MODULAR INSULATED CONCRETE WALL PANEL SYSTEM

Abstract

The present invention provides a modular insulated concrete wall panel system comprising at least one assembled panel, each assembled panel comprising a precast concrete panel and one or more insulation panels. The concrete panel has an outer frame and plurality of vertical ribs that engage with corresponding channels on the insulation panels. There is also provided a method of forming a modular concrete wall panel system of the present invention, comprising the steps of: providing the at least one preformed insulating panel laid horizontally with the vertical channels facing in an upward direction; pouring concrete around the at least one preformed insulating panel such that the concrete fills the channels in the insulating panel, thereby forming the concrete panel rib elements; and allowing the concrete panel to set and cure.

Claims

1. An insulated concrete wall panel system comprising at least one assembled panel, the at least one assembled panel comprising: a concrete panel comprising: a first face and a second face; an outer frame extending around a periphery of the first face of the panel, the outer frame being formed from a top frame element extending from the top edge of the first face, a bottom frame element extending from the bottom edge of the first face, and first and second vertical frame elements extending between respective ends of the top and bottom frame elements; and at least one rib element extending between the top and bottom frame elements on the first face of the panel; wherein the outer frame elements and the at least one rib element form cavities on the first face of the concrete panel; and at least one insulation panel comprising: a first face and a second face, the first face of the insulation panel being configured to conform to corresponding cavities on the concrete panel, each said insulation panel comprising on said first face at least one vertical channel, each said vertical channel being configured to receive a respective rib element on the concrete panel.

2. The system of claim 1, wherein the concrete panel comprises two or more rib elements extending between the top and bottom frame elements on the first face of the concrete panel, and each said at least one insulation panel comprises two vertical channels on the first face of the insulation panel.

3. The system of claim 2, further comprising a first end insulation panel and a second end insulation panel.

4. The system of claim 1, wherein the concrete panel further comprises a connector slot at each corner of the outer frame, the system further comprising a connector element configured to engage the connector slots on two adjacent concrete panels to hold the two concrete panels together in abutting arrangement.

5. The system of claim 4, wherein the connector element has a generally tapered shape and is provided with shoulder bumps.

6. The system of claim 1, wherein the insulation panels further comprise one or more vertical electrical chases extending through the length of each insulation panel.

7. The system of claim 1, wherein the insulation panels further comprise one or more horizontal electrical chases extending through the width of each insulation panel.

8. The system of claim 1, wherein the insulation panels further comprise one or more channel slides on the second face of the insulation panel, the channel slides being configured to receive metal channel slides to facilitate attachment of drywall or eternal fixtures.

9. The system of claim 1, wherein the insulation panels are formed from expanded polystyrene.

10. A method for forming the insulated concrete wall panel system as defined in claim 1, comprising the steps of: providing the at least one preformed insulating panels laid horizontally with the vertical channels facing in an upward direction; pouring concrete around the at least one preformed insulating panel such that the concrete fills the channels in the insulating panel, thereby forming the concrete panel rib elements; and allowing the concrete panel to set and cure.

11. The method of claim 10, further comprising the step of finishing the second face of the concrete panel to create the outer layer of the concrete wall panel system.

12. The method of claim 10, further comprising the step of providing an exterior finish selected from stucco finish, painted finish, faux brick finish, stone finish or simulated wood finish.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0008] FIG. 1 illustrates a perspective view of components of an insulated concrete wall assembly in accordance with one embodiment of the present invention.

[0009] FIG. 2 illustrates a perspective view of components of an insulated concrete wall assembly in accordance with one embodiment of the present invention.

[0010] FIG. 3A illustrates a cross-sectional view of two coupled wall assemblies of an embodiment of the invention, along the line C-C shown in FIG. 3B. FIG. 3C is a perspective view of two coupled wall assemblies in accordance with one embodiment of the present invention.

[0011] FIG. 4A-D illustrate multiple views of two coupled wall assemblies in accordance with one embodiment of the present invention.

[0012] FIGS. 5A-D, 6A-B and 7 illustrate multiple views of a insulation panel for use in an insulated concrete wall assembly in accordance with one embodiment of the present invention.

[0013] FIGS. 8A-C, 9A-B and 10A-B illustrate multiple views of a right end insulation panel for use in an insulated concrete wall assembly in accordance with one embodiment of the present invention.

[0014] FIG. 11A-D illustrates multiple views of the conical connector for use in an insulated concrete wall assembly in accordance with one embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0015] The term EPS stands for expanded polystyrene.

[0016] As used herein, the term about refers to a +/10% variation from the nominal value. It is to be understood that such a variation is always included in a given value provided herein, whether or not it is specifically referred to.

[0017] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

[0018] The present invention provides a lightweight insulated concrete wall panel system that is easy and quick to install. The system of the present invention eliminates several steps in the construction process and substantially shortens the timeframe from start of construction to completion.

[0019] The concrete wall panel system of the present invention employs at least one precast concrete panel in combination with one or more insulation panels. The concrete panel has on one face a plurality of cavities that are adapted to engage with corresponding channels on the insulation panels, essentially creating an interlocking interaction. The system of the present invention can be used to provide an insulated wall that meets 2030 Code requirements on both the material side as well as on the carbon footprint side.

[0020] The concrete wall panel system of the present invention is formed by pouring concrete around preformed insulating panels. In the method of forming the wall panel, the preformed insulating panel is laid flat with the side that has the horizontal slide channels facing down, and concrete is then poured on top of the insulating panel such that the concrete fills the channels in the insulating panel, thereby forming the concrete panel ribs. The outer layer of the concrete panel is then finished to create the outer layer of the wall.

[0021] These precast concrete panels can be made with a ready exterior finish with a variety of finishes from stucco finish, painted finish, faux brick finish, stone or simulated wood finish, thereby eliminating the need for exterior trades. Windows and doors can be installed at time of production, again eliminating the need for on-site trades, which can minimize the damage that is often incurred during on-site installation.

[0022] The wall panel system of the present invention can also provide insulated walls that are around 30% lighter that foundation walls made using conventional methods and materials.

[0023] The wall panel system of the present invention can also be assembled more quickly and easily than conventional systems, and as such, one crew should be able to complete one house per day to be ready for installation of wiring and interior cladding.

[0024] With the current shortage off trades and inability to construct housing, this modular construction will not only speed up construction, but also provides a much better and much more environmentally sustainable product that has a smaller carbon footprint than conventional methods.

[0025] In one embodiment, wall manufactured using the system of the present invention can be employed in building up to six stories tall. When manufactured with low carbon concrete, fire resistance will be substantially higher. With the high strength, it will also provide excellent volatile weather resistance and much better noise protection and tenant damage resistance.

[0026] In accordance with the present invention, the insulated concrete wall panel system comprises a concrete panel and at least one insulation panel.

[0027] In one embodiment, the concrete panel comprises a first face and a second face, and an outer frame extending around a periphery of the first face. The outer frame is formed from a top frame element extending from the top edge of the first face, a bottom frame element extending from the bottom edge of the first face, and first and second vertical frame elements extending between respective ends of the top and bottom frame elements on the first face of the panel. At least one rib element is provided, extending between the top and bottom frame elements. In a preferred embodiment, the panel is provided with a plurality of rib elements. The outer frame elements and the rib elements form cavities on the first face of the concrete panel.

[0028] In one embodiment, each insulation panel has a first face and a second face, the first face of the insulation panel being configured to conform to corresponding cavities on the concrete panel, each said insulation panel comprising at least one vertical channel on it first face, each vertical channel being configured to receive a respective rib element on the concrete panel.

[0029] In one embodiment, the at least one insulation panel includes at least one central insulation panel and a first end insulation panel and a second end insulation panel.

[0030] In one embodiment, the insulated panels are formed from expanded polystyrene (EPS), or any comparable material that has the same water resistance, dew point resistance, strength, rigidity and insulation factor.

[0031] In one embodiment, the insulation panels further comprise one or more vertical electrical chases extending through the length of each insulation panel and/or one or more horizontal electrical chases extending through the width of each insulation panel.

[0032] In one embodiment, the insulation panels further comprise one or more channel slides on the second face of the insulation panel configured to receive metal channel slides to facilitate attachment of drywall or eternal fixtures.

[0033] The invention will now be described with reference to specific examples. It will be understood that the following examples are intended to describe embodiments of the invention and are not intended to limit the invention in any way.

[0034] FIG. 1 depicts a fully assembled panel 100, as well as the components of a disassembled panel, including concrete panel 10, EPS insulation panels 25, 26 and 20 and connector 30. Concrete panel 10 includes top frame 11, bottom frame 12, end frames 13, which define an outer perimeter. Multiple ribs 15 extend vertically between top and bottom frames and form a plurality of cavities 14. Ribs 15 conform to channels formed on insulation panels 25, 26 and 20.

[0035] Each of panels 25, 26 and 20 includes vertical electrical chases 29 which extend through the length of each panel and horizontal electrical chases 27, which extend through the width of each panel, and which are provided to accommodate electrical wiring. The outer faces of each of 25, 26 and 20 includes a plurality of channel slides 28, which are configured to receive metal channel slides (not shown) that are provided to facilitate attachment of drywall or other fixtures (not shown). The upper and lower corners of each concrete panel 10 includes respective connector slots 32 configured to receive connector 30 in a manner that holds two fully assembled panels 100 together to form a coupled wall assembly 200.

[0036] FIG. 2 depicts two fully assembled panels 100, with connector 30.

[0037] FIG. 3A is a cross-sectional view of a coupled wall assembly 200, along the line C-C shown in FIG. 3B. FIG. 3C and FIGS. 4A-D show multiple views of coupled wall assembly 200.

[0038] FIGS. 5A-D, 6A-B and 7 illustrate multiple views of insulation panel 20. Shown are the panel insert portions which conform to the corresponding cavities on concrete panel 10, including outer insert portions 43a and 43b and central insert portion 42, as well as channel portions 21 which are configured to receive corresponding ribs 15 on the concrete panel. Also shown are horizontal electrical chases 27 and channel slides 28.

[0039] FIGS. 8A-C, 9A-B and 10 illustrate multiple views of end insulation panel 25. Shown is panel insert portion 45, which is inserted into the corresponding cavities on concrete panel 10. Also shown are horizontal electrical chases 27 and channel slides 28.

[0040] FIG. 11B-D illustrates multiple views of connector 30, which has a generally tapered shape to facilitate introduction into connector slot 32. Connector 30 is also provided with shoulder bumps 33, configured to engage connector slot 32, as shown in FIG. 11A, to hold the two assembled panels 100 together in abutting arrangement.

[0041] It is obvious that the foregoing embodiments of the invention are examples and can be varied in many ways. Such present or future variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.