Method and apparatus for fabricating a low density wall panel with interior surface finished
A fabricated low density concrete foundation/wall panel is provided with a plurality of insulation panels and reinforcing ribs to improve strength and reduce the density of the wall panel. The wall panels are easily placed and interconnected together to quickly provide a foundation adapted to support the main walls of a home, for example. The fabricated wall panels in one embodiment generally includes an inner wall sheathing that is interconnected to the load-supporting segments of the wall panel during fabrication.
This application claims the benefit of U.S. Provisional Patent Application Ser. Nos. 60/697,169 and 60/744,736, filed Jul. 6, 2005 and Apr. 12, 2006, respectively, which are incorporated by reference in their entireties herein. This application is also related to pending U.S. patent application Ser. No. 11/096,705, which is a continuation-in-part of pending U.S. patent application Ser. No. 10/772,148, filed Feb. 3, 2004, which is a continuation-in-part of pending U.S. patent application Ser. No. 10/423,286, filed Apr. 24, 2003, which is a continuation-in-part of U.S. patent application Ser. No. 10/150,465, now U.S. Pat. No. 6,729,090, filed May 17, 2002, which is a continuation-in-part of U.S. patent application Ser. No. 10/093,292, now U.S. Pat. No. 6,701,683, filed Mar. 6, 2002, each of the pending applications or issued patents being incorporated by reference in their entirety herein.
FIELD OF THE INVENTIONThe present invention relates to building components, and more specifically low density concrete wall panels that are manufactured in a controlled environment and can be selectively interconnected on-site to fabricate modular buildings.
BACKGROUND OF THE INVENTIONDue 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.
The relatively large weight per square foot of building panels of the prior art has resulted in high expenses arising not only from the amount of materials needed for fabrication, but also the cost of transporting and erecting the modules. Module weight also places effective limits on the height of structures, such as stacked modules e.g., due to load limitations of the building foundations, footings and/or lowermost modules. Furthermore, there is substantial fabrication labor expense that can arise from design, material, and labor costs associated with providing and placing reinforcement materials. Accordingly, it would be useful to provide a wall panel system for modular construction that is relatively light, can be readily stacked to increased heights and, preferably, inexpensive to design, manufacture, transport and erect.
In many situations panels or modules are situated in locations where it is desirable to have openings therethrough to accommodate doorways, windows, cables, pipes and the like. In some previous approaches, panels were required to be specially designed and cast so as to include any necessary openings, requiring careful planning and design, thus increasing costs due to the special, non-standard configuration of such panels. In other approaches, panels were cast without such openings and the openings were formed after casting, e.g. by sawing or similar procedures. Such post-casting procedures such as cutting, particularly through the thick and/or steel-reinforced panels as described above, is a relatively labor-intensive and expensive process. In many processes for creating openings, there is a relatively high potential for cracking or splitting of the panel or module. Accordingly, it would be useful to provide panels and modules wherein openings such as doors and windows may be integrated in desired locations with a reduced potential for cracking or splitting.
One other problem associated with metallic wire or bar materials used in conjunction with concrete is the varying rates of expansion and contraction. Thus, with extreme heating and cooling the embedded metallic materials tend to separate from the concrete, thus creating cracks which may lead to exposure to moisture and the eventual degradation of both the concrete and wire reinforcement due to corrosion.
One example of a composite building panel that attempts to resolve the aforementioned problems inherent in modular panel construction of the prior art is described in U.S. Pat. No. 6,202,375 to Kleinschmidt (the '375 patent), which is incorporated by reference in its entirety herein. In this invention, a building system is provided that utilizes an insulative core with an interior and exterior sheet of concrete and which is held together with a metallic wire mesh positioned on both sides of an insulative core. The wire mesh is embedded in concrete, and held together by a plurality of metallic wires extending through the insulative core at a right angle to the longitudinal plane of the insulative core and concrete panels. Although providing an advantage over homogenous concrete panels, the composite panel disclosed in the '375 patent does not provide the necessary strength and stiffness properties required during transportation and in high wind environments. Further, the metallic wire mesh materials are susceptible to corrosion when exposed to water during fabrication, and have poor insulative qualities due to the high heat transfer properties of metallic wire. Thus, the panels disclosed in the '375 patent may be more susceptible to failure when exposed to stresses during transportation, assembly or subsequent use.
In addition, attempts have been made to employ improved building materials that incorporate carbon fiber. For example, in U.S. Pat. No. 6,230,465 to Messenger, et al., which is incorporated herein in its entirety by reference, discloses concrete with a carbon fiber and steel reinforced precast frame. Unfortunately, the insulative properties of this invention are relatively poor due to the physical nature of the concrete and steel. Further, the excessive weight of the panels and inherent problems associated with transportation, stacking, etc. are present. Previously known prefabricated building panels have also not been found to have sufficient tensile and compressive strength when utilizing only concrete insulative foam materials or wire mesh. Thus, there is a significant need for a lightweight concrete building panel that has increased tensile and compressive strength, and which utilizes one or more commonly known building materials to achieve this purpose.
Furthermore, there is a need for a precast concrete foundation wall system that can be directly positioned on a prepared soil gravel or sand surface and interconnected to one or more foundation walls. After interconnection, a concrete floor can be poured which is operatively interconnected to the foundation walls and provides additional support.
Accordingly, there is a significant need in the construction and building industry to provide composite building panel walls and foundation walls that may be used in modular construction that are lightweight, that provide superior strength and that have high insulative values. Further, a method of making these types of building panels is needed that is inexpensive, utilizes commonly known manufacturing equipment, and which can be used to mass produce building panels for use in the modular construction of warehouses, low cost permanent housing, hotels, and other buildings. Finally there is a significant need for a precast foundation wall system that can be positioned on a prepared soil or gravel surface and operably interconnected to a poured concrete floor without utilizing onsite forms or other expensive building techniques.
SUMMARY OF THE INVENTIONIt is one aspect of the present invention to provide a composite wall panel that has superior strength, high insulating properties, is lightweight for transportation and stacking purposes and is cost effective to manufacture. As used herein the term foundation wall panel, wall panel, foundation/wall panel all refer to a manufactured, low density wall comprised at least partially of concrete and which can be utilized as a foundation wall or any other wall in a commercial or residential structure. Thus, in one embodiment of the present invention, a substantially planar insulative core with interior and exterior surfaces is positioned between concrete panels that are reinforced with carbon fiber grids positioned substantially adjacent to the insulative core. In a preferred embodiment of the present invention, the interior layer of concrete is comprised of a low-density concrete. Furthermore, as used herein, insulative core may comprise any type of material that is thermally efficient and has a low heat transfer coefficient. These materials may include, but are not limited to, Styrofoam®-type materials such as expanded polystyrenes, extruded polystyrenes, extruded polypropylene, polyisocyanurate, combinations thereof and other materials, including wood materials, rubbers, and other materials well known in the construction industry.
It is a further aspect of the present invention to provide a lightweight, composite concrete wall panel that is adapted to be selectively interconnected to a structural steel frame. Thus, in one embodiment of the present invention attachment hardware is selectively positioned within the wall panel during fabrication that is used to quickly and efficiently interconnect the panel to a structural frame.
It is another aspect of the present invention to provide a low density concrete wall panel that has sufficient compressive strength to allow a second building panel to be stacked in a vertical relationship, on which can support a vertical load in the form of a floor truss or other structural member. Alternately, it is another related aspect of the present invention to provide a composite lightweight wall panel that can be utilized in a corner adjacent to a second wall panel, or aligned horizontally with a plurality of wall panels in a side by side relationship.
It is still yet another aspect of the present invention to provide a composite wall panel that can be easily modified to accept any number of interior textures, surfaces or cladding materials for use in a plurality of applications. Thus, the present invention is capable of being finished with a stucco, siding, brick, drywall other type of interior or exterior surface.
It is yet another aspect of the present invention to provide a composite modular wall panel that can be used to quickly and efficiently construct modular buildings and temporary shelters and is designed to be completely functional with regard to electrical wiring and other utilities such as telephone lines, etc. Thus, the present invention in one embodiment includes at least one utility line which is positioned at least partially within the composite wall panel and which accepts substantially any type of utility line which may be required in residential or commercial construction, and which can be quickly interconnected to exterior service lines. This utility line may be oriented in one or more directions and is generally positioned near the interior surface of the foundation wall panel.
It is yet another aspect of the present invention to provide a novel configuration of the insulative core that assures a preferred spacing between the insulative core and the reinforcing ribs. More specifically, the spacing is designed to provide a gap between the insulative core panels to assure that concrete carbon fiber stirrups and/or metallic reinforcing bars are properly positioned between the insulative core panels. This improved and consistent spacing enhances the strength and durability of the panel
It is still yet another aspect of the present invention to provide an insulated concrete wall panel that is comprised of a exterior face wall with a plurality of reinforcing ribs emanating therefrom. The space between the ribs receives foam insulation, thereby increasing the insulative properties of the wall panel and reducing the overall density of the wall panel. The exterior face in one embodiment of the invention is additionally strengthened with at least one carbon fiber grid that generally extends horizontally therethrough. During fabrication, the carbon fiber band is preferably tensioned between about 500-3000 lbs. so that once released the carbon fiber band will retract somewhat, thus placing the hardening concrete in a compressed state. The wall panel may also include a footer positioned adjacent to a top edge and a bearing pad positioned at a bottom edge. The footer provides a location for the placement of main building walls and the bearing pad is designed to increase the footprint of the wall panel on a soil or pea stone, and which subsequently becomes operably interconnected to the concrete floor surface.
It is still yet another aspect of the present invention to provide an insulative panel that is quickly manufactured and durable. More specifically, one embodiment of the present invention is manufactured in an exterior face up configuration. As used herein, “face up” configuration refers to the exterior surface of the foundation wall panel being in an uppermost portion of the casting form during fabrication. This configuration allows for the efficient placement of the insulative foam panels, reinforcing strands and carbon fiber grid material. Alternatively, a panel of Dens-Armor, traditional gypsum, drywall, or other building material may be placed in the fixture initially and the remaining members of the wall placed thereon to yield a wall panel with a completed interior wall. Since the wall panel is substantially comprised of a concrete base material, the finished product is fire resistant, substantially maintenance free, mold resistant, insect proof, wind resistant and projectile resistant. To increase the fire and smoke resistance of the panel, a fire and smoke resistant surface may be affixed to the insulative foam. In addition, the use of insulation in-between the ribs provides a foundation wall panel that is insulated, in one embodiment having an R factor of about 20 or more. Further, with proper treatment of the concrete, the foundation wall panel is substantially water resistant.
Thus, in one embodiment of the present invention, a low density concrete wall panel is provided, comprising:
a concrete exterior face wall extending between said first end and said second end;
a plurality of foam panels positioned adjacent to said concrete exterior face wall, said plurality of foam panels operably spaced to define a reinforcing rib between each of said foam panels which is filled with concrete;
at least one reinforcing rod positioned within each of said reinforcing ribs; and
an interior sheathing material interconnected to said plurality of foam panels on a side opposite said exterior face wall.
Alternatively, it is another aspect of the present invention to provide a method of manufacturing a low density, concrete building wall wherein the interior face material is poured during the manufacturing process. More specifically, rather than interconnecting one or more foam panels to an interior face material such as Dens-Armor or drywall sheets, the gypsum or other interior face material may first be poured within the casting form, and preferably on a plastic sheeting material. Once the gypsum or other material has been poured, the foam panels can be positioned on top of the interior face material, and the concrete subsequently poured within the channels and around the perimeter edges of the building panel as previously described. That it is another aspect of the present invention to provide a method of manufacturing a low density concrete foundation/wall panel, comprising:
a) providing a casting form having a first end, a second end, and lateral edges extending therebetween;
b) positioning a flexible plastic material within the confines of the form;
c) interconnecting at least one foam core panel to an interior face building material;
d) positioning the at least one foam core panel and said interior face building material within said form on said flexible plastic material, wherein a channel is formed between two of said foam core panels;
e) positioning at least one reinforcing bar in said channel;
f) providing a layer of concrete within said channels and on an upper surface of said at least one foam core panel;
g) curing said concrete; and
h) removing said lightweight, concrete building panel from said form.
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 DRAWINGSThe accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above and the detailed description of the drawings given below, serve to explain the principles of these inventions.
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.
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As shown in the drawing, in one embodiment a recessed joint fastener which utilizes a bolt or other attachment hardware is utilized to properly interconnect the joints. Furthermore, a gasket or other sealing means may be positioned within the joint to provide a waterproof seal between the two wall panels at the juncture of the joints and, to assure there is no penetration from exterior moisture. In one embodiment, the gasket may be a bentonite material, a polyethylene material, rubber, caulking compound or other sealing materials well known in the art. As additionally shown in
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In an alternative embodiment of the present invention, it is anticipated that gypsum, drywall materials or other building materials could actually be poured into the casting form as opposed to interconnecting the exterior sheathing materials to the foam panels. Once the interior sheathing material is poured into the casting form, the foam panels can be positioned on top of the interior sheathing material, the rebar positioned within the channels created by the foam panels, and the concrete subsequently poured. Thus, in this embodiment the step of interconnecting the foam panels to a rigid interior face material would be eliminated.
In another aspect of the invention not identified in
As generally provided in the drawings and photographs, foundation/wall panels are shown in a variety of embodiments. More specifically, foundation wall panels may be formed in a variety of shapes and sizes depending on the application and design criteria. In addition, the foundation wall panels may be arranged such that they are interconnectable, or have a bend integrated therein, such that a plurality of angled walls are provided by one panel. Further, it should be understood by one skilled in the art that a plurality of apertures 46 may be integrated into the wall panel(s) 2 so that conduits for electrical lines, sewage lines and/or water lines may be accommodated.
In addition, reinforcing bars preferably span substantially the entire height of the foundation wall panel 2. More specifically, one embodiment of the present invention includes reinforcing bars that are integrated into the reinforcing ribs of the panel from the plate to the shoe, i.e. lateral edge to lateral edge, providing additional strength and rigidity.
Other embodiments of the present invention include reinforcing bars integrated horizontally between a first and second end of the wall panel. One skilled in the art will appreciate that the horizontal reinforcing bars and the longitudinal reinforcing bars may be interconnected to increase strength and rigidity. In addition, carbon fiber may be added to the ribs, the shoe, and/or the plate, in conjunction with steel reinforcing bars or alone, to increase the wall panel strength. Further, foundation/wall panels as contemplated by the present invention may also include lifters and inserts that receive a lifting device to facilitate transportation and erection of the foundation wall panels 2.
Furthermore, an interconnection scheme employed in certain embodiments of the present invention is shown. More specifically, one embodiment of the foundation wall panels may be interconnected via a bolt or other attachment hardware. Preferably, the foundation wall panels include an angled outer edge that engages a matching angled edge of an adjacent foundation wall panel. These edges are similar to that of miter joints as known in the art. Bolt pockets may also be provided that are located adjacent to the upper edge and the lower edge of the foundation wall panels for interconnection. The bolt pockets allow for the insertion of a fastener, such as a bolt through coincident apertures on each wall panel. The adjacent foundation wall panels can then be securely interconnected by a nut or other attachment hardware known in the art. Alternatively, welding may be utilized to prevent movement of the two panels. In addition, steel plates may be included, affixed to either an inner corner or an outer corner of the finished interconnected joint, to add increased strength thereto. These plates are interconnected to the foundation wall panels via fasteners, such as bolts, or alternatively welded.
As further provided, one method of constructing the insulative foundation panel is shown and described. Embodiments of the present invention are constructed with the exterior surface “face up”, which is believed novel. Initially, the insulation panels are placed in the casting form, wherein the reinforcing ribs are defined by the spaces between the insulative panels. Reinforcing bars are then positioned within the space for the reinforcing ribs. Concrete is then poured into the space. One skilled in the art will appreciate that additional steps, such as vibration, may be employed to ensure that the consistency of the concrete is per specification, and to improve the density of the concrete. Finally, wood, foam, or metal screw strips may be applied along the edges of the ribs. Although not shown, the insulative foundation panel may include a footer and a bearing pad that is placed when the ribs are formed, and which may be tied into the face wall with reinforcing bar and stirrups as well. The footer may subsequently be covered at least partially with concrete when the concrete floor is poured during installation at the building site, thus providing additional structural support.
With regard to the concrete utilized in various embodiments of the present application, the face wall and associated ribs may be comprised of a low density concrete such as Cret-o-Lite™, which is manufactured by Advanced Materials Company of Hamburg, N.Y. This is an air dried cellular concrete that is nailable, drillable, screwable, sawable and very fire resistant. In a preferred embodiment, the face wall is comprised of a dense concrete material to resist moisture penetration and in one embodiment is created using VISCO CRETE™ or equal product, which is a chemical that enables the high slumped short pot life liquification of concrete to enable the concrete to be placed in narrow wall cavities with minimum vibration and thus create a high density substantially impermeable concrete layer. VISCO-CRETE™ is manufactured by the Sika Corporation, located in Lyndhurst, N.J. The face wall is preferably about 2 inches thick. This concrete layer has a compression strength of approximately 5000 psi after 28 days of curing.
Positioned within the ribs is one or more reinforcing bars “rebar”, which are generally manufactured from carbon steel or other similar metallic materials. Preferably, the reinforcing bar has a diameter of at least about 0.25 inches, and more preferably about 0.75-1.50 inches. As appreciated by one skilled in the art, the reinforcing bars may be any variety of dimensions or lengths depending on the length and width of the wall panel, and the strength requirements necessary for any given project.
The foregoing description of the present invention has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the invention to the form disclosed herein. Consequently, variations and modifications commenced here with the above teachings and the skill or knowledge of the relevant art are within the scope in the present invention. The embodiments described herein above are further extended to explain best modes known for practicing the invention and to enable others skilled in the art to utilize the invention in such, or other, embodiments or various modifications required by the particular applications or uses of present invention. It is intended that the dependent claims be construed to include all possible embodiments to the extent permitted by the prior art.
Claims
1. A low density, concrete wall panel having a first end, a second end and laterals edges extending therebetween, comprising:
- a concrete exterior face wall extending between said first end and said second end;
- a plurality of foam panels positioned adjacent to said concrete exterior face wall, said plurality of foam panels operably spaced to define a reinforcing rib between each of said foam panels which is filled with concrete;
- at least one reinforcing rod positioned within each of said reinforcing ribs; and
- an interior sheathing material interconnected to said plurality of foam panels on a side opposite said exterior face wall.
2. The low density wall panel of claim 1, further comprising a reinforcing rib extending around a perimeter edge of said wall panel, said reinforcing rib comprised of concrete and a metal reinforcement material.
3. The low density wall panel of claim 1, further comprising a plurality of utility channels extending at least partially between said first end and said second end which are adapted to receive electrical wiring, piping or other utilities.
4. The low density wall panel of claim 1, further comprising a lifting lug interconnected to at least one of said first end and said second end.
5. The low density wall panel of claim 1, wherein said perimeter edges are comprised of concrete extending from said exterior face wall to said interior face wall.
6. A method for fabricating a low density concrete building panel, comprising the steps of:
- a) providing a casting form having a first end, a second end, and lateral edges extending therebetween;
- b) positioning a flexible plastic material within the confines of the form;
- c) interconnecting at least one foam core panel to an interior face building material;
- d) positioning the at least one foam core panel and said interior face building material within said form on said flexible plastic material, wherein a channel is formed between two of said foam core panels;
- e) positioning at least one reinforcing bar in said channel;
- f) providing a layer of concrete within said chapels and on an upper surface of said at least one foam core panel;
- g) curing said concrete; and
- h) removing said lightweight, concrete building panel from said form.
7. The method of claim 6, further comprising the step of positioning an interior frame within said casting form prior to said providing a layer of concrete, wherein an opening for a window or a door is provided.
8. The method of claim 6, further comprising the step of positioning at least one lift anchor within said concrete building panel to facilitate the removal of said lightweight building panel from said casting form.
9. The method of claim 6, wherein said foam core is comprised of at least one of an expanded polystyrene material, an extruded polypropylene and a polyisocyanurate material.
10. The method of claim 6, further comprising the step of reinforcing at least one of a plurality of perimeter edges of said concrete building panel with at least one of a metallic reinforcing bar and a carbon fiber material.
11. The method of claim 6, further comprising the step of vibrating said first concrete material, wherein a density of said first concrete material is increased.
12. The method of claim 6, wherein interconnection of said at least one foam core panel and said interior face building material is accomplished within the casting form.
13. The method of claim 12, where said interior face building material is poured within said casting form during fabrication of the low density building panel.
14. A low density fabricated concrete wall panel, comprising an upper end, a lower end and lateral edges extending between, comprising:
- an interior sheathing material positioned substantially between said upper end, said lower end and said lateral edges;
- a plurality of foam panels positioned adjacent to said interior sheathing material and oriented to define a space between said at least two of said plurality of foam panels between said upper end and said lower end;
- a cavity extending within at least one of said plurality of foam panels between said upper end and said lower end, said cavity adapted to receive a utility;
- a concrete material positioned on an exterior surface of said plurality of foam panels to define an exterior face and within said space between said at least two of said plurality of foam panels to define a reinforcing rib.
15. The low density wall panel of claim 14, wherein said sheathing material is comprised at least partially of a gypsum material.
16. The low density wall panel of claim 14, wherein said plurality of foam panels are comprised of at least one of an expanded polystyrene material, an extruded polypropylene and a polyisocyanurate material.
17. The low density wall panel of claim 14, further comprising a metallic rod positioned within said space and formed between said at least two of said plurality of foam panels.
18. The low density wall panel of claim 14, Further comprising a lift anchor positioned along a perimeter edge to facilitate lifting the low density wall panel.
Type: Application
Filed: Jul 6, 2006
Publication Date: Jun 28, 2007
Inventors: Harold Messenger (Rehoboth, MA), Thomas Rotondo (Harwinton, CT)
Application Number: 11/456,057
International Classification: E04C 1/00 (20060101);