Wall Panel Apparatuses And Methods

Abstract

Apparatuses and methods for a wall panel having a support element and an insulation element.

Description

FIELD OF THE INVENTION

[0001] This invention is related to building construction, and more particularly to the construction of walls that may be prefabricated and may be frost walls, basement or foundation walls, or above grade exterior walls or other walls or portions thereof, such as wall panels.

BACKGROUND OF THE INVENTION

[0002] Concrete block and poured concrete foundation and structural walls are thought to account for the majority of existing building foundation and structural walls. Most of the remaining foundation and structural walls are thought to be constructed from precast concrete. There is thought to be a need for a cost effective multi-material wall and portions thereof that provide sufficient support for their application, and which may be prefabricated and quickly erected on a building site. The wall or portion thereof may be positioned at least partially underground such that the earth provides a balanced lateral load to the wall or portion thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The accompanying drawings, wherein like reference numerals are employed to designate like components, are included to provide a further understanding of wall panel apparatuses and methods, are incorporated in and constitute a part of this specification, and illustrate embodiments of a wall panel apparatus and method that together with the description serve to explain the principles of wall panel apparatuses and methods.

[0004] Various other objects, features and advantages of the invention will be readily apparent according to the following description exemplified by the drawings, which are shown by way of example only, wherein:

[0005] FIG. 1 shows a perspective view of a support shelf panel and a wall including multiple wall panels, in accordance with one embodiment.

[0006] FIG. 2 shows a top view of a wall panel, in accordance with one embodiment.

[0007] FIG. 3 shows a front view of a wall panel, in accordance with one embodiment.

[0008] FIG. 4 shows an end view of a wall panel, in accordance with one embodiment.

[0009] FIG. 5 shows a cross-sectional top view of the wall panel of FIG. 3 along section A-A, in accordance with one embodiment.

[0010] FIG. 5A shows a top view of part of a wall panel with a support element that includes a nailer securing portion, in accordance with one embodiment.

[0011] FIG. 6 shows a top view of portions of two wall panels, in accordance with one embodiment.

[0012] FIG. 7 shows a top view of a nailer, in accordance with one embodiment.

[0013] FIG. 8 shows a top view of portions of a wall panel and inside corner wall panel, in accordance with one embodiment.

[0014] FIG. 9 shows a top view of portions of a wall panel and outside corner wall panel, in accordance with one embodiment.

[0015] FIG. 10 shows a top view of a support shelf panel, in accordance with one embodiment.

[0016] FIG. 11 shows a front view of a support shelf panel, in accordance with one embodiment.

[0017] FIG. 12 shows an end view of a support shelf panel, in accordance with one embodiment.

[0018] FIG. 13 shows a cross-sectional top view of the support shelf panel of FIG. 11 of along section A-A, in accordance with one embodiment.

[0019] FIG. 14 shows a top view of portions of two support shelf panels, in accordance with one embodiment.

[0020] FIG. 15 shows a top view of portions of a support shelf panel and inside corner support shelf panel, in accordance with one embodiment.

[0021] FIG. 16 shows a top view of portions of a support shelf panel and outside corner support shelf panel, in accordance with one embodiment.

[0022] FIG. 17 shows a top view of a beam pocket wall panel, in accordance with one embodiment.

[0023] FIG. 18 shows a partial front view of a beam pocket wall panel, in accordance with one embodiment.

[0024] FIG. 19 shows a cross-sectional top view of the beam pocket wall panel of FIG. 17 along section A-A, in accordance with one embodiment.

[0025] FIG. 20 shows a cross-sectional top view of the beam pocket wall panel of FIG. 17 along section B-B, in accordance with one embodiment.

[0026] FIG. 21 shows a cross-sectional top view of a wall panel for a door or window, in accordance with one embodiment.

[0027] FIG. 22 shows a partial front view of a wall panel for a door or window, in accordance with one embodiment.

[0028] FIG. 23 is a flow chart of a process for casting a wall panel, in accordance with one embodiment.

[0029] FIG. 24 shows a top view of an insulation element that may disposed in a mold for forming a wall panel, in accordance with one embodiment.

[0030] FIG. 25 shows a front view of insulation element that may disposed in a mold for forming a wall panel, in accordance with one embodiment.

[0031] FIG. 26 shows a perspective view of another insulation element, in accordance with one embodiment.

[0032] FIG. 27 shows a partial perspective view of another insulation element, in accordance with one embodiment.

[0033] FIG. 28 shows a partial perspective view of another insulation element, in accordance with one embodiment.

[0034] FIG. 29 shows a top view of another insulation element, in accordance with one embodiment.

[0035] FIG. 30 shows a back view of another insulation element, in accordance with one embodiment.

[0036] FIG. 31 shows a top view of portions of two wall panels, each including a panel securing holder and a mechanical connection element, in accordance with one embodiment.

DETAILED DESCRIPTION

[0037] Reference will now be made to embodiments of wall panel apparatuses and methods, examples of which are illustrated in the accompanying drawings. Details, features, and advantages of the wall panel apparatuses and methods will become further apparent in the following detailed description of embodiments thereof.

[0038] Any reference in the specification to "one embodiment," "a certain embodiment," or a similar reference to an embodiment is intended to indicate that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of such terms in various places in the specification do not necessarily all refer to the same embodiment. References to "or" are furthermore intended as inclusive, so "or" may indicate one or another of the ored terms or more than one ored term.

[0039] The wall panel embodiments described herein, such as the wall panel embodiments described with respect to FIGS. 1-22 and herein, including the wall panel 2, inside corner wall panel 302, outside corner wall panel 402, support shelf panel 502, inside corner support shelf panel 732, outside corner support shelf panel 752, beam pocket wall panel 802, and wall panel 1102 for a door or window, may include a portion of a foundation or other wall. The wall panel may be installed partially or fully underground, or partially or fully above ground.

[0040] FIG. 1 shows a perspective view of a wall 1, including wall panels 2, 802, and 1102, in accordance with one embodiment. FIG. 1 also shows a perspective view of a support shelf panel 502 embodiment. Wall panels that may form a wall 1, including, as described below, the aforementioned wall panels and also wall panels 302, 402, 732, and 752, may respectively include one or more of each of an integral footer, an integral header, a nailer, a sealant groove, and/or one or more other elements.

[0041] FIGS. 2-4 respectively show a top view, front view, and end view of a wall panel 2, in accordance with one embodiment. FIG. 5 shows a cross-sectional top view of the wall panel 2 along section A-A of FIG. 3. Referring to FIGS. 2-5, the wall panel 2 may include a panel body 10. The panel body 10 may be shaped such that its opposing surfaces are substantially parallel, although the panel body 10 may be otherwise shaped. The panel body 10 may have a top surface 20, and bottom surface 30. The panel body 10 and wall panel 2 may have an outer surface 40, inner surface 50, first end surface 60, and second end surface 70. The outer surface 40 may face toward the outside of a residential structure such as a house, a light commercial building, or other structure in which the wall panel 2 is assembled, and the inner surface 50 may face toward the inside of the structure.

[0042] In one embodiment, the panel body 10 includes a support element 90 and insulation element 120. The support element 90 may include concrete in one embodiment, or another material or materials that may provide structural support to the panel body 10 and wall panel 2. The support element 90 may include one or more ribs 92, such as three ribs in an embodiment. The one or more ribs 92 may each be reinforced, such as with a rebar 93, such as a #3 rebar. The support element 90 may include an outer support portion 94, which may be a structure that includes, or is positioned adjacent, the outer surface 40 of the wall panel 2. The outer support portion 94 may be slender, or may be otherwise shaped. The outer support portion 94 may further include a first mating portion 96 and second mating portion 98 that include a portion of, or are positioned adjacent, the first end surface 60 and second end surface 70, respectively. Where two wall panels 2 are assembled together, the first mating portion 96 of one wall panel 2 may align with the second mating portion 98 of the other wall panel 2, such as shown in the embodiment of FIG. 6, which is described below. The first mating portion 96 or second mating portion 98 may also align with a mating portion of another wall panel, such as one of the wall panels 302, 402, 502, 732, 752, 802, and 1102 described herein.

[0043] The one or more ribs 92 may, in an embodiment, be integral with the outer support portion 94, and may be so formed through a casting operation, such as described below with respect to FIG. 23.

[0044] The insulation element 120, such as shown in FIG. 5, may include EPS foam in one embodiment, or another material or materials. The support element 90 may be disposed adjacent (or partially so) to the insulation element 120. In an embodiment, the support element 90 and insulation element 120 are disposed adjacently and form an approximately or mostly solid structure along with any embedded elements, such as the one or more rebars 93 and/or one or more nailers 210 (described below).

[0045] In an embodiment, the support element 90 and insulation element 120 are formed together in a casting operation, such as described below with respect to FIG. 23. Where the support element 90 includes ribs 92 with reinforcing rebar 93, the ribs 92 and rebar 93 may be formed together in the casting operation.

[0046] Referring to FIG. 5, the one or more ribs 92 may protrude from the support element 90 at the outer support portion 94 in a bowed out shape such that the thickness T2 of each rib 92 at least one distance D2 from the support element 90 is greater than the thickness of the rib 92 at least one distance less than D2. In one embodiment, the thickness T2 of each rib 92 continuously increases as the distance D2 from the support portion 90 increases, such as shown. In other embodiments, the thickness T2 may not continuously increase. Such configurations of the ribs 92 may allow the support element 90 to interlock with a mated insulation element 120 when the wall panel 2 is formed, which may facilitate holding the support element 90 and insulation element 120 together. Such configurations may also allow the outer support portion 94 to be thin, since the abutting insulation element 120 may provide structural support to the outer support portion 94 and thus the wall panel 2.

[0047] Referring again to FIGS. 2-5, the wall panel 2, in an embodiment, includes one or more attachment holes formed in each of the first end surface 60 and the second end surface 70. For example, attachment holes 100 and 101 may be formed in the first mating surface 96 of the support element 90, and attachment holes 102 and 103 may be formed in the second mating surface 98 of the support element 90. The attachment holes 100-103 may each allow another wall panel 2, or, as described in embodiments below, a wall panel 302, 402, 502, 732, 752, 802, or 1102, with similarly shaped and positioned holes to be secured thereto.

[0048] For example, FIG. 6 shows a top view of portions of two wall panels 2, in accordance with one embodiment. In this embodiment, the two wall panels 2 are secured together through attachment holes 100, 101 of one wall panel 2 and aligned attachment holes 102, 103, respectively, of the other wall panel 2, by anchor bolts 105. Other methods of securing the wall panels 2 together, such as by threaded rods and nuts, or other affixation systems such those as described with respect to the panel securing holders 1684 of the insulation element 1600 of FIGS. 26-30 below, may be substituted in other embodiments.

[0049] The wall panel 2 may include, in one embodiment, one or more locator elements 110, each of which may protrude from the top surface 20 of the panel body 10. If the wall panel 2 includes a header 201 that is integral with the support element 90 of the panel body 10, as described below, the one or more locator elements 110 may each protrude from the integral header 201. The locator elements 110 may be elongated, such as in an elongated cylindrical shape as shown, or may be another shape. In an embodiment, each locator element 110 is part of a rebar 93 that extends through a rib 92. The locator elements 110 may be anchor bolts in another embodiment. The locator elements 110 may locate a structure onto or near the top surface 20 of the panel body 10 (or the header 201 if formed with the wall panel 2). For example, where the wall panel 2 is included in a residential structure and the locator elements 110 are anchor bolts, the locator elements 110 may locate and attach thereon residential structure framing above the wall panel 2.

[0050] For example, the locator elements 110 may locate a header (if header is not formed with the wall panel 2) and/or a sill plate, for example. Such a separate header may comprise wood, pressure treated wood, metal, such as light or moderate gauge steel, concrete, or another construction material. The separate header and/or sill plate may be formed with apertures in its bottom surface such that the locator elements 110 may extend therein or therethrough to accurately position the header and/or sill plate adjacent to the panel body 10. The header and/or sill plate may be secured to the wall panel 2 by the locator elements 110, such as by washer and nut.

[0051] In an embodiment, the wall panel 2 includes a footer element 200, which may be an elongated plank or another shape. The footer element 200 may be reinforced. The reinforcement may include, in an embodiment, two continuous #4 steel reinforcement bars that extend through the length of the footer element 200. In an embodiment, the footer element 200 is integral with the support element 90 adjacent to the bottom surface 30 of the panel body 10, such as by casting these elements together as described below with respect to FIG. 23.

[0052] In one embodiment, the footer element 200 is formed with a slab-locating groove 230. The slab-locating groove 230 may be a groove formed in the inner surface 231 of the footer element 200 such that when the wall panel 2 is assembled on site and a slab is poured, the slab will enter the slab-locating groove 230. Thus, the poured slab will enter the slab-locating groove 230 to "lock" the slab and footer element 200, which may prevent differential settlement between the wall panel 2 and the slab. Such locking may also prevent or reduce water seepage between the slab and footer element 2. In an embodiment, the slab-locating groove 230 is a V-shaped groove formed in the inner surface 231 of the footer element 200. The V-shaped groove may extend from one end of the inner surface 231 (adjacent the first end surface 60 of the panel body 10) to the other end (adjacent the second end surface 70 of the panel body 10).

[0053] In one embodiment, the footer element 200 is formed with an embedded slab tie 202, which may partially protrude from the footer element 200 to project into a slab. A slab tie 202 may facilitate securing the footer element 200 and slab during installation of the wall panel 2 and pouring of the slab. The slab tie 202 may thus facilitate securing the footer element 200 and wall panel 2 to the slab.

[0054] In an embodiment, the wall panel 2 includes a header 201. The header 201 may be integral with the support element 90 adjacent to the top surface 20 of the panel body 10. The footer element 200 and header 201 may both be integral with the support element 90 in an embodiment, such as by being cast together in a mold as described below at 1415 of the process 1400 of FIG. 23. In this embodiment, the support element 90, footer element 200, and header 201 may all include the same material, such as a high compressive strength concrete or another type of concrete. The materials for the wall panel 2 may be chosen to meet building code requirements.

[0055] In one embodiment, the header 201 does not cover the entire top surface 20, allowing for mechanical access of electrical wiring and other elements without having to remove concrete or other header 201 material. Such a configuration of the header 201 may prevent cracking or other weakening of the header 201 that may have been caused by such removal of header 201 material.

[0056] In an embodiment, the wall panel 2 includes one or more nailers 210. The one or more nailers 210 may be made of wood, metal, or another material or materials. Each nailer 210 may be positioned in the insulation element 120 of the panel body 10. Each nailer 210 may be so positioned by hot-wiring the insulation element 120 to form an opening, described below with respect to the nailer voids 1510 of FIG. 24, into which the nailer 210 may be placed. Each nailer 210 may also be secured to the support element 90 of the panel body 10, such as via the casting operation described below with respect to FIG. 23.

[0057] For example, as shown with respect to FIG. 5A, which shows a top view of part of one embodiment of a wall panel 2, a portion of the support element 90 may include a nailer securing portion 211. The nailer securing portion 211 may extend from the outer support portion 94 of the support element 90 to a nailer securing portion end 212. The nailer securing portion end 212 may be shaped to be disposed in a portion interior to the nailer 210 to secure the nailer 210 thereto. Each nailer 210 may also or alternatively be secured to (if included) either or both the integral footer element 200 and header 201. Securing the nailer 210 to the support element 90, footer element 200, and/or the header 201 may hold the nailer 210 in place, such as, for example, in case the insulation element 120 melts during a fire.

[0058] The wall panel 2 may include one or more sealant grooves 220 in an embodiment. In an embodiment, a sealant groove 220 may be formed in the support element 90 in the first mating portion 96. The sealant groove 220 may be a 3/8 inch diameter half-cylinder or another size and shape. In an assembled wall, such as two secured-together wall panels 2, the first mating portion 96 (with sealant groove 220) of one wall panel 2 may abut the second mating portion 98 of the other wall panel 2, and a sealant may be injected into the sealant groove 220 to protect the sealant from the elements and provide a stronger and more secure finish. The sealant may be a grout, which may be expandable or non-expandable, or may be another sealant. In an embodiment, after two wall panels 2 have been secured together, an expandable, polyurethane-based grout is pressure injected into the sealant groove 220 and expands to fill the sealant groove 220. In another embodiment, the sealant groove 220 may be positioned in the second mating portion 98.

[0059] The wall panel 2 may include an exterior finish (not shown) in an embodiment. That finish may be protective, decorative (for example, where the wall panel 2 extends above ground), or for another purpose. The exterior finish may be spray coated or applied by trowel onto the wall panel 2. The exterior finish may be polymer based or cement based, or another type of material may be used when spray coating.

[0060] The wall panel 2 may be sized as desired. For example, referring to FIG. 4, the total height H1 of the wall panel 2 (in an embodiment including the footer element 200 and a header 201) may be about 8 feet. As shown in the cross-sectional top view of the wall panel 2 in FIG. 5, the wall panel 2 may have a width W1 of about 4 feet. The wall panel 2 may have a thickness T1 of about 10 inches. Alternately, the thickness T1 may be any thickness desired for structural integrity.

[0061] The support element 90 of the wall panel 2 may also be variously sized and shaped. In an embodiment, as shown in FIG. 5, the outer support portion 94 of the support element 90, including the first mating portion 96 and second mating portion 98, may have a thickness O1 of about 1 inch. The first and second mating portions 96 and 98 may extend from the outer surface 40 of the wall panel 2 along the first and second end surfaces 60 and 70, respectively, to a length M1 of about 6 inches. The distance D1 between each of the first and second mating portions 96 and 98 and its adjacent rib 92 may be about 6 inches.

[0062] The ribs 92 of the support element 90 may extend a length R1 of about 9 inches from the outer surface 40 of the wall panel 2 (and 8 inches from the outer support portion 94). In an embodiment, the thickness T2 of each rib 92 may steadily increase in proportion to the distance D2 from the outer support portion 94 such that the thickness T2 increases from about 2 inches to about 2.5 inches. The distance D3 between adjacent ribs 92 may be about 14 inches, and the center-to-center distance C1 between adjacent ribs 92 may be about 16 inches.

[0063] The header 200 and footer 201, in embodiments in which they are included in the wall panel 2, may be dimensioned as desired. For example, the header 200 and footer 201 may cover the top surface 20 and bottom surface 30, respectively, of the panel body 10. The header 200 and footer 201 may have desired thicknesses.

[0064] Where one or more nailers 210 are included, each nailer 210 may be dimensioned as desired. For example, as shown in the top view of the nailer 210 in the embodiment of FIG. 7, each nailer 210 may be about N1=2.39 inches by N2=1.02 inches with N3=0.3 inches. The thickness of the nailer 210 may be about 0.03 inches. The center-to-center distances C2 between nailers 210 may about 16 inches, and each nailer 210 have a center-to-center distance C3 between it and an adjacent rib 92 of about 43/8 inches.

[0065] At least some of the aforementioned shapes and sizes may facilitate transport of one or more of the wall panels described herein from the manufacturing site to the building site. For example, each of the wall panels 2 may be sized and weighted to facilitate stacking and then transporting the wall panels 2 on a single truck. For example, because each wall panel 2 may include a relatively light insulation element 120, the wall panels 2 may be lighter than wall panels with a higher concrete percentage, and thus more easily transportable. The size of the wall panel 2 may be customized, such as with the aforementioned specific dimensions in one embodiment, to fit within the transporting truck when stacked.

[0066] In another embodiment as shown in FIG. 8, a top view of portions of a wall panel 2 and inside corner wall panel 302 are shown. The inside corner wall panel 302 may have one or more elements as described with respect to the wall panel 2, but may have its attachment holes differently positioned. Thus, the inside corner wall panel 302 may have attachment holes 310, 311 (instead of the attachment holes 100, 101 of the wall panel 2). The attachment holes 310, 311 may be formed in the outer support portion 94 of the support element 90. The wall panels 2 and 302 may be secured together through attachment holes 102, 103 of the wall panel 2 and aligned attachment holes 310, 311 of the inside corner wall panel 302, respectively, by anchor bolts 105. The secured-together wall panels 2 and 302 may be configured such that the inner surface 50 and first end surface 60 of the inside corner wall panel 302 form an inside corner 316 of a wall in which the wall panels 2 and 302 are included.

[0067] A secured-together configuration of wall panels may also form an outside corner of a wall. In the embodiment shown in FIG. 9, a top view of portions of a wall panel 2 and outside corner wall panel 402 are shown. The outside corner wall panel 402 may have one or more elements as described with respect to the wall panel 2, but may have its attachment holes differently positioned. Thus, the outside corner wall panel 402 may have attachment holes 410, 411 (instead of the attachment holes 100, 101 of the wall panel 2). The attachment holes 410, 411 may be formed in the inner surface 50. The wall panels 2 and 402 may be respectively secured together through attachment holes 102, 103 of the wall panel 2 and aligned attachment holes 410, 411 of the outside corner wall panel 402, respectively, by anchor bolts 105. The secured-together wall panels 2 and 402 may be configured such that the outer surface 40 and first end surface 60 of the outside corner wall panel 402 form an outside corner 416 of a wall in which the wall panels 2 and 402 are included.

[0068] Embodiments of the inside corner wall panel 302 and outside corner wall panel 402 may include the aforementioned dimensions, materials, etc., of the wall panel 2, or those dimensions, materials, etc., may be altered as desired.

[0069] FIGS. 10-12 illustrate a top view, front view, and end view, respectively, of another embodiment of a wall panel, a support shelf panel 502. FIG. 13 shows a cross-sectional top view of a support shelf panel 502 along section A-A of FIG. 11. The support shelf panel 502 may include features and components described in connection with the wall panel 2 in FIGS. 2-5 above. In one embodiment, the support shelf panel 502 forms part of a wall, which may also include one or more wall panels 2, 302, 402, 502, 732, 752, 802, and/or 1102 described herein. The support shelf panel 502 may be included in a residential or other structure.

[0070] Elements 510, 520, 530, 540, 550, 560, 570, 590, 592-594, 596, 598, 600-603, 610, 620, 700, 701, 710, 702, 720, 730, and 731 in FIGS. 10-13 may respectively correspond to elements 10, 20, 30, 40, 50, 60, 70, 90, 92-94, 96, 98, 100-103, 110, 120, 200, 201, 202, 210, 220, 230, and 231 of the wall panel 2 in FIGS. 2-5. The support shelf panel 502 may also include a nailer securing portion (not shown) that corresponds to nailer securing portion 211 of the wall panel 2.

[0071] As shown in FIG. 12, the outer surface 540 may have a stepped configuration, forming a support shelf 542 onto which brick fascia or another structure or structures may be set. Instead or additionally, in another embodiment, the inner surface 550 has a stepped configuration to form a support shelf (not shown). Thus, the support shelf panel 502 may include one or more support shelves. The support shelf or shelves may be customized in an embodiment such that if the support shelf panel 502 is to be embedded partially in the ground when installed on site, each support shelf will sit near ground level.

[0072] In the embodiment shown in FIG. 12, the support shelf 542 is integral with the support element 590. Forming the support shelf panel 502 with that integral support shelf 542, as opposed to a support shelf that is not integral, may reduce or eliminate a bending moment imparted by the housing or other structure in which the support shelf panel 502 forms a part when installed. Thus, the support shelf panel 502 may, when installed, be subject to an axial or mostly axial load (in a direction from its top surface 520 to its bottom surface 530). The support shelf panel 502 may thus be able to be made with less concrete or other material in the support element 590, as compared to a wall panel or other wall portion having a non-integral support shelf, and may thus be lighter. In one embodiment, the support shelf panel 502 weighs about 250 pounds per square foot, although the weight may be different in other embodiments.

[0073] The support shelf panel 502 may include, in an embodiment, an exterior finish, such as described above with respect to the wall panel 2.

[0074] As described above with respect to the wall panel 2, the support shelf panel 502 may be sized as desired. The support shelf panel 502 may be shaped, sized, and have a weight facilitating its transport.

[0075] FIG. 14 shows a top view of portions of two support shelf panels 502, in accordance with one embodiment. In this embodiment, the two support shelf panels 502 are secured together through attachment holes 600, 601 of one wall panel 502 and aligned attachment holes 602, 603, respectively, of the other wall panel 502, by anchor bolts 105. Other methods of securing the wall panels 502 together, such as by threaded rods and nuts, may be substituted in other embodiments.

[0076] In another embodiment as shown in FIG. 15, a top view of portions of a support shelf panel 502 and inside corner support shelf panel 732 are shown. The inside corner support shelf panel 732 may have one or more elements as described with respect to the support shelf panel 502, but may have its attachment holes differently positioned. Thus, the inside corner support shelf panel 732 may have attachment holes 740, 741 (instead of the attachment holes 600, 601 of the support shelf panel 502). The attachment holes 740, 741 may be formed in the outer support portion 594 of the support element 590 of the inside corner support shelf panel 732. The support shelf panels 502 and 732 may be secured together through attachment holes 602, 603 of the support shelf panel 502 and aligned attachment holes 740, 741 of the inside corner support shelf panel 732, respectively, by anchor bolts 105. The secured-together wall panels 2 and 732 may be configured such that the inner surface 550 and first end surface 560 of the inside corner support shelf panel 732 form an outside corner 744 of a wall in which the wall panels 502 and 732 are included. The support shelves 542 of the support shelf panels 502 and 732 may thus face the outside of a structure in which they are included. In this embodiment, the support shelves 542 may form an angle .theta.1 of about 90.degree. or another angle.

[0077] In another embodiment as shown in FIG. 16, a top view of portions of a support shelf panel 502 and outside corner support shelf panel 752 are shown. The outside corner support shelf panel 752 may have one or more elements as described with respect to the support shelf panel 502, but may have its attachment holes differently positioned. Thus, the outside corner support shelf panel 752 may have attachment holes 760, 761 (instead of the attachment holes 600, 601 of the support shelf panel 502). The attachment holes 760, 761 may be formed on the inner surface 550 of the outside corner support shelf panel 752. The support shelf panels 502 and 752 may be secured together through attachment holes 602, 603 of the support shelf panel 502 and aligned attachment holes 760, 761 of the outside corner support shelf panel 752, respectively, by anchor bolts 105. The secured-together wall panels 2 and 752 may be configured such that the outer surface 540 and first end surface 560 of the outside corner support shelf panel 752 form an outside corner 764 of a wall in which the wall panels 502 and 752 are included. The support shelves 542 of the support shelf panels 502 and 752 may thus face the outside of a structure in which they are included. In this embodiment, the support shelves 542 may form an angle .theta.2 of about 270.degree. or another angle.

[0078] FIGS. 17-18 illustrate a top view and partial front view, respectively, of another embodiment of a wall panel, a beam pocket wall panel 802. FIG. 19 shows a cross-sectional top view of the beam pocket wall panel 802 along section A-A of FIG. 18. FIG. 20 shows a cross-sectional top view of the beam pocket wall panel 802 along section B-B of FIG. 18. The beam pocket wall panel 802 may include features and components described in connection with the wall panel 2. In one embodiment, the beam pocket wall panel 802 forms part of a wall, such as the wall 1 shown in FIG. 1 or a wall that includes one or more wall panels 2, 302, 402, 502, 732, 752, or 1102 described herein. The panel with beam pocket 802 may be included in a residential or other structure.

[0079] Elements 810, 820, 840, 850, 860, 870, 890, 892-894, 896, 898, 920, 1001, 1010, and 1020 of the beam pocket wall panel 802 in FIGS. 17-20 may respectively correspond to elements 10, 20, 40, 50, 60, 70, 90, 92-94, 96, 98, 120, 201, 210, and 220 of the wall panel 2 in FIGS. 2-5. The beam pocket wall panel 802 may also include one or more elements (not shown in FIGS. 17-20) that correspond to elements 30, 100-103, 110, 200, 202, 211, 230, 231, and an exterior finish of the wall panel 2. For example, an integral footer 1000 that may be incorporated into the beam pocket wall panel 802 is shown in the embodiment of FIG. 1.

[0080] The beam pocket 1050 of the beam pocket wall panel 802 may be a void, which may be cuboidal in an embodiment or otherwise shaped to receive a portion of a support beam. The beam pocket wall panel 802 may include a beam pocket rib 1060, which may include a base portion 1062 and a pocket portion 1064. The base portion 1062 may be positioned under the beam pocket 1050 and may extend to an integral footer (not shown) or other footer or otherwise along the beam pocket wall panel 802. The base portion 1062 may provide vertical support to a support beam partially disposed in the beam pocket 1050. The pocket portion 1064 may be positioned at the sides and under the beam pocket 1050 to provide further support. In an embodiment, the beam pocket rib 1060 is reinforced, such as with one or more rebar 1066, such as #3 rebar, in both the base portion 1062 and pocket portion 1064. In an embodiment, the header 1001, or otherwise a portion positioned above the beam pocket 1050, may be reinforced, such as with a rebar 1002.

[0081] As described above with respect to the wall panel 2, the beam pocket wall panel 802 may be sized as desired. For example, in one embodiment, the beam pocket rib 1060 may have a width Y1 of about 4 inches. The beam pocket wall panel 802 may be shaped, sized, and have a weight facilitating its transport.

[0082] FIGS. 21-22 illustrate a cross-sectional top view and partial front view of another embodiment of a wall panel, a wall panel 1102 for a door or window. The wall panel 1102 may include features and components described in connection with the wall panel 2. In one embodiment, the wall panel 1102 for a door or window may form part of a wall, such as the wall 1 shown in FIG. 1 or a wall that includes one or more wall panels 2, 302, 402, 502, 732, 752, or 802 described herein. The wall panel 1102 may be included in a residential or other structure.

[0083] Elements 1110, 1120, 1140, 1150, 1160, 1170, 1190, 1192-1194, 1196, 1198, 1220, 1301, 1310, and 1320 in FIGS. 21-22 may respectively correspond to elements 10, 20, 40, 50, 60, 70, 90, 92-94, 96, 98, 120, 201, 210, 211, and 220 of the wall panel 2 in FIGS. 2-5. The wall panel 1102 may also include one or more elements (not shown) that correspond to elements 30, 100-103, 110, 200, 202, 230, 231, and an exterior finish of the wall panel 2. For example, an integral footer 1300 is shown in the embodiment of FIG. 1.

[0084] The door or window opening 1350 of the wall panel 1102 may be a void, which may be cuboidal in an embodiment or otherwise shaped to receive a door or window. That void may extend through the wall panel 1102, from the outer surface 1140 to the inner surface 1150. The wall panel 1102 may include a door or window rib 1360, which may include a base portion 1362 and a door or window portion 1364. The base portion 1362 may be positioned under and/or over the door (possibly just over the door) or window opening 1350 and may extend to an integral footer (not shown) or other footer and an integral header 1301 or other header. The base portion 1362 may provide vertical support to the wall panel 1102. The door or window portion 1364 may be positioned at the sides and above the door or window opening 1350, and possibly below the window opening, to provide further support. In an embodiment, the door or window rib 1360 is reinforced, such as with rebar 1366. In an embodiment, the header 1301, or otherwise a portion positioned above the door or window opening 1350, may be reinforced, such as with a rebar 1302, such as a #3 rebar.

[0085] The wall panel 1102 may include rough openings in which further door or window support elements 1370, such as nominal lumber in an embodiment, may be disposed. Duplex nails 1371 may be positioned through the window support elements 1370 to secure the window support elements 1370 in the wall panel 1102, such as to the door or window rib 1360. In an embodiment, a removable screed or screeds 1372 may be positioned adjacent the door or window opening 1350, such as in a rough opening.

[0086] As described above with respect to the wall panel 2, the wall panel 1102 may be sized as desired. The wall panel 1102 may be shaped, sized, and have a weight facilitating its transport.

[0087] FIG. 23 is a flow chart of one embodiment of a process 1400 for casting a wall panel, which may be, for example, one of the wall panels 2, 302, 402, 502, 732, 752, 802, and 1102. As an example, the process 1400 is described below for forming the wall panel 2, although the process may similarly be applied to form one of the other wall panels. At 1405, a mold, insulation element 120, and possibly one or more blockouts are selected for the wall panel 2 to be produced. Depending on the embodiment, one or more wall panel elements, such as rebar or other reinforcement, locator elements 110, a slab tie 202, and/or other elements to be embedded in the wall panel 2 during casting, such as described below at 1410, may also be selected. In an embodiment, one shape of mold is used for all wall panels. That mold may have the maximum outer dimensions of all of the wall panels such that any wall panel may be cast from the mold.

[0088] For example, FIGS. 24-25 respectively show a top view and front view of an insulation element 120 that may be selected for the wall panel 2, in accordance with one embodiment. The mold may be in a tub-like shape that surrounds what will become the wall panel 2 periphery, i.e., as shown in FIGS. 2-5, the top surface 20 and/or an integral header 201 adjacent the top surface 20, bottom surface 30 and/or an integral footer 200 adjacent the bottom surface 30, inner surface 50, first end surface 60, and second end surface 70. In this embodiment, elements 20, 30, 40, 50, and 60 are the same as the like-numbered elements in, e.g., FIGS. 2-5, since the insulation element 120 includes these surfaces at least in part, as shown. The insulation element 120 may have portions removed by hot-wiring or another method. For example, nailer voids 1510 may be hot wired in an embodiment to support the insertion of one or more nailers 210, either before or after casting. Such removal may be customized based on the various elements of the wall panel being cast, such as the elements of any of wall panels 2, 302, 402, 502, 732, 752, 802, and 1102.

[0089] The insulation element 120 may be shaped, along with the mold, to form various elements of the wall panel 2 during casting. For example, the insulation element 120 may be shaped to form a support element void 1520 that includes, e.g., a first mating portion void 1512, second mating portion void 1514, and rib voids 1530. After the concrete or other material is poured during casting, the material will cure to form, referring also to FIGS. 2 and 5, a support element 90 in the support element void 1520, with a first mating portion 96 in the first mating portion void 1512, a second mating portion in the second mating portion void 1514, and ribs 92 in the rib voids 1530.

[0090] With reference also to FIGS. 3-4, if an integral footer element 200 is cast adjacent the bottom surface 30 of the panel body 10, the footer element 200 may be positioned against the support element 90 and insulation element 120. In that configuration, during assembly of a wall on site, a slab may be poured directly against secured together wall panels 2. Formwork may not be needed in this case, since the insulation element 120 adjacent the footer element 200 of each wall panel 2 may prevent the concrete (or other material) of the slab from flowing into the wall panel 2.

[0091] Returning to FIG. 23, at 1410, for the wall panel 2, the insulation element 120, one or more blockouts, and one or more wall panel elements are disposed in the mold (or the mold may be formed such that blockouts are not needed). The blockouts may be removable after the support element 90 is poured and the wall panel 2 is thereby cast. The blockouts may thereby form voids to form, depending on the embodiment, attachment holes 100-103, a sealant groove 220, and/or another void or voids.

[0092] In other wall panel embodiments, other blockouts may be used such that the same shape of mold may be used to form the wall panel as was used with the wall panel 2. For example, a support shelf panel 502 as in FIGS. 10-13 may be cast from the mold by inserting the aforementioned blockouts in the mold for the wall panel 2, but also inserting a blockout to form a void that results in the support shelf 542 when the blockout is removed after casting. In forming a beam pocket wall panel 802 as in FIGS. 17-20, a blockout shaped like the beam pocket 1050 may be inserted to form a void that will form the beam pocket 1050 when the blockout is removed. For a wall panel 1102 for a door or window as in FIGS. 21-22, a removable blockout forming a void shaped like the door or window opening 1350 may be inserted. Other blockouts may be disposed in the mold and/or the insulation element may be hot-wired or otherwise shaped based upon the wall panel being cast.

[0093] Where elements of the wall panel were selected at 1405, these elements may be positioned in the mold so as to be embedded in the wall panel as cast. For example, in one embodiment for forming the wall panel 2, additionally at 1410, one or more bars, such as continuous #4 steel reinforcement bars, may be positioned in the mold such that the footer element 200 will be formed with the bars. Further at 1410, one or more locator elements 110 may be positioned at least partially in the mold where the ribs 92 are to be formed, such that the locator elements 110 will each protrude from a different rib 92 at the top end 20 of the wall panel 2 and/or from the integral header 201 (if included) when the wall panel 2 is cast. A slab tie 202 may also be disposed at least partially in the mold such that the slab tie 202 at least partially extends into the area where the footer 200 is to be formed during casting.

[0094] In other wall panel embodiments, other and/or additional elements selected at 1405 may be disposed in the mold before casting. For example, for the beam pocket 802 as in FIGS. 17-20, a rebar 1066 or other reinforcement for the beam pocket 1050 may be disposed in the mold. For the wall panel 1102 for a door or window as in FIGS. 21-22, rebar 1193, 1302, and 1366 and/or other reinforcement may be disposed in the mold. Window support elements 1370, duplex nails 1371, and/or removable screeds 1372 may also be disposed in the mold, as desired.

[0095] At 1415, a casting material may be inserted in the mold to cast the wall panel 2. The casting material may be concrete, such as high compressive strength concrete. Various elements may be formed in or as part of the wall panel 2, such as described above. Thus, in one embodiment at 1415, the wall panel 2 may be formed with one or more of attachment holes 100, locator elements 110, an integral footer element 200, and an integral header 201, along with reinforcement and/or other elements disposed in the mold at 1410. The cast wall panel 2 may be allowed to cure.

[0096] At 1420, after the wall panel 2 has cured, one or more exterior finishes may be applied to the wall panel 2. The exterior finish may be a spray coating in an embodiment, such as described above with respect to the wall panel 2. In one embodiment, the exterior finish is applied during installation at 1430 (described below) at the building site.

[0097] The process 1400 from 1405 to 1420 may be repeated to produce additional wall panels 2, and, with customization of the insulation element and other elements as described above, one or more of the wall panels 302, 402, 502, 732, 752, 802, and 1102. Any of these wall panels may have their sizes and shapes and elements altered by hot-wiring or otherwise removing portions of the insulation element, and by disposing different wall panel elements and/or blockouts in the mold.

[0098] At 1425, the wall panel or panels may be loaded onto a flatbed crane truck or other vehicle and shipped to the installation site.

[0099] At 1430, the wall panel or panels may be installed, such as by a light crane, boom truck, or other means, as part of a residential or other structure. The wall panel or panels may be positioned directly onto a sub-base such as a stone soil sub base. Multiple wall panels may be mechanically fastened together via the attachment holes, such as by anchor bolts 105, to form a wall, such as the wall 1, for example.

[0100] Other portions of the residential or structure in which the wall is included may be secured thereto. For example, if the wall panels included headers integral with the panel bodies, sill plates may be secured to the headers, and a structure may be built atop the wall and may be at least partially supported by the sill plates.

[0101] Other insulation elements may be substituted for those described herein in other embodiments. For example, FIGS. 26-30 respectively show a perspective view, partial perspective view, partial perspective view, top view, and back view of another insulation element 1600 that may be selected for a wall panel, in accordance with one embodiment. The insulation element 1600 may, in an embodiment, substitute for the insulation element 120 of FIGS. 2-5 of the wall panel 2. The insulation element 1600 may include elements 1602, 1610, 1612, 1614, 1620, 1630, 1632, 1640, 1650, 1660, and 1670 that respectively correspond to elements 20, 1510, 1512, 1514, 1520, 1530, 30, 40, 50, 60, and 70 of the insulation element 120 described with respect to FIGS. 24-25.

[0102] The insulation element 1600 may also include one or more other elements. In an embodiment, the insulation element 1600 may be hollowed to include one or more mechanical chases 1672, such as two in an embodiment. The mechanical chases 1672 may allow electrical wiring, plumbing pipes, and other elements to extend therethrough. Where a wall panel comprising the insulation element 1600 includes a header 1674 (shown in FIG. 30 for illustration, but not part of the insulation element 1600), the insulation element 1600 may include knockouts 1676. The insulation element 1600 may be formed with a top layer 1678, which may form at least part of the top surface 1602 and at least partially cover the mechanical chases 1672. The top surface 1602 may not be in one plane as shown such that the header 1674 does not cover the entire top surface 1602, or the top surface may be in one plane in another embodiment. The knockouts 1676 may protrude from the top layer 1678 of the top surface 1602, such that each knockout 1676 is positioned above a different mechanical chase 1672. When a wall panel including the insulation element 1600 is cast, such as by the process 1400 of FIG. 23 at 1415, the wall panel may include the knockouts 1676 as extending through the header 1674. The knockouts 1676 may be poked out to reach the mechanical chases 1672 without cracking or otherwise damaging the concrete or other material of the header 1674.

[0103] The insulation element 1600 may include other portions to support positioning certain wall panel elements in a mold while forming the wall panel, such as with the process 1400 of FIG. 23 at 1410. In an embodiment, the insulation element 1600 includes one or more rib rebar seats 1680, such as three in one embodiment, in each of the rib voids 1630. Each rib rebar seat 1680 may be curved or otherwise grooved to receive and seat a rebar (corresponding to a rebar 93 of the wall panel 2 of FIGS. 2-5) in place during the process 1400 of FIG. 23 at 1410.

[0104] The insulation element 1600 may include one or more, such as two, footer rebar seats 1682, which may be positioned adjacent the bottom surface 1632 of the insulation element 1600. The footer rebar seats 1682 may also be curved or otherwise grooved to receive and seat a rebar or other reinforcement at 1410 of FIG. 23 to be embedded in a cast-in footer element at 1415.

[0105] The insulation element 1600 may include one or more panel securing holders 1684, which may be adjacent the top surface 1602 of the insulation element 1600. Each panel securing holder 1684 may position and hold an affixation or other securing element including a hole or slot, such as Unistrut.RTM. framing, through which an anchor bolt or threaded rod may extend to secure the wall panel to another wall panel. In one embodiment, the insulation element 1600 includes two panel securing holders 1684 adjacent the top surface 1602, one adjacent the first end surface 1660 and the other adjacent second end surface 1670. A Unistrut.RTM. channel or other mechanical connection element may be slid over each panel securing holder 1684, such as at 1410 of FIG. 23. At 1415, the header 1674 may be cast such that the Unistrut.RTM. channel or other mechanical connection element is partially embedded in the header 1674 with the slot or hole of the affixation element exposed. The wall panel may then be secured to another wall panel through facing mechanical connection elements, such as with an anchor bolt or threaded rod.

[0106] For example, FIG. 31 shows a top view of portions of two wall panels 1702, each including a panel securing holder 1684 (which may be part of an insulation element 1600 or other insulation element) and a mechanical connection element 1704, in accordance with one embodiment. The wall panels 1702 may include elements that correspond to elements of one or more wall panels described herein, customized for inclusion with the insulation element 1600 or other insulation element. Each mechanical connection element 1704, which may be a Unistrut.RTM. channel or other mechanical connection device, has been slid over each panel securing holder 1684 and then cast in the header 1706 of a wall panel 1702, such as at 1415 of the process 1400 of FIG. 23. Thus, each mechanical connection element 1704, as cast, may be disposed around a panel securing holder 1684. A bolt 1708 extends through two washers 1710, and the washers 1710 have been tightened around the exposed portion of the lips 1712 of the mechanical connection element 1704 to secure the wall panels 1702 together.

[0107] The insulation element 1600 may also be customized to include other elements, such as one or more of those corresponding to the wall panel 502, 802, or 1102, or another wall panel described herein. Any of the aforementioned insulation elements of wall panels 2, 302, 402, 502, 732, 752, 802, and 1102 may include one or more of the elements of the insulation element 1600. For example, instead of or in addition to one or more of the attachment holes, any of those insulation elements may include one or more panel securing holders 1684. The one or more panel securing holders 1684 may each position and hold a mechanical connection element 1704 that is cast in the corresponding wall panel, such as at 1415 of the process 1400 of FIG. 23.

[0108] While specific embodiments of the invention have been described in detail, it would be appreciated by those skilled in the art that various modifications and alternations would be developed in light of the overall teachings of the disclosure. For example, it will be understood by those skilled in the art that, while the present invention is described primarily with respect to the construction of a residential home and light commercial buildings, the wall panels of the present invention can be used for industrial building and other construction as well. In another example, dimensions of matter described with respect to certain embodiments may be approximate and may be altered as desired. Accordingly, the particular arrangements, apparatuses, systems, and methods disclosed are meant to be illustrative only and not limiting as to the scope of the invention.

Claims

1. A wall panel, comprising: a support element; an insulation element to be adjacent the support element; and a footer element integral with the support element.

2. The wall panel of claim 1, the footer element to be adjacent the insulation element.

3. The wall panel of claim 1, the support element comprising one or more ribs.

4. The wall panel of claim 3, the one or more ribs each to be reinforced.

5. The wall panel of claim 1, the support element comprising a first mating portion and a second mating portion.

6. The wall panel of claim 1, further comprising a support shelf.

7. The wall panel of claim 1, further comprising a beam pocket.

8. The wall panel of claim 1, further comprising a window opening.

9. The wall panel of claim 1, further comprising a door opening.

10. The wall panel of claim 1, wherein the wall panel is to form an inside corner.

11. The wall panel of claim 1, wherein the wall panel is to form an outside corner.

12. The wall panel of claim 1, further comprising a first end surface of the support element and a second end surface of the support element, the first end surface and the second end surface each including one or more attachment holes.

13. The wall panel of claim 12, the attachment holes on each of the first end surface and second end surface to secure the wall panel to another wall panel.

14. The wall panel of claim 1, further comprising one or more locator elements.

15. The wall panel of claim 14, wherein the locator elements are anchor bolts.

16. The wall panel of claim 1, further comprising a header adjacent the support element.

17. The wall panel of claim 16, further comprising at least one locator element protruding from the header.

18. The wall panel of claim 1, wherein the insulation element includes EPS foam.

19. The wall panel of claim 1, wherein the panel body comprises high compressive strength concrete.

20. The wall panel of claim 1, wherein the wall panel includes an exterior finish.

21. The wall panel of claim 20, wherein the exterior finish is a spray coating.

22. The wall panel of claim 1, further comprising a slab tie embedded at least partially in the footer element.

23. The wall panel of claim 1, wherein the footer element is formed with a slab-locating groove.

24. The wall panel of claim 23, wherein the slab-locating groove is V-shaped.

25. The wall panel of claim 1, further comprising one or more mechanical connection elements and one or more panel securing holders, each of the one or more mechanical connection elements disposed around a different one of the one or more panel securing holders.

26. A process for forming a wall panel, comprising: disposing an insulation element in a mold; inserting a casting material in the mold to integrally form a support element and a footer element adjacent to the insulation element.

27. The process of claim 26, wherein the inserting of the casting material in the mold is further to integrally form a header with the support element.

28. The process of claim 26, further comprising forming a sealant groove in the support element.

29. The process of claim 26, wherein the support element is to be adjacent to the insulation element such that the support element and the insulation element interlock.

30. The process of claim 26, further comprising forming one or more ribs in the support element.

31. The process of claim 26, further comprising forming a first mating portion and a second mating portion in the support element.

32. The process of claim 26, further comprising disposing one or more locator elements in the mold before inserting the casting material in the mold.

33. The process of claim 26, further comprising forming a support shelf on the wall panel.

34. The process of claim 26, further comprising forming a beam pocket in the wall panel.

35. The process of claim 26, further comprising forming at least one of a door and a window in the wall panel.

36. The process of claim 26, further comprising forming one or more attachment holes in the support element.

37. The process of claim 26, further comprising curing the wall panel and applying an exterior finish to the wall panel.

38. A wall panel, comprising a support element; an insulation element disposed adjacent the support element; and a header element formed integral with the support element.

39. The wall panel of claim 38, wherein the support element comprises a first mating portion, the sealant groove formed in the first mating portion.

40. A wall panel, comprising: a support element having a sealant groove formed therein; and an insulation element disposed adjacent the support element.

41. A wall panel, comprising: a support element; an insulation element to be disposed adjacent the support element; and one or more nailers disposed in the insulation element.

42. The wall panel of claim 41, the one or more nailers secured to the support element.

43. The wall panel of claim 41, further comprising a header and a footer, the one or more nailers secured to the header and the footer.

44. The wall panel of claim 43, wherein the header and footer are integral with the support element.

45. A wall panel, comprising: a support element having one or more ribs, the one or more ribs protruding from the support element in a bowed out shape; and an insulation element disposed adjacent the one or more ribs.

46. A wall panel, comprising: a support element; an insulation element to be adjacent the support element; and a support shelf integral with the support element.

47. An insulation element for a wall panel, comprising: one or more rib voids; and one or more rib rebar seats disposed in each of the one or more rib voids.

48. The insulation element of claim 47, wherein the one or more rebar seats disposed in each of the one or more rib voids includes three rebar seats.

49. The insulation element of claim 47, further comprising one or more mechanical chases.

50. The insulation element of claim 47, further comprising one or more nailer voids.

51. An insulation element for a wall panel, comprising: a top surface; and one or more panel securing holders adjacent the top surface.

52. The insulation element of claim 51, wherein the one or more panel securing holders includes two panel securing holders.

53. The insulation element of claim 51, further comprising one or more knockouts protruding from the top surface.

54. The insulation element of claim 53, further comprising one or more mechanical chases, each of the one or more knockouts positioned above a different one of the one or more mechanical chases.

55. An insulation element for a wall panel, comprising: a bottom surface; and one or more footer rebar seats adjacent the bottom surface.

56. The insulation element of claim 55, wherein the one or more footer rebar seats includes two rebar seats.