Method for interlocking molded building panels

Abstract

A method for interlocking building panels that have a channel integrally formed in and substantially coextensive with each panel edge so that abutting panel edges form a generally vertical joint post channel and adjacent panel edges form a generally horizontal beam channel, atop a poured foundation or other supporting structure to fabricate a building wall, which includes the steps of: placing into the supporting structure at the point on the supporting structure where the joint post channels are formed between abutting panels, a first rebar that extends at least partially into the joint post channel; inserting a second rebar into the joint post channel so that a first end is juxtaposed with the extending end of the first rebar, and a second, opposite end extends from the joint post channel; bending the second, extending end of the second rebar so that once bent, it lies in the generally horizontal beam channel intersecting with the joint post channel; and, filling both the generally vertical joint post channel and the generally horizontal beam channel with concrete. Further disclosed is a method for creating openings useful for window and door frames in such construction.

Description

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] The present invention relates in general to the art of building construction and, in particular, to a method for interlocking molded modular building wall panels to fabricate a building and also for interlocking molded modular building wall panels to fabricate openings useful for door and window frames in a building.

[0003] 2. Description of the Prior Art

[0004] A long felt need in the construction industry, and more particularly in the building wall panel field, is to find a durable, yet relatively inexpensive construction method that would allow the construction of structurally sturdy, yet attractive and durable buildings in a quick and economic manner using molded modular building panels.

[0005] Although the thrust of this need has initially been to provide housing for low-income families or for first time home buyers, any such construction method could also be easily adapted for more expensive homes, multi-family housing units, and commercial buildings.

[0006] One such attempt to create such a relatively inexpensive construction method has resulted in the use of precast or molded glass fiber reinforced concrete (GFRC) building panels.

[0007] The development of lightweight precast construction panels has been gradual and not without many shortcomings. Initial attempts to manufacture such panels have met with many problems, for example, during construction of a building, how to interlock such independent, modular building panels into a structural unity.

[0008] Various interlocking methods, designs and inserts have been tried, for example, inserting rebars that have extending ends, which are then used as lashing points for holding the panels in place. Other methods include embedding or inserting bolts and corresponding anchoring nuts into the panels during the molding process so that during construction these bolts and nuts would be aligned and mated to provide for attachment between panels. However, such locking inserts posed new challenges in embedding the insert in the panel so as to produce a consistent and useful building panel capable of general use during the construction process. In many instances, careful planning was required during the manufacturing of the panels to assure that the panels, once assembled, would have the inserts in position for proper interlocking. Each panel was then fairly restricted in its positioning in the structure being fabricated, i.e., a panel designed for a wall could only be abutted by a corresponding wall panel designed for mating with the first wall panel.

[0009] Accordingly, while much work has been done in exploring various methods of interlocking such molded panels by embedding anchoring accessories in the panels during their molding, no current method is known to meet the demands of providing either a universal interlocking system or providing for an overall structural rigidity or unity in the completed building using such modular panels. In addition, these construction methods also require added cost, expertise in properly encasing such reinforcing bars and a greater expertise in the construction team workers installing the panels.

[0010] By way of example, the prior art of casting such GFRC building panels, including such methods of interlocking such panels, is found in such representative references as U.S. Pat. No. 3,885,008 to Martin; U.S. Pat. No. 3,965,635 to Renkert; U.S. Pat. No. 4,185,437 to Robinson; U.S. Pat. No. 4,232,494 to Bauch et al.; U.S. Pat. No. 4,453,359 to Robinson; U.S. Pat. No. 4,531,338 to Donatt; U.S. Pat. No. 4,542,613 to Leyte-Vidal; U.S. Pat. No. 4,691,490 to Leaver; and U.S. Pat. No. 6,182,416 B1 to Bracklin.

[0011] However, these known molding processes are time consuming, labor intensive, and operationally expensive and produce building panels that are not only expensive, but also hard to obtain, leading to long construction delays in building the structures themselves. Likewise, the known interlocking processes used with current building panels are costly, time consuming, and require workers having expertise in connecting the panels into the desired structure.

[0012] The present invention provides a solution to these and other problems of the present art in building structures using molded building panels by providing a construction method for interlocking standardized molded panels that utilizes a minimal amount of skilled labor and that easily interconnects the panels during the construction process to produce a sturdy structure.

[0013] At least in these respects, the method of construction and composition of the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides a method primarily developed for the purpose of interlocking molded building panels in constructing durable and economical housing or other structures in a time and cost efficient manner.

[0014] In these regards, at least, the present invention substantially fulfills these needs of the present art in molded building panel construction.

SUMMARY OF THE INVENTION

[0015] In view of the foregoing disadvantages inherent in the known types of building panels and methods of interlocking such panels now present in the art, the present invention provides an improved method of interlocking molded composite construction panels.

[0016] The panels contemplated in the present method include those panels that have at least one integrally formed channel in their edge portions. The channel may be arcuate or multi-faceted in which case it would preferably be a semi-hexagon in cross-section, that is substantially coextensive with at least one side edge of the panel for construction connection purposes as will be better described below. However, the channel can be of any other cross-sectional shape such as a semi-circle, star, or X shape, just to indicate three acceptable shapes as examples, without limitation. In general, a goal for the choice of channel cross-sectional shape is that when adjacent panels are connected, the abutting channels meet to form a passageway big enough to hold at least one piece of reinforcing bar (rebar) while allowing concrete to be poured into the passageway to form an integral structure for reinforcing the connected panel construction in situ as taught in the present invention for interlocking such panels during construction.

[0017] As such, the general purposes of the present invention, which will be described subsequently in greater detail, are to provide a new and improved method of connecting molded building panels in construction, which has all the advantages of the prior art and none of the disadvantages.

[0018] To attain this, the present invention, in an embodiment for a method of connecting building panels during the construction process, generally includes the steps of:

[0019] placing a first rebar into the foundation at the point on the foundation where the joint post channels are to be formed between abutting panels, the rebar extending at least partially into the joint post channel;

[0020] inserting a second rebar into the joint post channel so that a first end is juxtaposed with the extending end of the first rebar, and a second, opposite end extends out of the joint post channel;

[0021] bending the second, extending end of the second rebar so that once bent, it lies in the generally horizontal beam channel intersecting with the joint post channel; and,

[0022] filling both the generally vertical joint post channel and the generally horizontal beam channel with concrete.

[0023] Also, for additional strength, it is preferred to add an additional step as follows:

[0024] inserting a third rebar in the generally horizontal beam channel across the joint post channel before filling with concrete.

[0025] It should be noted that the strength and flexibility of the method of connecting the panels embodying the present invention can be used throughout a structure for both load supporting and non-load supporting walls, headers and even roofs. In fact, by utilizing the present invention a unitary or connected supporting structure can be created that holds the panels in position in the building.

[0026] There has thus been defined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.

[0027] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.

[0028] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

[0029] It is therefore an object of the present invention to provide a new and improved construction and connection method for molded building panels, which has all the advantages of the prior art of construction using molded building panels and none of the disadvantages.

[0030] It is another object of the present invention to provide a new and improved construction and connection method for molded building panels, which may be easily and efficiently done.

[0031] It is a further object of the present invention to provide a new and improved construction and connection method for molded building panels, which produces a durable and reliable construction.

[0032] An even further object of the present invention is to provide a new and improved construction and connection method for molded building panels, whose design, structure, and construction steps are simplified, while permitting a mastery and optimal control of the molding and interconnecting process for such precast building panels.

[0033] Still yet another object of the present invention is to provide a new and improved construction and connection method for molded building panels, whose use and steps facilitate the construction process.

[0034] Lastly, it is an object of the present invention to provide a new and improved construction and connection method for molded building panels, which is safe for home and commercial construction use.

[0035] These together with other objects of the invention, along with the various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is an illustrated preferred embodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:

[0037] FIG. 1 is a cross sectional view of a molded building panel at the footing that has been constructed in accordance with the principles of the present invention;

[0038] FIG. 2 is a cross-sectional plan view illustrating a construction in accordance with the present invention of two adjoining molded building panels on a foundation;

[0039] FIG. 3 is a top cross-sectional view of two adjoining molded building panels at a construction corner that has been constructed in accordance with the principles of the present invention;

[0040] FIG. 4 is a cross-sectional view illustrating a construction in accordance with the present invention of adjoining molded building panels providing a window frame in the constructed wall on a foundation;

[0041] FIG. 5 is a cross-sectional view illustrating how a molded building panel used as a header panel is secured to a molded wall building panel embodying the present invention;

[0042] FIG. 6 is a cross-sectional view illustrating how a molded building panel used as a footer panel is secured to a molded wall building panel embodying the present invention;

[0043] FIG. 7 is a cross-sectional view illustrating how a molded building panel used as a header panel is secured to a molded wall building panel that incorporates a passageway for wiring and such with the grout dam in place that embodies the present invention; and,

[0044] FIG. 8 is a cross-sectional view, similar to that of FIG. 7, illustrating how a molded building panel used as a header panel is secured to a molded wall building panel that incorporates a passageway for wiring with the grout dam removed that embodies the present invention.

[0045] Similar reference characters refer to similar parts throughout the several views of the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0046] With reference now in the drawings, a new and improved construction method for connecting molded building panels, which embody the principles and concepts of the present invention and generally designated by the reference numerals will be described. For ease in reference, the hundreds position of the reference numeral generally indicates the Figure in which it appears and the remaining digits refer to similar parts throughout the several views of the drawings, i.e., reference numerals 110, 210, 310 all refer to the same general item being described as it appears in FIGS. 1, 2 and 3 respectively.

[0047] To better illustrate the method of the present invention in connecting or interlocking such panels, the construction of such a panel will first be described below.

[0048] Generally, the molded composite construction panel 10 as envisioned for use with the present invention is comprised of a plurality of components that are integrated into a single unit. In some embodiments, such components may include a lightweight internal foam cellular core insert of rigid foam material 12 encased in a relatively thin skin matrix of glass fiber reinforced concrete 14. Relatively thin skin of glass fiber reinforced concrete means, generally, an encasing layer having about {fraction (1/16)} to ½ inch thickness. Many other embodiments of the panels themselves are possible and within the scope of the present invention, including without limitation panels of solid concrete and panels of various other composite structures.

[0049] The components of the panels are individually configured and correlated with respect to each other so as to attain the desired construction or structural objectives for which the panel is being manufactured; that is, the size, shape and composition of the panel may be changed to suit the desired structural demands of the particular job and location of the specific panel. For example, FIG. 4 shows shortened panels 416 and 418 respectively that are intended for use as window headers and footers respectively, while FIG. 5 shows a shortened panel 520 intended for use as a door header.

[0050] Each panel 10 preferably has integrally formed multi-faceted channels 22 that are substantially coextensive with the side edges of the panel as shown in FIGS. 1 to 6. Channels 22 are shown as semi-polygonal in cross-section, such as a semi-hexagon for joining two panels during construction, but may be other shapes as well.

[0051] Testing has shown that while many cross-sectional shapes are useful, the greater the number of facets and planar intersections found in the cross-sectional aspect of the channels, the greater the strength when panels are joined. In the limit, the cross-section of the channels could be a semicircle, so as to form a cylindrical post.

[0052] Generally, as shown in the Figures, channels 22 are butted one to another to form a sealed channel 24. Steel reinforcing bars 44, 46 are placed in the channels and a concrete fill 28 is poured in to fill the channels. Once the concrete fill 28 is hardened, the joint forms a very strong construction, capable of bearing tremendous loads.

[0053] In all cases where reinforcing bars (“rebar”) are shown, it is possible to use other forms of reinforcement within the scope of this invention. For example, in buildings with very thick walls and a need for extreme strength in the post and beam system, the rebar shown here could be replaced with, for example, steel I-beams, hollow steel tubes, or a “cage” of interconnected rebar. In all cases, it is required that the reinforcing means must fit within the channels 24 formed by the panel edges.

[0054] Wall ends and the sides of door and window openings can be made using these molded building panels as shown in FIGS. 4 and 5 where the otherwise open channel 22 has reinforcing bars 44, 46 placed in it and a concrete fill 28 is molded to the desired open edge shape using molding dams 30.

[0055] Following this general introduction to molded building panels, their use, and generally how the present invention utilizes such panels, reference is now made to the specific Figures and a description of each is provided.

[0056] FIG. 1 illustrates a cross sectional view of a molded building panel 110 at the footing comprising a concrete footing block 132 supporting a concrete slab and turndown 134 and a concrete slab (or finished grade) 136. The foot portion of panel 110 is supported by concrete slab 134. A rebar 138 has been embedded in both concrete footing block 132 and concrete slab 134 and extends into the channel formed by the edge of panel 110 as shown. Rebar 138 provides not only a secure attachment point to secure the base of panel 110 to slab 134, but also a retaining and strengthening element in the channel formed by the edge of panel 110 when another panel abuts with panel 110 and the edges form a sealed channel that is filled with concrete as described below.

[0057] Note that the method of construction described herein can be used for walls on upper floors of a building, in addition to those on the lowest level that are attached to the foundation. For upper floors, it will be readily understood that the wall panels must be placed upon and attached to the lower wall structure and/or the floor structure instead of to the building foundation. Therefore, in FIG. 1 it should be understood that for an upper floor, 134 would represent the upper floor structure rather than the foundation, and if that floor structure is not made of concrete, the rebar 138 would be replaced with a threaded bolt or other connection means suitable for attachment to the floor structure. Similarly in FIG. 2 (described below), for an upper floor, 232 would represent the upper floor structure or the top of the lower walls, rather than the foundation, and the rebar 238 may instead be a bolt or other suitable fastener.

[0058] FIG. 2 is a cross-sectional plan view illustrating two adjoining molded building panels 210 on a foundation footing 232 and how they are joined together and secured to the foundation during construction using the present invention. The peripheral channels 222 formed in each panel join along abutting panel edges to form a generally vertical sealed channel 224. Reinforcing steel bar 238 is embedded in footing 232 and extends into sealed channel 224. Another steel reinforcing bar 240 is placed in the lower channel 242 and is preferably connected or attached to steel bar 238 by any of the standard methods as by twisted wires, interweaving or hooks. Likewise, reinforcing bars 244 and 246 are placed in the generally vertical sealed channel 224 and are preferably connected or attached to the bar 238 embedded in the footing 232 and may even be connected to horizontal bar 240 for even greater strengthening of the construction.

[0059] The upper portions 252 of bars 244 and 246 are bent so as to permit them to lie in the generally horizontal channel 248 appearing in the top portion of the panels. In addition, it is preferred that bar 250 be placed in horizontal channel 248 and attached or connected to the upper portions 252 of bars 244 and 246 for further strengthening purposes.

[0060] Once all of the panels and bars are in place, the channels are filled with a concrete mixture which is allowed to harden, forming a unitary whole that not only joins the panels, but provides a load supporting skeletal structure within the constructed building as well.

[0061] FIG. 3 is a top cross-sectional view showing in greater detail two adjoining molded building panels 314 at a construction corner that has been constructed in accordance with the principles of the present invention. Here is illustrated the upper channel 348 of each panel 314 and in dotted line the joining of channels 322 to form a sealed vertical channel 324. In vertical channel 324 is shown the bent portion 352 of a rebar similar to that described in FIG. 2 with the reference numeral 244. Also shown are bars 350 lying in the upper channel 348, which are similar to those appearing in FIG. 2 and referenced with the numeral 250. In these corner constructions it is also preferred to add an additional L-shaped bar 354 for additional rigidity in the corner construction. All of these reinforcing bars may be wired together for greater strength. Horizontal channel 348 and vertical channel 324 are filled with the concrete mixture and all of these reinforcing bars are embedded therein.

[0062] The method of the present invention is also useful in fabricating openings in a building using the modular, molded panels described above for use as door or window frames.

[0063] FIG. 4 shows a window frame constructed using modular, molded building panels embodying the present invention. Panels 410 are building panels forming a construction wall in which a window frame is to be fabricated. Intermediate panels 410 are two shorter panels 416 and 418 which form the window frame header and footer sections respectively. Each of the panels has a peripheral channel 422 which, when abutting with the peripheral channel of an adjacent panel forms a sealed channel 424. However, due to the nature of two panels 416 and 418 being of unequal length with that of panels 410, an open vertical channel portion 456 is created on each of the vertical sides of the window jamb. Likewise, there may be a horizontal open channel portion in the window jamb, or the window header and footer panels 416 and 418 may be molded without a channel in these horizontal edges.

[0064] In order to seal these open channel portions 456, a grout dam 430 is placed inside of the opening as shown in FIG. 4. These grout dams 430 act as the missing channel portion needed to seal the channel for the concrete fill. The vertical grout dams at the sides of the opening also serve to support the header panel during construction. Once the channels are filled with the concrete mixture and it has hardened, the grout dams 430 may be removed as the concrete fill, in its hardened form, no longer needs the dams 430 for support.

[0065] Grout dams 430 may have any desired shape and may hold anchoring hardware 460, such as nuts for bolts, or extending tie bars useful to hold a window frame or finishing work in place. Such anchoring hardware would be inserted into the channel before it was filled with the concrete mixture and left embedded in the mixture when the dam was removed after hardening.

[0066] A doorway would be made similar in construction to that of a window frame as described above. Such an opening useful as a doorway is illustrated in FIG. 5.

[0067] In FIG. 5, the right side of doorway opening 562 is illustrated in cross section (the left side view being a mirror image of the same). Wall panel 510 abuts a smaller panel 520 that acts as a door header panel. In this illustration, grout dams 530 are shown sealing the vertical and horizontal channels 522 in the panel edges. Reinforcing bar 544 runs in the vertical channel while horizontal reinforcing bar 550 runs in the horizontal channel 548 at the top of the panels. Additional strengthening is provided by reinforcing bar 564 running in the lower channel 566 in the header panel 520 having its ends bent to lie in the adjoining vertical channels 522 formed between the wall panel 510 and the door header panel 520. Means for strongly attaching a top plate, which may be a part of a roof assembly, is provided by having J-shaped bolts 568 attached to a top plate 570 and hooked around horizontal bar 550.

[0068] FIG. 6 shows in further detail reinforcing bars and their interconnection similar to that described above in FIG. 3 for a corner, but for joining panels at a midpoint or a shorter panel to a longer as in door and window headers and footers.

[0069] In FIG. 6, lower panel 618 has reinforcing bars 664 and 670 placed in its upper horizontal channel 622. Reinforcing bar 664 is bent into a generally L shape so as to allow it to lie in the vertical channel formed in the side of wall panel 610. Reinforcing bar 644 also lies in the vertical channel formed in the side of wall panel 610. These reinforcing bars may be wired together for additional tensile strength of the final construction. Grout dams 658 act to seal otherwise open channel portions 656 in the panel side channels 622 while the channels are being filled with the concrete mixture as taught by the present invention.

[0070] While the panels described so far have a flat or planar configuration, it is also within the scope of the present invention to utilize the present invention with panels of varying configurations and shapes.

[0071] The method of the present invention then, as indicated in discussing the construction above, utilizes the modular building panels and reinforcing bars described above and includes the following steps for interlocking these building panels that have a channel integrally formed in and substantially coextensive with each generally vertical panel edge and the top panel edge, so that abutting panel edges form a generally vertical joint post channel and adjacent panel edges form a generally horizontal beam channel, to fabricate a building wall:

[0072] placing a first rebar, that extends upward some distance into the joint post channel, into the foundation or other supporting structure at the point below the location where each joint post channel is formed between abutting panels;

[0073] inserting a second rebar into the joint post channel so that a first end is juxtaposed with the extending end of the first rebar, and a second, opposite end extends to the top of the joint post channel and bends so that it lies in the generally horizontal beam channel intersecting with the joint post channel; and,

[0074] filling both the generally vertical joint post channel and the generally horizontal beam channel with concrete.

[0075] Additionally, inserting a third rebar in the generally horizontal beam channel across the joint post channel aids in strengthening the construction.

[0076] The step of placing a first rebar into the foundation or other supporting structure at the point where the joint post channels are formed between abutting panels, may further include the steps of:

[0077] marking a drill point on the supporting structure where the joint post channels are formed between abutting panels;

[0078] drilling a hole into the supporting structure at the drill point;

[0079] injecting an epoxy holding compound into the drilled hole; and,

[0080] inserting the first rebar into the drilled hole so that it partially extends in a generally vertical direction from the foundation.

[0081] An alternate included method of placing a first rebar into the foundation at the point on the foundation where the joint post channels are formed between abutting panels, further comprises the steps of:

[0082] marking an embedding point on the foundation where the joint post channels are formed between abutting panels; and,

[0083] embedding the first rebar into the foundation while the foundation is being poured so that it partially extends in a generally vertical direction from the foundation.

[0084] The step of filling both the generally vertical joint post channel and the generally horizontal beam channel with concrete, further comprises the steps of:

[0085] using a pressurized hose to pump the concrete into both the generally vertical joint post channel and the generally horizontal beam channel. Preferably this filling is done in one continuous pouring of the concrete mixture.

[0086] The present invention provides a method for interlocking building panels that have a channel integrally formed in and substantially coextensive with each panel edge so that abutting panel edges form a generally vertical joint post channel, where the abutting edges of the panels are of unequal length, so that a portion of the channel formed in the longer panel edge is exposed. In this embodiment, the method of the invention comprises the steps of:

[0087] covering the exposed portion of the channel formed in the longer panel edge with a mold to form a sealed joint post channel;

[0088] filling the sealed joint post channel with concrete; and,

[0089] removing the mold from the exposed portion of the channel formed in the longer panel edge once the concrete filling the sealed joint post channel has hardened.

[0090] In addition, the method also includes a step of:

[0091] inserting and releasably retaining fittings for anchoring bolts on the inside of the mold; and,

[0092] embedding the fittings on the inside of the mold in the concrete filling the joint post channel.

[0093] The method of the present invention also includes steps for incorporating conduit channels or passageways to openings in the disclosed interlocking building system, as for windows and doors, so that wires, and the like, can be run through the post channels once they have been filled with cement for various purposes, for example, to connect sensors for a burglar alarm system. Such wiring channels could also be used for any other wiring that might be appropriate at such openings, such as a doorbell switch at a front door, or an intercom or video system.

[0094] The method is illustrated in FIGS. 7 and 8. FIG. 7 shows a door or window opening 700 before pouring the grout for the post and beam system, with the grout dam 705 in place, and FIG. 8 shows the opening 800 after the grout is poured and cured, with the grout dam removed.

[0095] In the present method of interlocking panels disclosed here, each door or window opening shown is comprised of a header panel 710, 810 that is joined to normal full-height vertical wall panels 715, 815 on each side. Between the header and the wall panel, the panel edges 720, 820 create the form for part of the reinforced post 725, 825. Grout dams are used on the sides of the opening to support the header during construction and to complete the form for the vertical posts. A grout dam 705 is shown in FIG. 7. Generally, wiring of all types is connected at the top 730, 830 of the panel pairs 710/720 and 810/820 respectively, and through the attic area or between the joists of the upper floor. Some of the wall panels have wiring races 735, 835 built in to lead wires to outlets, switches, etc. The method described here provides a way to lead some wires from the top of the panels down to the window and door openings, which would not otherwise be reachable through the wiring races inside panels.

[0096] A hollow plastic tube 740, 840 is inserted into the posts 725, 825 at the sides of all openings. This tube could be shaped like the letter L, but with a gradual bend so wires can easily be pushed through. FIGS. 7 and 8 show an alternative that may be superior to a tightly bent L shape, in which the tube is bent into a gentle curve that is very easy to pass wires through. The main problem with the L shape is that the bend may require a special process, such as heating, to allow the bend to be made without kinking the tube. If so, it also means we would need to keep a supply of L-shaped tubes of various lengths to handle headers of various heights. In contrast, the gentle continuous bend can be made in any straight piece of tubing, and cut off at any desired length.

[0097] In either case, tube 740, 840 is placed into the vertical post channel 745, 845 between the header 710, 810 and the wall panel 715, 815 before the grout is poured into the vertical post channel 745, 845. The lower part 750 of the tube is pushed through a hole 755, 855 in the inner face 760, of the grout dam 705, so the tube protrudes into the window or door opening 700, 800. This requires that the grout dams have a hole drilled in the inner wall (facing the opening) some distance below the top. This hole is preferably drilled at an angle similar to the angle of the bottom of the tube, so the tube will fit snugly in the hole. The lower part of the plastic tube is inserted into that hole so the tube protrudes a few inches into the opening. Plugs can be inserted in the tube to prevent any grout from getting inside. These tubes should be wide enough so at least two or three pairs of wires can be inserted. That means the inside diameter of the tube is preferably at least ¼″ or ⅜″. The tubes do not have to be centered; both the top and bottom ends can be positioned off center as needed to make it most convenient to connect the wires.

[0098] With the grout dams in place, the tubes are held in place as well. Then the grout can be poured, and each window and door opening will have hollow plastic tubes leading from the opening 700, 800 up to the top of the wall 765, 865. After grout dam 705 is removed, as in FIG. 8, the lower part 750 of the plastic tube can be cut off flush with the hardened concrete now filling vertical post channel 845. Wires may then be inserted into the tube 840, with the ends of the wires extending a foot or so at both the top and the bottom of the tube, providing enough length to make connections as needed. Within the window and door openings, these wires may be hidden within the window or door frame assembly.

[0099] In summary then, the present invention further includes the steps of:

[0100] Drilling a hole in the grout dam or mold that covers the exposed portion of the vertical or horizontal post channel in an opening creating a door or window frame;

[0101] Inserting a hollow tubing in the vertical or horizontal post channel so that a first end of the tubing protrudes through the hole in the grout dam or mold, and a second, opposite end that extends out of the channel, the tubing providing a passageway for wiring through the channel once the channel is filled with concrete.

[0102] Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

Claims

1. A method for interlocking building panels that have a channel integrally formed in and substantially coextensive with each generally vertical panel edge and the top panel edge, so that abutting panel edges form a generally vertical joint post channel and adjacent panel edges form a generally horizontal beam channel, atop a foundation or other supporting structure, to fabricate a building wall, comprising the steps of:

placing into the supporting structure at the point on the supporting structure where the joint post channels are formed between abutting panels, a first rebar that extends at least partially into the joint post channel;

inserting a second rebar into the joint post channel so that a first end is juxtaposed with the extending end of the first rebar, and a second, opposite end extends to the top of the joint post channel and bends so that it lies in the generally horizontal beam channel intersecting with the joint post channel; and,

filling both the generally vertical joint post channel and the generally horizontal beam channel with concrete.

2. A method as in claim 1 further comprising the step of:

inserting a third rebar in the generally horizontal beam channel across the joint post channel.

3. A method as in claim 1 wherein the step of placing a first rebar into the supporting structure at the point on the supporting structure where the joint post channels are formed between abutting panels, further comprises the steps of:

marking a drill point on the supporting structure where the joint post channels are formed between abutting panels;

drilling a hole into the supporting structure at the drill point;

injecting an epoxy holding compound into the drilled hole; and,

inserting the first rebar into the drilled hole so that it partially extends in a generally vertical direction from the supporting structure.

4. A method as in claim 1 wherein the step of placing a first rebar into the supporting structure at the point on the supporting structure where the joint post channels are formed between abutting panels, further comprises the steps of:

marking an embedding point on the supporting structure where the joint post channels are formed between abutting panels; and,

embedding the first rebar into the supporting structure while the supporting structure is being poured so that it partially extends in a generally vertical direction from the supporting structure.

5. A method as in claim 1 wherein the step of filling both the generally vertical joint post channel and the generally horizontal beam channel with concrete, further comprises the steps of:

pumping the concrete into both the generally vertical joint post channel and the generally horizontal beam channel.

6. A method as in claim 5 wherein the step of filling both the generally vertical joint post channel and the generally horizontal beam channel with concrete, further comprises the steps of:

using a pressurized hose to pump the concrete into both the generally vertical joint post channel and the generally horizontal beam channel.

7. A method as in claim 5 wherein the step of filling both the generally vertical joint post channel and the generally horizontal beam channel with concrete, further comprises the steps of:

pumping sufficient concrete to fill both the generally vertical joint post channels and the generally horizontal beam channels in one continuous pour.

8. A method for interlocking building panels that have a channel integrally formed in and substantially coextensive with each panel edge so that abutting panel edges form a generally vertical joint post channel, where the abutting edges of the panels are of unequal length, so that a portion of the channel formed in the longer panel edge is exposed, comprising the steps of:

covering the exposed portion of the channel formed in the longer panel edge with a mold to form a sealed joint post channel;

filling the sealed joint post channel with concrete; and,

removing the mold from the exposed portion of the channel formed in the longer panel edge once the concrete filling the sealed joint post channel has hardened.

9. A method as in claim 8 further comprising the step of:

inserting and releasably retaining fittings for anchoring bolts on the inside of the mold; and,

embedding the fittings on the inside of the mold in the concrete filling the joint post channel.

10. A method for interlocking building panels that have a channel integrally formed in and substantially coextensive with each panel edge so that abutting panel edges form a generally vertical joint post channel, where the abutting edges of the panels are of unequal length, so that a portion of the channel formed in the longer panel edge is exposed, comprising the steps of:

covering the exposed portion of the channel formed in the longer panel edge with a mold to form a sealed joint post channel;

Drilling a hole in the grout dam or mold that covers the exposed portion of the vertical or horizontal post channel in an opening creating a door or window frame;

Inserting a hollow tubing in the vertical or horizontal post channel so that a first end of the tubing protrudes through the hole in the grout dam or mold, and a second, opposite end extends out of the channel, the tubing providing a passageway for wiring through the channel once the channel is filled with concrete;

filling the sealed joint post channel with concrete; and,

removing the mold from the exposed portion of the channel formed in the longer panel edge once the concrete filling the sealed joint post channel has hardened.