipt of
a reinforcing members 86 to reduce shrinkage stress. In operation,
prior to the introduction of concrete to the form, the plugs may be
removed from the ports 122 to allow for the incorporation of a
conduit or utility line. After the concrete is placed to the form
and the finished wall panel is fabricated, the conduit would then
be firmly positioned within the thickness of the wall and would be
able to receive power, water, or other type of utility cables or
lines.
[0122] Referring now specifically to FIGS. 31-33, the
interconnection of two cavity formers 6 of the type shown in FIGS.
27-30 is shown. More specifically, the lips 114 adjacent the cavity
formers 6 are joined, thereby aligning their respective seats 118.
Since these embodiments of the present invention employ seats with
90 degree grooves 130 to receive rebar or reinforcing materials,
the placement of an adjacent seat define a 180.degree. groove 130
that can adequately support a reinforcing member. These figures
also show that the ports 122 of adjacent cavity formers 6 are
generally aligned such that removal of their plugs will provide
space for a continuous conduit through the concrete, cavity former
legs 30 and ribs 80 of the finished wall panel. As succinctly shown
in FIG. 32, the seats 118 positioned near the end wall 110 of each
cavity former 6 are uniquely positioned to receive and locate a
reinforcing bar that will be positioned horizontally along the wall
panel after fabrication. It is envisioned that such reinforcing
members may be added to the top and bottom of the wall panel and
may be tensioned during concrete placement to provide a
prestressed, strengthened low density wall panel. It is also
contemplated that the cavity formers 6 be reinforced, as described
above, to resist the weight of the concrete when it is introduced
into the form. One skilled in the art will also appreciate that
during forming, a layer of malleable material, such as Sheet-Crete
may be added prior to the placement of a series of cavity formers
6, thereby providing an insulated interior wall panel.
[0123] Referring now to FIGS. 34-41, yet another embodiment of the
insulating cavity former 6 is shown. More specifically, the cavity
former 6 shown includes legs 30 and a planar surface 26 wherein the
planar surface 26 extends beyond the legs 30 to form a lip 114
about the peripheral edge of the cavity former 6. A plurality of
seats 118 are provided on the lip 114 that may include an arcuate
profile for the receipt of reinforcing members 86, as described
above. The legs 30 also include a plurality of ports 122, which may
be plugged, to allow for the integration of conduit. The legs may
be supported by the addition of a plurality of gussets 134 that are
situated along the length of the cavity former 6. In addition,
embodiments of the present invention employ a plurality of clips
136, preferably made of carbon fiber, positioned within the lip 14
for interconnection to concrete 82. The clips 136 are generally
comprised of carbon fiber, but may also be comprised of fiberglass,
metal, plastic materials and other materials known in the
construction trade.
[0124] Referring now specifically to FIGS. 36-41, the formation of
a wall panel using this embodiment of the present invention is
provided. As described above, the cavity former 6 may include
reinforcing mesh 18 to increase structural integrity. In addition,
a plurality of clips 138 may be included along the lip 114 of the
cavity former 6. The clips 136 are integrated into the concrete
wall mold during production and preferably extend below the cavity
former 6 and above the cavity former 6. In operation, a first level
of concrete 82 is placed in the form. Thereafter, a plurality of
cavity formers 6 are placed in the form wherein the lips 114 of
adjacent cavity formers 6 contact each other to define a rib space
38 (see FIG. 41). When the cavity formers 6 are placed on top of
the wet concrete 82, the clips 138, positioned below the cavity
formers are inserted into the concrete 82, thereby securing the
cavity former 6 to the first layer of concrete 82. Next, a
plurality of reinforcing members 86 are added to the form. With
specific reference to FIG. 40, reinforcing members 86 are placed on
the seats 118 provided above and below the cavity formers 6. In
addition, a rebar bridge 142 may be added to the reinforcing
material 86 to facilitate placement of the reinforcing member 86
between adjacent cavity formers 6. That is, cavity formers 6 of one
embodiment of the present invention provide a gap of a specific
width to define a rib 38 in the finished concrete wall. The rebar
bridge 142 having slightly greater width than the gap is
interconnected to the reinforcing member 86 and the assembly is
placed within the gap. Since the rebar bridge 142 has a greater
dimension than the gap, the reinforcing member will be situated in
a predetermined location to provide ideal strength characteristics.
After the reinforcing members 86 are situated within the form,
another layer of concrete is placed within the form.
[0125] Placement of concrete 82 between adjacent cavity formers 6
the concrete will create ribs in the wall panel. As mentioned
above, the clips 138 include a portion that extends above the lip
114, which will be covered bythe concrete as it is introduced
between adjacent cavity formers 6. Thus structural integrity is
provided between the formed rib 38 and the portion of the wall
panel initially placed.
[0126] In one embodiment of the present invention, during
fabrication the concrete 86 is placed adjacent to an upper surface
146 of the cavity former 6. Thereafter, the wall panel is allowed
to cure and transported to the work site. After the wall panel is
erected, an interior hollow wall is provided that consists of the
inner surface of the cavity former 6, which allows integration of
various utilities within the length and width of the wall panel.
After all of the required utilities are included into the wall
panel, additional insulation, either expanded foam, fiberglass,
etc. maybe added to the cavity provided by the cavity former 6.
Finally, a sheet of drywall or other internal building material,
may be interconnected to the upper surface 146 of the wall panel to
complete the wall panel assembly.
[0127] Referring now to FIGS. 42-51, yet another embodiment of an
insulating cavity former 6 is provided that is very similar to that
provided in FIGS. 36-41. However, in this embodiment, the lip 114
extends only from the end walls 110 and one leg 30 of the cavity
former 6. As succinctly shown in FIG. 49 a channel 150 is provided
along the length of the cavity former 6 such that when a plurality
of cavity formers 6 are engaged, the end of a lip 114 would fit
into the channel 150 provided. This configuration has the advantage
of interlocking adjacent cavity formers 6 together when they are
placed upon an initial layer of concrete, for example. This
embodiment of the present invention also includes at least one
groove 148 located along the width of the cavity former 6. The
groove(s) 148 is similar to the seats 118 provided along the lip
114 of the cavity former 6 such that the groove 148 provides a
location for the integration of a reinforcing member 86 during
fabrication (See FIG. 45).
[0128] With specific reference to FIGS. 44-47, fabrication of a
concrete wall initially proceeds with placing a layer of concrete
82, or in some instances, nailable fibrous concrete 152 into a
form. Thereafter, the cavity formers 6 are placed a top the fibrous
concrete 150 such that the clips 138 provided within the lip 114
embed themselves within the fibrous concrete layer 152. The clip
138 may be associated with a slot 156 that reduces the distance
between the concrete 82 or fibrous concrete initially placed in the
form, thereby enhancing load transmission through the thickness of
the wall panel. In addition, a reinforcing member 86 may be
integrated into the fibrous concrete layer 152 and situated within
the groove 148 provided by the cavity former 6. One skilled in the
art will appreciate that when a plurality of cavity formers 6 are
situated side-to-side within a form, the reinforcing member 86
would tie them together. After the cavity formers 6 are placed
within the form, a plurality of reinforcing members 86 are situated
on the seats 118 provided which are succinctly shown in FIG. 50.
Thereafter, concrete 82 introduced to the form above, below and in
between the cavity formers 6. The concrete 82 between adjacent
cavity formers provides ribs within the finished wall panel. As
above, the clips 138 then structurally interconnect the concrete 86
and the fibrous concrete 152 through the thickness of the wall
panel.
[0129] Referring now to FIGS. 52-62, yet another embodiment of a
cavity former 6 similar to that described above having a
non-continuous lip 114 is provided. The major difference between
this embodiment and that of FIGS. 42-48 is that a plurality of
shear nails 160 are employed as opposed to clips. In addition, the
shear nails 160 rest in a plurality of slots 156 integrated into
the lip 114. The slots 156 allow concrete 82 that is placed above,
below and between adjacent cavity formers 6 to contact the concrete
82 originally placed with the form to form a continuous load path
through the thickness of the wall panel. The shear nails 160, which
are preferably constructed of polypropylene, carbon fiber, metal or
fiberglass, include a plurality of arms 164 that pierce the initial
layer of concrete or fibrous concrete 152, placed in the form and
the concrete 82 placed above the lips 114 of the cavity former 6
that define the top, bottom and the ribs of the finished wall
panel. Preferably, a locator 168 is provided that stabilizes and
maintains the shear nail 160 within the slot 156.
[0130] Referring now to FIGS. 63-83, still yet another embodiment
of the present invention is shown that is very similar to those
previously described that employs a mechanism for tying the cavity
former 6 into the initial layer of concrete 82 or fibrous concrete
152 placed within the form. Here, the cavity former 6 includes a
lip 114 that at least is positioned about three sides of the cavity
former 6. Instead of employing a clip or a shear nail, this
embodiment of the present invention employs a pin 172. Although the
pin 172 is preferably constructed of a polypropylene material, one
skilled in the art will appreciate that many other materials may be
employed without departing from the scope of the invention. The pin
172 is adapted to situate the cavity former 6 on the initially
placed material in the form and provides the mechanism that binds
the cavity former 6 onto the initially placed material. A channel
150 may also be included that provides interlocking relationship
between a cavity former 6 and the lip 114 of an adjacently placed
cavity former 6. Creation of a wall panel is similar to that
described above wherein the pins 172 of the cavity formers 6 are
then placed within the still wet first layer of concrete 82 or
fibrous concrete 152. Thereafter, concrete 82 is introduced to the
form and is allowed to fill the voids between adjacent cavity
formers 6 and above and below the cavity formers 6. Concrete is
also allowed to fill the voids defined by the slots 156 to create a
continuous structural load path between the initially placed
fibrous concrete 152 and the subsequently placed concrete 82. In
order to prevent concrete 82 from entering the void provided by the
cavity former 6, a film 176, preferably of biaxially-oriented
polyethylene terephthalate (boPET) polyester film, i.e. Mylar.RTM.,
may be interconnected to the upper surface of the cavity former
6.
[0131] Referring now again to FIGS. 1-83, the cavity formers 6 of
embodiments of the present invention are made of an insulative
material, preferably expanded polystyrene foam (EPS). One skilled
in the art will appreciate that other insulated materials, such as
extruded polystyrene foam (XPS) may be employed as well. In
operation, EPS pellets are taken from a hopper, heated and
introduced into the form 66 that contains the reinforcing mesh 18.
In one embodiment of the present invention, the EPS is shaped by
pumping warm prepped polystyrene beads into a closed cavity heated
mold then chilled to cure the polystyrene beads into a
predetermined shape. The mold may impart a surface texture onto the
cavity former 6. For example, small irregular shaped holes may be
added to the surfaces of the cavity former that will enhance the
bond between the concrete and the cavity former 6.
[0132] Embodiments of the present invention employ any number of
reinforcing members 18 into the mesh. Preferably, fiberglass is
utilized that is coated with polyvinyl chloride (PVC). The heat of
the molten EPS is, in some embodiments, approximately equal to the
melting point of PVC, thereby melting the PVC and mechanically
and/or chemically bonding it to the EPS. This marriage of PVC and
EPS results in a composite insulated material with enhanced
strength that allows for the individual thicknesses of planar
surfaces 26 and legs 30 to be decreased, thereby decreasing the
costs and weight of the cavity former 6 while maintaining the
strength. Alternatively, carbon fiber mesh may be added to the EPS
foam to provide rigidity. Other materials that would provide
rigidity are also contemplated by embodiments of the present
invention and which one skilled in the art will appreciate could be
used. In addition, many materials may be used with or without the
coating of PVC. Further, one skilled in the art will appreciate the
fiber orientation of the reinforcing mesh may be altered depending
on the final use of the reinforced insulation. Preferably, a
fiberglass fiber is used as oriented at 0 and 90 degrees thereby
providing approximately a square mesh. Alternatively, mesh may be
woven or positioned at 45 degree angles thereby providing a diamond
sheet to be used within the thickness of the insulation.
Embodiments of the present invention include reinforcing members 18
that are tensioned during molding to yield a pre-stressed cavity
former 6.
[0133] While various embodiments of the present invention have been
described in detail, it is apparent that modifications and
alterations of those embodiments will occur to those skilled in the
art. However, it is to be expressly understood that such
modifications and alterations are within the scope and spirit of
the present invention, as set forth in the following claims.
* * * * *