Interlocking construction panel showing fabrication thereof and the building system
A prefabricated building panel to be used in constructing a building structure includes a generally planar concrete panel one surface and opposite surface also generally planar with a plurality of arrayed hooks couple through an insulation pad opposing hooks of a similar panel mostly mirrored to the first panel providing a cavity space being back filled with a foam insulation providing an lightweight foam core building panel with improved thermal isolation.
The invention relates to concrete shapes used in construction or various structures. More particularly, it relates to panels providing walls and finished structures having increased strength over prior art to resist storms and earthquakes. Constructs derived from this building panel have improved thermal and insulation.
BACKGROUND INFORMATIONConcrete blocks of the prior art are conventionally rectangular shapes having cavities extending from top to bottom through the blocks. These cavities are often filled with an insulation material to reduce the heat transfer. Often aligning features have been proposed to assist the workers in laying the block, however these are at an increased cost which makes these aids cost prohibitive and in the end skilled masonry workers prevail. Various mortarless interlocking blocks have been derived to facilitate construction of block walls and structures and the cost to benefit ratio works out so that it also is prohibitive.
Block construction remains very much unchanged; applying mortar and laying block end to end then course on top of course with the set mortar providing the aligning feature to resist the blocks being displaced. When a catastrophe of sufficient forces to overcomes the mass loading and displaces these blocks more than a crack then the effected blocks must be reset or worse fall with crushing force. Much less dramatic shifting of the foundation is the most common reason that a building suffers occasionally a complete loss. The state of the art has shown this block construction to be non-compliant when the acting forces overcome the stiffness, then full recovery is not likely.
While the proposed designs have shown blocks that require less skill to build with them and some even have improved thermal properties none are created by an outer panel and an inner panel joined by hooks insulated between the coupling surfaces. An approximate half pitch vertically staggered course joint is achieved by starting at the base with a half panel and likewise a staggered vertical joint line is achieved. None of the art seen has demonstrated these features.
SUMMARY OF THE INVENTIONThe present invention provides a panel having a specialized texture or natural finish planar surface and for special applications the surface might be curved. This generally rectangular surface has a substantially parallel opposite side with hook shaped protrusions with the body extending angularly with a tip segment at right angle to the body and a tip. The panel size determines the quantity, shape and arrangement to consider the load requirement of these hooks. In example, to cast the hooks of small panel because it is difficult to fill small features in a mold it would be preferable to produce them as continuous across the panel.
The panel according to the present invention one method of manufactured will be by casting of concrete in a foam mold. At a manufacturing site a foam mold the rectangular size of the panel to be cast and having the intended hook and rib features created in the upper side is placed on a platen. Removable walls are closely fitted to all sides and extend above the top surface of the foam mold equal to the panel thickness to. This dammed area is filled with concrete level to the top of the walls and vibrated to fill all of the features of the mold. Prior to allow the concrete to set a finish surface or texture is applied. A finished panel is created when wall are removed and the mold material is cleared exposing the hooks. Another method of manufacturing construction panels is using a permanent mold in the mold process.
BRIEF DESCRIPTION OF DRAWINGSIn the annexed drawings:
Referring to the drawings and initially to
In
A primary assembly 100 is shown in
All construction panels previously shown have been simplified and shown without foam in place.
Claims
1. A panel that is useful in the construction of walls for buildings and dwellings that is a rectangular planar face with edges and an opposite face having hook features thereby coupled with hook features of a similar panel enclosing a core cavity producing a core panel with planar faces and has a thickness:
- a) a planar face with a uniform thickness
- b) a bottom edge with a flange to connect footer
- c) a top edge with a flange to connect to upper floor beams or roof truss
- d) an opposite face with an array of hooks
- e) a cavity between coupled panels back filled with insulation material
- f) a cavity between coupled panels back filled with insulation material providing spaces for service conduit
- g) a planar face with optional decorative surface
- h) a planar face with provisions for orifice to access service conduit
2. A panel as in claim 1 wherein said planar face is curved having a vertical axis.
3. A panel as in claim 1 wherein said planar face is a dihedral with vertical apex.
4. A panel as in claim 1 wherein said planar face has window feature and header with sill.
5. A panel as in claim 1 wherein said planar face is a door feature and sills with header.
6. A panel as in claim 1 wherein said planar face has feature to join wall at right angle.
7. A panel as in claim 1 wherein said panels are coupled so as having staggered vertical joint.
8. A panel as in claim 1 wherein coupling features is a dovetail.
9. A panel as in claim 1 wherein coupling features is a fastener connection.
10. A panel that is useful in the construction of walls for buildings and dwellings that is a rectangular planar face with edges and an opposite face having hook features thereby coupled with hook features of a similar panel enclosing a core cavity producing a core panel with planar faces and has a thickness:
- a) a planar face with a uniform thickness
- b) a bottom edge with a flange
- c) a top edge with a flange
- d) an opposite face with an array of hooks
- e) a cavity between coupled panels back filled with insulation material
- f) a cavity between coupled panels back filled with insulation material providing spaces for service conduit
- g) a planar face with optional decorative surface
- h) a planar face with provisions for orifice to access service conduit
11. Said panel of claim 10 whereby panels are laid in courses with horizontal and vertical staggered joints.
12. A panel as in claim 10 wherein said planar face is curved having a vertical axis.
13. A panel as in claim 10 wherein said planar face is a dihedral with vertical apex.
14. A panel as in claim 10 wherein said planar face has window feature and header with. sill.
15. A panel as in claim 10 wherein said planar face is a door feature and sills with header.
16. A panel as in claim 10 wherein said planar face has feature to join wall at right angle.
17. A panel as in claim 10 wherein coupling features is a dovetail.
18. A panel as in claim 10 wherein coupling features is a fastener connection.
19. A building comprising but not limited to panels shown.
20. A building comprising of construction panels having inner and outer panel joints staggered
21. A tool for aligning and placing construction panels
Type: Application
Filed: Feb 22, 2005
Publication Date: Aug 24, 2006
Inventor: Lanny Lee (Toms River, NJ)
Application Number: 11/063,041
International Classification: E04F 13/08 (20060101);