Lightweight concrete composite wall panels
Unitary lightweight concrete composite wall panels include a frame filled with lightweight composite concrete. The wall panels may be used in the construction of either interior or exterior walls, and a wall panel may be configured as a load bearing or non load bearing. The size of a wall panel ranges from an individual wall panel forming a portion of a wall to a wall panel spanning an entire wall length, thereby furnishing a single complete wall. A wall panel may further be configured to support either a window or door.
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This application is a continuation-in-part of application Ser. No. 10/374,886, filed Feb. 26, 2003, which was a continuation-in-part of U.S. Pat. No. 6,827,570 B2, issued Dec. 7, 2004.
This present application claims all available benefit, under 35 U.S.C. § 119(e), of U.S. provisional patent application Ser. No. 60/604,947, filed Aug. 27, 2004. By this reference, the full disclosure of U.S. provisional patent application Ser. No. 60/604,947 is incorporated herein as though now set forth in its entirety.
BACKGROUND OF THE INVENTION1. Field of the Invention
The present invention relates to lightweight concrete and, more particularly, but not by way of limitation, to unitary lightweight concrete composite wall panels.
2. Description of the Related Art
The primary building materials utilized today are wood and concrete. Wood unfortunately has become extremely expensive due to reduced supplies caused by restrictions resulting from today's environmentally conscious society. Further, wood often does not provide the structural safety available from other building materials, such as concrete. Concrete is unfortunately expensive, which restricts its use to projects requiring the structural safety advantages associated with concrete.
Thus, the building industry constantly seeks to reduce building costs while at least meeting or actually improving upon structural safety standards. One such improved product consists of lightweight concrete, which is composed of water, cement, and polystyrene. Lightweight concrete provides reduced costs in materials by replacing cement with less expensive polystyrene. Lightweight concrete further provides structural safety comparable to cement and improved over wood.
Lightweight concrete is currently formed in blocks that are stacked and then secured together to form building walls. Lightweight concrete is currently not employed in the form of wall panels, whereby one panel may form an interior or exterior load or non-load bearing wall or multiple wall panels placed side by side and secured together comprise an interior or exterior load or non-load bearing wall. Accordingly, unitary lightweight concrete composite wall panels that are easy to manufacture and are suitable for use in constructing interior or exterior load or non-load bearing walls would significantly improve over current building materials.
SUMMARY OF THE INVENTIONIn accordance with the present invention, a unitary lightweight concrete composite wall panel includes a frame and lightweight concrete composite disposed within the frame wherein upon curing the lightweight concrete composite adheres to the frame, thereby forming the wall panel. The unitary lightweight concrete composite wall panel further includes at least one reinforcing bar disposed within the lightweight concrete composite. The frame may include apertures that receive the at least one reinforcing bar therethrough to secure the at least one reinforcing bar to the frame.
The unitary lightweight concrete composite wall panel still further includes at least one conduit disposed within the lightweight concrete composite wherein the at least one conduit includes at least one opening communicating exterior to the wall panel. The at least one conduit includes at least one end connected to an electrical box disposed within the lightweight concrete composite wherein the at least one conduit receives electrical wiring therethrough. The at least one conduit may also comprise plumbing piping or an air duct.
The frame includes at least a first side, a second side, and a third side. More particularly, the frame includes a top end, a bottom end, a first side, and a second side. The top end, the bottom end, the first side, and the second side each are U-shaped to maximize the surface area engaged by the lightweight concrete composite. The frame may further include a first support member coupled to the top end and the bottom end. The frame may still further include at least one second support member coupled to one of the first side or the second side and the first support member.
The frame may be configured to receive therein a window frame or a door frame. The frame accordingly includes a header, a first side, and a second side. The frame may further include a footer. The header, the first side, and the second side each are U-shaped to maximize the surface area engaged by the lightweight concrete composite.
It is therefore an object of the present invention to provide unitary lightweight concrete composite wall panels suitable for constructing structures.
Still other objects, features, and advantages of the present invention will become evident to those of ordinary skill in the art in light of the following.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing invention is a unitary lightweight concrete composite wall panel. The wall panel may be used in the construction of either interior or exterior walls. A wall panel may be configured as a load bearing or non-load bearing wall. The size of a wall panel ranges from an individual wall panel forming a portion of a wall to a wall panel spanning an entire wall length thereby furnishing a single complete wall.
As illustrated in
As described more fully herein, a frame 121 is placed into a form and a form-loading station screeds lightweight concrete composite 127 into the frame 121. The lightweight concrete composite 127 is compressed and then cured thereby forming a finished wall panel 120 when the frame 121 and cured lightweight concrete composite 127 are removed from the form. As illustrated in
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As described more fully herein, a frame 151 is placed into a form and a form-loading station screeds lightweight concrete composite 157 into the frame 151. The lightweight concrete composite 157 is compressed and then cured thereby forming a finished wall panel 150 when the frame 151 and cured lightweight concrete composite 157 are removed from the form. The wall panel 150 may also include electrical conduit and boxes 201 as well as items normally used inside building walls, such as plumbing piping, air ducts, and the like.
As illustrated in
As illustrated in
In the preferred embodiment, the bottom assembly 11 is a rectangular plate 14 with two sidewalls 15 and two endwalls 16. Each sidewall 15 is hingedly attached along a respective long length of the rectangular plate 14. Furthermore, the long edge of each sidewall 15 terminates in an L-shaped lip. Also, T-shaped latches 18 are hingedly attached to each corner of each sidewall 15, which rotate between locked and unlocked positions. Those of ordinary skill in the art should understand that the interior of the bottom assembly 11 may be shaped to house any one of the frames 121, 131, 141, and 151.
Referring to
To assemble the bottom assembly 11, the sidewalls 15 rotate up to a vertical position, thereby forming a rectangular box. Next, the latches 18 rotate to the locked position and couple with the catches 19, thereby securing the bottom assembly 11. This will be referred to as the assembled position. To disassemble the bottom assembly, the latches 18 uncouple from the catches 19 and the sidewalls 15 rotate down to a horizontal position. This will be referred to as the disassembled position.
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The form-loading station 3 includes a cap removal/replacement assembly 30 and a screed assembly 40. Referring to
The screed assembly 40 includes a frame 50 having supporting legs and screed tracks 50A attached thereto. The legs mount to the foundation on either side of the conveying system 3 by any suitable means, such as brackets attached to each leg and bolts sunk into a foundation. The screed assembly 40 further includes a screed box 41, a leveling hopper 42, an auger 43, a screed motor 44, two leveling cylinders 45, a screed cylinder 46, a filling conveyor 47, and a mounting bracket 48. The screed box 41 is a rectangular with an open top and a slot in the bottom the same size as the top opening of the form 10. The edges of the screed box 41 rest within the screed tracks 50A, which run perpendicular to the loading conveyor 8a. The screed cylinder 46 is connected to the frame 50 between an end of the screed track 50A and a side of the screed box 41. When the screed cylinder 46 extends, it slides the screed box 41 directly over the loading conveyor 8A, which will be referred to as the loading position. When the screed cylinder 46 retracts, it slides the screed box 41 to a position adjacent the loading conveyor 8A, which will be referred to as the retracted position.
The leveling hopper 42 resides inside the screed box 41. The two leveling cylinders 45, which are any suitable hydraulically or pneumatically operated cylinders, connect from the screed box 41 to the leveling hopper 42 using a mounting bracket 48. The leveling cylinders 45 extend and retract their pistons to slide the leveling hopper 42 inside the screed box 41. The auger 43 is mounted inside the leveling hopper 42 using any suitable means, such as bearings. The screed motor 44 is coupled to the end of the auger 43 through a lengthwise slot in the screed box 41. The slot allows the screed motor 44 and auger 43 to slide along with the leveling hopper 42 when the leveling cylinders 45 extend and retract. Those of ordinary skill in the art should understand that the interior of the leveling hopper 42 may be shaped to deliver lightweight concrete composite into any one of the frames 121, 131, 141, and 151.
In operation, the first station conveyor 7a conveys a form 10 onto a disabled loading conveyor 8a. When the form 10 arrives at the form-filling station 3, the bottom assembly 11 is in the assembled position with the cap 12 resting on top in the unlocked position. The lifting cylinder 31 begins in the engagement position so that, as the form 10 arrives at the form filling station 3, the short lifting rail 33 and the tall lifting rail 33 engage a corresponding tall cap bracket 26 and a short cap bracket 25. Upon conveyance onto the loading conveyor 8a, the form 10 engages a micro-switch that outputs a signal that overrides the first station conveyor 7a. Thus, first station conveyor 7a remains disabled during the filling of the form 10. The micro-switch further outputs a signal that retracts the lifting cylinder 31 to the raised position, thereby removing the cap 12. With the cap 12 removed, an operator inserts a desired frame 121, 131, 141, or 151 and all necessary electrical conduit or electrical boxes into the form. Next, the lifting cylinder 31, in its retracted position, engages a micro-switch that outputs a signal directing the screed cylinder 46 to extend the screed box 41 to the loading position directly over the bottom assembly 11. In the loading position, the leveling hopper 42 is located directly underneath a filling conveyor 47, which is any suitable conveyor, such as a belt conveyor. As the screed box 40 reaches the loading position, it engages a micro-switch, which outputs a signal that opens a lightweight concrete composite source and activates the filling conveyor 47 to deliver the lightweight concrete composite to the leveling hopper 42. The lightweight concrete composite source in the preferred embodiment is the lightweight concrete composite source disclosed in U.S. patent application Ser. No. 09/887,369. The micro-switch further outputs a signal that activates the screed motor 44, thereby rotating the auger 43 to evenly distribute the lightweight concrete composite throughout the leveling hopper 42. A micro-switch positioned within the leveling hopper 42 or the lightweight concrete composite source senses when either the leveling hopper 42 is full or the lightweight concrete composite source is empty. Upon sensing either condition, the micro-switch outputs a signal closing the lightweight concrete composite source and deactivating the filling conveyor 47 and the screed motor 44.
As generally illustrated in
The form assembly station 4 is a manually operated station. First, the operator depresses the cap 12 onto the bottom assembly 12, thereby compressing the lightweight concrete composite within the form. Next, the operator couples the latches 18 of the cap 12 to the catches of the bottom assembly 11, thereby sealing the form. Finally, the operator delivers the form from the first roller conveyor 9a to the second station conveyor 7b to convey the form through the curing oven. While a manually operated form assembly station 4 is disclosed, those of ordinary skill in the art will recognize that the form assembly station 4 may be automated.
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The cap removal/lockdown assembly 60 includes lifting cylinders 61, lifting rails 62, rail rods 63, pivot rods 64, support brackets 65, lockdown rods 66, and lockdown rails 67. The lifting cylinders 61 are vertically suspended directly above the frame for extending and retracting from a raised position to an engagement position. The lifting rails 62 are C-shaped rails attached to the ends of the lifting cylinders 61 for engaging the cap brackets 20 of the form 10. Support brackets 65 attached to the frame 160 couple with the pivot rods 64 by any suitable means, such as bearings, so that the pivot rods 64 rotate freely. The rail rods 63 fixedly attach by any suitable means, such as welding, to the pivot rods 64, thereby extending perpendicularly to hingedly attach to the lifting rails 62. The lockdown rods 66 are fixedly attached to the ends of the pivot rods 64 opposite the rail rods 63, thereby extending perpendicularly to hingedly attach to the lockdown rails 67. The lockdown rails 67 are L-shaped channels with a locking tab 68 attached in the center by any suitable means, such as welding, for engaging the pins 24 of the form 10. When the lifting cylinders 61 extend, the lifting rails 62 lower to a position where they may engage the cap brackets 20. Simultaneously, the rail rods 63 rotate the pivot rods 64, which rotate the lockdown rods 66, thereby raising the lockdown rails 67 to a level sufficient to clear any forms 10 located on the unloading conveyor 8b. This position will be referred to as the engagement position. Oppositely, when the lifting cylinders 61 retract, thereby raising the lifting rails 62 to remove the cap 12, the lockdown rails 67 lower to engage the pins 24 of the bottom assembly 11. This will be referred to as the lockdown position.
The dispatch assembly 70 includes dispatch cylinders 71, mounting brackets 72, and a ram plate 73. The dispatch cylinders 71 mount horizontally to the frame 160 via the mounting brackets 72. Both dispatch cylinders 71 are hingedly attached to the ram plate 73, whereby the ram plate 73 can rotate between a ram position and a bypass position. When the dispatch cylinders 71 extend, the ram plate 73 remains in a vertical position to strike a concrete composite block 10A and push the concrete composite block 10A onto the dispatch conveyor 51, which will be referred to as the ram position. When the dispatch cylinders 71 retract, the ram plate 73 rotates to a horizontal position to bypass the form 10, which will be referred to as the bypass position.
In operation, the second station conveyor 7b delivers a form 10 onto a disabled unloading conveyor 8b. The forms 10 are spaced along the conveyor system 2 such that a form 10 enters the block removal station 6 at the same time another form 10 enters the form-loading station 3. Consequently, the block removal station 6 controls the stopping and starting of the first station conveyor 7a. Nevertheless, those of ordinary skill in the art will recognize that the form-loading station 3 could control the first station conveyor 7a. Furthermore, synchronous operation of the block removal station 6 and the form-loading station 3 is disclosed, those of ordinary skill in the art will recognize other control schemes for regulating the movement of the forms through the block removal station 6 and the form-loading station 3.
The lifting cylinders 61 of the cap removal/lockdown assembly 60 begin in the engagement position so that, as the form 10 arrives at the block removal station 6, the cap rails 62 engage the cap brackets 20 of the cap 12. Upon conveyance onto the unloading conveyor 8b, the form 10 engages a micro-switch that outputs a signal that overrides the second station conveyor 7b. Thus, second station conveyor 7b remains disabled during the removal of the block 10A. In addition, the micro-switch outputs a signal that informs an operator to unlock the cap 12 from the bottom assembly 11 by uncoupling the corresponding latches 18 from the catches 19. After this is done, the operator engages a micro-switch that outputs a signal that retracts the lifting cylinders 61 to the lockdown position, thereby removing the cap 12 and locking down the bottom assembly 11. Upon lockdown of the bottom assembly 11, a micro-switch outputs a signal that informs the operator to uncouple the remaining latches 19 on the bottom assembly 11 and rotate the sidewalls 15 down to a horizontal position. Next, the operator engages a micro-switch that outputs a signal to the dispatch cylinders 71 to extend and retract, thereby pushing the finished block 10A onto the dispatch conveyor 51. Then the operator reassembles the bottom assembly 11. Once the finished block 10A is removed and the bottom assembly is reassembled, the operator engages a micro-switch, which outputs a signal to extend the lifting cylinders 61 to the engagement position, thereby placing the cap 12 onto the bottom assembly 11. Finally, the unloading conveyor 8b advances the form to the second roller conveyor 9b to start the process all over again.
A micro-switch control scheme is employed whereby the engaging of various micro-switches controls the conveyor system 2, the form-loading station 3, and the block removal station 6. The micro-switches employed are of a type well known to those of ordinary skill in the art, such as optical sensing switches, pressure switches, mechanically activated switches, and the like. Further, the use of such switches to control the components of the apparatus for manufacturing lightweight concrete composite wall panels 120, 130, 140, and 150 are well known and understood by those of ordinary skill in the art. It should be understood, however, that a computer control scheme could be implemented in the apparatus for manufacturing lightweight concrete composite wall panels 120, 130, 140, and 150.
To assemble the lightweight concrete wall panels 120, 130, 140, and 150 into a functional structure, four types of installation methods are used, standard installation, second level installation, framing installation, and heavy cabinet installation. Standard installation is intended for installation on the first floor of a structure. Second level installation is intended for installation of floors above the first floor. Finally, framing installation is intended for installation of doors and windows, and cabinet installation is intended for the mounting of cabinets onto the lightweight concrete wall panels 120.
In a standard installation, the first step is to erect a support frame. As shown in
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Although the present invention has been described in terms of the foregoing embodiment, such description has been for exemplary purposes only and, as will be apparent to those of ordinary skill in the art, many alternatives, equivalents, and variations of varying degrees will fall within the scope of the present invention. That scope, accordingly, is not to be limited in any respect by the foregoing description; rather, it is defined only by the claims that follow.
Claims
1. A unitary lightweight concrete composite wall panel, comprising:
- a frame; and
- lightweight concrete composite disposed within the frame.
2. The unitary lightweight concrete composite wall panel according to claim 1, wherein upon curing the lightweight concrete composite adheres to the frame, thereby forming the wall panel.
3. The unitary lightweight concrete composite wall panel according to claim 1, further comprising at least one reinforcing bar disposed within the lightweight concrete composite.
4. The unitary lightweight concrete composite wall panel according to claim 3, wherein the frame comprises apertures that receive the at least one reinforcing bar therethrough to secure the at least one reinforcing bar to the frame.
5. The unitary lightweight concrete composite wall panel according to claim 1, wherein the frame comprises at least a first side, a second side, and a third side.
6. The unitary lightweight concrete composite wall panel according to claim 5, wherein the first side, the second side, and the third side each are U-shaped to maximize the surface area engaged by the lightweight concrete composite.
7. The unitary lightweight concrete composite wall panel according to claim 1, wherein the frame comprises a top end, a bottom end, a first side, and a second side.
8. The unitary lightweight concrete composite wall panel according to claim 7, wherein the top end, the bottom end, the first side, and the second side each are U-shaped to maximize the surface area engaged by the lightweight concrete composite.
9. The unitary lightweight concrete composite wall panel according to claim 1, wherein the frame further comprises a first support member coupled to the top end and the bottom end.
10. The unitary lightweight concrete composite wall panel according to claim 9, wherein the frame further comprises at least one second support member coupled to one of the first side or the second side and the first support member.
11. The unitary lightweight concrete composite wall panel according to claim 1, wherein the frame defines an opening that supports a window frame therein.
12. The unitary lightweight concrete composite wall panel according to claim 1, wherein the frame defines an opening that supports a door frame therein.
13. The unitary lightweight concrete composite wall panel according to claim 1, wherein the frame comprises a header, a first side, and a second side.
14. The unitary lightweight concrete composite wall panel according to claim 13, wherein the frame further comprises a footer.
15. The unitary lightweight concrete composite wall panel according to claim 13, wherein the header, the first side, and the second side each are U-shaped to maximize the surface area engaged by the lightweight concrete composite.
16. The unitary lightweight concrete composite wall panel according to claim 1, further comprising at least one conduit disposed within the lightweight concrete composite.
17. The unitary lightweight concrete composite wall panel according to claim 16, wherein the at least one conduit includes at least one opening communicating exterior to the wall panel.
18. The unitary lightweight concrete composite wall panel according to claim 16, wherein the at least one conduit includes at least one end connected to an electrical box disposed within the lightweight concrete composite.
19. The unitary lightweight concrete composite wall panel according to claim 16, wherein the at least one conduit receives electrical wiring therethrough.
20. The unitary lightweight concrete composite wall panel according to claim 16, wherein the at least one conduit comprises plumbing piping.
21. The unitary lightweight concrete composite wall panel according to claim 16, wherein the at least one conduit comprises an air duct.
22. A form for facilitating the curing of lightweight concrete composite into wall panels, comprising:
- a bottom assembly that supports a frame of the wall panel therein; and
- a cap that seats on the bottom assembly, whereby, upon curing, the lightweight concrete composite adheres to the frame, thereby forming the wall panel.
23. The form for facilitating the curing of lightweight concrete composite into wall panels according to claim 22, wherein the bottom assembly comprises:
- walls; and
- mating assemblies that couple the walls, thereby forming the desired shape that is assembled and disassembled.
24. The form for facilitating the curing of lightweight concrete composite into wall panels according to claim 23, wherein the walls comprise:
- two sidewalls located opposite and parallel to each other; and
- two endwalls located opposite and parallel to each other.
25. The form for facilitating the curing of lightweight concrete composite into wall panels according to claim 22, further comprising a mating assembly that couples the bottom assembly with the cap.
26. The form for facilitating the curing of lightweight concrete composite into wall panels according to claim 22, further comprising an insert that shortens the form to produce smaller blocks.
Type: Application
Filed: Aug 22, 2005
Publication Date: Dec 29, 2005
Applicant:
Inventor: Orbin Sumrall (San Antonio, TX)
Application Number: 11/208,937