Concrete wall section

Abstract

A concrete wall section manufactured with a weight that allows the user of the concrete wall section to transport manually the concrete wall section. Combinations of concrete wall sections can be used to replace traditional frames of a structure.

Claims

1. A concrete wall section sandwich comprising: a) a first inward face of an inward concrete slab; the inward concrete slab comprising a first width; b) a second inward face of an outward concrete slab comprising a second width; c) a polymeric insulator-connector sandwiched between the first inward face and the second inward face, the insulator-connector extending vertically beyond the first inward face and the second inward face; d) concrete bonds integral with and extending from the first inward face and the second inward face, wherein the concrete bonds penetrate into pores of the insulator-connector and secure the inward concrete slab and the outward concrete slab to the insulator-connector and the concrete bonds are oblique to longitudinal axes of the inward concrete slab and the outward concrete slab; and e) mesh configured to engage a horizontal plane, a vertical plane or both planes of lengthwise edges of the insulator-connector.

2. The concrete wall section sandwich of claim 1, wherein an insulator of the insulator-connector comprises R-values of from about 3.85 per inch to about 4.20 per inch.

3. The concrete wall section sandwich of claim 2, wherein horizontal surfaces of the lengthwise edges of the insulator-connector are continuous uninterrupted horizontal surfaces.

4. The concrete wall section sandwich of claim 3, wherein a density of an insulator portion of the insulator-connector is from about 1.0 pound/ft.sup.3 to about 1.2 pounds/ft.sup.3.

5. A concrete wall section sandwich comprising: a) a first inward face of an inward concrete slab; b) a second inward face of an outward concrete slab; c) a polymeric insulator-connector sandwiched between the first inward face and the second inward face, the insulator-connector extending vertically beyond the first and second faces, wherein the insulator-connector comprises continuous uninterrupted horizontal surfaces of lengthwise edges of the insulator-connector; d) concrete bonds integral with and extending from the first inward face and the second inward face, wherein the concrete bonds penetrate into pores of the insulator-connector and the concrete bonds are oblique to longitudinal axes of the inward concrete slab and the outward concrete slab; and e) mesh configured to engage a horizontal plane, a vertical plane or both planes of the lengthwise edges of the insulator-connector.

6. The concrete wall section sandwich of claim 5, wherein an insulator of the insulator-connector comprises R-values of from about 3.85 per inch to about 4.20 per inch.

7. The concrete wall section sandwich of claim 6, wherein a density of an insulator portion of the insulator-connector is from about 1.0 pound/ft.sup.3 to about 1.2 pounds/ft.sup.3.

8. The concrete wall section sandwich of claim 7, wherein pourable concrete forming a cured portion of the concrete wall section sandwich comprises from about 20% to about 30% water, from about 0% to about 20% aggregate, from about 30% to about 40% sand and Portland cement.

9. A concrete wall section comprising: a polymeric insulator-connector bonded to a first inward face of an inward concrete slab, including a first width, and a second inward face of an outward concrete slab, including a second width; the insulator-connector comprising: a) a top and a bottom extending vertically superior and inferior distances beyond vertical measurements of the first inward face and the second inward face; and b) the top and the bottom of the insulator-connector comprising four continuous and uninterrupted lengthwise edges created by intersections of vertical and horizontal planes of the insulator-connector; c) concrete bonds integral with and extending from the first inward face and the second inward face, wherein the concrete bonds penetrate into pores of the insulator-connector and secure the inward concrete slab and the outward concrete slab to the insulator-connector and the concrete bonds are oblique to longitudinal axes of the inward concrete slab and the outward concrete slab; and d) mesh configured to engage the horizontal plane, the vertical plane or both planes of the lengthwise edges.

10. The concrete wall section of claim 9, wherein a density of an insulator portion of the insulator-connector is from about 1.0 pound/ft.sup.3 to about 1.2 pounds/ft.sup.3.

11. The concrete wall section of claim 10, wherein pourable concrete forming each concrete slab comprises from about 20% to about 30% water, from about 0% to about 20% aggregate, from about 30% to about 40% sand and Portland cement.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a lateral perspective of concrete wall section (30).

(2) FIG. 2 is a cross-section of FIG. 1 along plane C-C.

(3) FIG. 3 is a lateral perspective of a representative segment of concrete wall (100) showing four vertically stacked concrete wall sections (30), where chinking is yet to be applied to receivers (90s, 90i, 96s, 96i) between the stacked concrete wall sections.

(4) FIG. 4 is a perspective of a representative segment of concrete wall (100) showing four vertically stacked concrete wall sections (30), where chinking was applied to receivers (90s, 90i, 96s, 96i) between the stacked concrete wall sections.

(5) FIG. 5 is a perspective of first and second concrete wall sections (30) provided with reciprocating interconnection members (120f, 120s).

(6) FIG. 6 is perspective of first and second concrete wall sections (30f, 30s) that have formed corner (150).

(7) FIGS. 7-10 portray methods of manufacturing concrete wall sections (30).

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(8) The disclosure hereof is detailed to enable those skilled in the art to practice the invention, and the embodiments published herein merely exemplify the present system, methods and devices and do not limit the scope of the claims appended hereto.

(9) The present invention is directed toward the provision of a concrete wall section (30). Meeting a long felt but unfulfilled need, the current concrete wall section (30) is an insulated concrete wall section (30) with a weight and dimension that allows the user to manually transport the concrete wall section to the construction site and about the worksite without the need of using lifts or other transportation devices. Preferred embodiments of the current invention, provide concrete wall sections (30) including interconnection members (120f, 120s) creating corners and concrete wall sections (30) without interconnection members (120f, 120s). Among other things, concrete wall sections (30) provide an insulated, low maintenance and durable walls for a structure.

(10) FIG. 1 is a lateral perspective of concrete wall section (30) and FIG. 2 is a cross section of FIG. 1 along plane C-C. Among other things, concrete wall section (30) includes outward concrete slab (40), inward concrete slab (50), insulator-connector (60) and one or more meshes (80s, 80i, 84s, 84i).

(11) Concrete slabs (40) and (50) are formed with predetermined widths, lengths, heights and weights. Widths can range from about 8 inches to about 12 inches. Lengths can range from about 60 inches to about 120 inches. Heights can range from about 10 inches to about 19 inches. Weights can range from about 81 pounds to about 162 pounds. In accordance with the current invention, the concrete wall section (30) is of such dimensions and weight that a human can move a single concrete wall section (30) without the assistance of lifts or other transportation devices. Within the scope of the present invention, concrete wall sections (30) can have a weight of from about 81 pounds to about 162 pounds.

(12) It has been discovered that pourable concrete used to manufacture concrete slabs (40) and (50) can have compositions of from about 20% to about 30% water, from about 0% to about 20% aggregate and from about 30% to about 40% sand with the remaining percentages of the compositions being Portland cement with or without additional constituents. For the purposes of this application, “pourable concrete” is defined as compositions of concrete that are pourable into molds to form the concrete mixture into solidified concrete slabs (40) and (50).

(13) Outward concrete slab (40) includes outer face (42) and opposed surface (44) separated by a predetermined width. According to engineering parameters, outer face (42) can be designed to have a preselected cured visual appearance from smooth to rugged.

(14) Inward concrete slab (50) includes inward face (52) and outward surface (54) separated by a predetermined width. According to engineering parameters, inward face (42) can be designed to have a preselected cured visual appearance from smooth to rugged.

(15) Insulator-connector (60) is interconnected with opposed surface (44) of outward concrete slab (40) and outward surface (54) of inward concrete slab (50). Insulator-connector (60) extends vertically for predetermined superior and inferior distances beyond the vertical lengths of outward concrete slab (40) and inward concrete slab (50) creating receivers (90s, 90i, 96s, 96i).

(16) During the concrete curing process, portions of the uncured opposed surface (44) and the uncured outward surface (54) penetrate into the insulator-connector (60) creating a bond between the insulator-connector (60) and the outward concrete slab (40) and the inward concrete slab (50). Among other things, the bond between the dried concrete and insulator-connector (60) stabilizes vertical section (30) for transport.

(17) It has been discovered that insulator-connector (60) can be a polystyrene polymer; in particular, a closed cell expanded polystyrene foam. Among other things, insulator-connector (60) has the dual function of connecting outward concrete slab (40) and inward concrete slab (50) to form concrete wall section (30), as well as providing insulation with R-values of from about 3.85 per inch to about 4.20 per inch. Within the scope of the present invention, density of the insulator portion of the insulator-connector (60) can range from about 1.0 pound/ft.sup.3 to about 1.2 pounds/ft.sup.3.

(18) Meshes (80s, 80i, 84s, 84i) are connected to portions of insulator-connector (60) extending beyond outward concrete slab (40) and inward concrete slab (50). In select preferred embodiments of the current invention, meshes (80s, 80i, 84s, 84i) are wire meshes. When engineering parameters require, one or more meshes (80s, 80i, 84s, 84i) contact a vertical and horizontal side of insulator-connector (60).

(19) FIG. 3 is a lateral perspective of a representative segment of concrete wall (100) showing four vertically stacked concrete wall sections (30), where chinking is yet to be applied to receivers (90s, 90i, 96s, 96i) between the stacked concrete wall sections.

(20) FIG. 4 is a perspective of a representative segment of concrete wall (100) showing four vertically stacked concrete wall sections (30), where chinking (180) was applied to receivers (90s, 90i, 96s, 96i) between the stacked concrete wall sections.

(21) Among other things, except for flooring and roof framing and their respective components, it has been discovered that use of vertical sections (30) to create walls can eliminate the use of conventional framing including the requirements of insulation, exterior wall studs, etc. incorporated into a conventional frame of a structure. Meshes (80s, 80i, 84s, 84i) are adapted to assist with holding chinking (180) applied subsequent to formation of the interconnected concrete wall sections (30).

(22) FIG. 5 is a perspective of first and second sections (30f, 30s) provided with reciprocating interconnection members (120f, 120s). As shown in FIG. 6, when interlocked, reciprocating interconnection members (120f, 120s) create a corner (150). In select preferred embodiments, interconnection members (120f, 120s) interlock at a right angle.

(23) Interconnection member (120f) includes extender (122f), outer side (124f), upper gap (126f) and lower gap (128f). Interconnection member (120s) includes extender (122s), outer side (124s), upper gap (126s) and lower gap (128s).

(24) FIG. 6 is perspective of first and second sections (30f, 30s) that have formed corner (150). Lower gap (128f) of first section (30f) interlocks with upper gap (126s) of second section (30s) creating corner (150). When the structure requires, sections (30) including interconnection members (120) are utilized to create corner (150).

(25) Select steps associated with methods of manufacturing concrete wall sections (30) are depicted in FIGS. 7-10.

(26) Steps 202-210 disclose a first method of manufacturing concrete wall sections (30).

(27) Steps 240-250 disclose a second method of manufacturing concrete wall sections (30).

(28) Having disclosed the invention as required by Title 35 of the United States Code, Applicants now pray respectfully that Letters Patent be granted for their invention in accordance with the scope of the claims appended hereto.