BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to an improved wall system where the structural insulating core uses various wall forming structures and various shapes of spacer blocks interconnecting between each other forming horizontal and vertical tongue and groove connections between spacer blocks where concrete is added forming a concrete wall.
A precast concrete wall is very difficult to insulated, that is rigid insulation can only be installed in the middle of a precast wall. When a concrete beam or column is installed within the wall, there is no insulation in the wall unless the precast wall has furring strips and insulation installed at the interior wall surface.
Thin faced precast concrete wall panels have been using light gauge metal framing for the structural backing for a few years now. When the concrete is poured face up, insulation supports the concrete until it has cured, while pouring the concrete face down in a forming bed, the light gauge metal framing is suspended over the forming bed and the metal channel is typically embedded into the concrete facing and usually no thermal break is accomplished. These systems do not combine the wall and sheathing insulation, plus have that thermal break as well as the flexibility to install columns and beams within the structure.
Different types of closed cell insulations can be used as a part of thin faced precast concrete wall panels, that is polystyrene, aerated autoclave concrete, cellular light weight concrete or light weight concrete with foam pellets. All of these materials are not load bearing materials, but are good insulation materials and some materials can withstand exterior weather conditions and some cannot without having to install an exterior coating. Some of the materials can have grooves or projections installed prior to pouring concrete, that is depending if the precast if formed face-up or face-down.
Smaller sizes of spacer blocks can be assembled together to form larger assembled wall panels into which concrete is then poured. The spacer blocks have overlapping tongue and groove connections both vertically and horizontally interlocking metal channels into the spacer blocks.
The horizontal bracing channels within the wall forming structure is generally provided by installing bridging members which tie the support channels together. These bridging members may be attached on the outside of the flanges of the support channels or maybe internal bridging members installed through openings provided in the web of the support channels. None of the bridging members used today have a limited function and do not provide a solution for interacting with rigid insulation between support channels and the holes the internal bridging members pass through.
DESCRIPTION OF PRIOR ART
A. Concrete Column & Beam Using Metal Channels
In U.S. Pat. No. 6,041,561 & U.S. Pat. No. 6,401,417 by LeBlang shows how a concrete column and beam can be installed within a wall using metal channels and rigid insulation/hard board or as a column and beam within a wall.
B. Precast Concrete Thin Panel Poured Face Down
Precast concrete panels when poured face down have the metal framing installed when the concrete face is being poured and other patents the metal framing is installed after the concrete has cured. None of the patents have a framing system in conjunction with a rigid insulation core.
Most of the precast panel poured face down have the metal framing embedded into the concrete like Schilger in U.S. Pat. No. 4,602,467, Bodnar in U.S. Pat. No. 4,909,007 & U.S. Pat. No. 6,708,459, Staresina in U.S. Pat. No. 4,930,278, Cavaness in U.S. Pat. No. 5,526,629, Ruiz in U.S. Pat. No. 6,151,858. In the 3 patents by Foderberg U.S. Pat. No. 6,817,151, U.S. Pat. No. 6,837,013& U.S. Pat. No. 7,028,439 the hat channel is secured to the metal channel and one is separated by a thermal break at the flange. The Nanaykkara U.S. Pat. No. 6,988,347 & U.S. Pat. No. 7,308,778 both are cast face down however in U.S. Pat. No. 7,308,778 has insulation between the two precast panels. In Rubio at U.S. Pat. No. 7,278,244 uses a bracket which is attached to the metal channel. In Cooney U.S. Pat. No. 5,138,813 has a bracket that is inserted and then fastened to the metal channels.
C. Precast Concrete Thin Panel Poured Face Up
The concrete panels poured face up have the metal channels embedded into concrete or poured concrete over rigid insulation with a connector attached. Precast concrete panels when poured face up; typically have the metal framing installed when the concrete face is being poured.
The patent by Mancini U.S. Pat. No. 5,758,463 and LeBlang U.S. Pat. No. 6,041,561 both showing the metal channels embedded into the concrete and patents by LeBlang U.S. Pat. No. 6,041,561 and Spencer U.S. Pat. No. 6,729,094 showed a connector attached to the metal channel and rigid insulation sheathing.
D. Precast Concrete Wall with Exposed Insulation
In Moore U.S. Pat. No. 6,438,918 & U.S. Pat. No. 6,481,178 use an ICF as a form and a precast concrete facing is attached to the ICF. In U.S. Pat. No. 6,681,539 (filed Oct. 24, 2001) by Yost uses metal channels, insulation and ties to pour a precast wall.
E. Foam Panel
In U.S. Pat. No. 5,943,775 (filed May 7, 1998) and U.S. Pat. No. 6,167,624 (filed Nov. 3, 1999) by Lanahan uses a polymeric foam panel with metal channels installed within the foam. The panels are interlocked together by a tongue and groove connection using the foam as the connector. An electrical conduit is horizontally installed within the panel for electrical distribution. The metal channels are embedded within the foam. None of the Lanahan patents use their panels to form concrete columns or beams. Walpole in U.S. Pat. No. 7,395,999 embeds a metal channel in foam for support and uses a tongue & groove joint sealer between panels. In U.S. Pat. No. 5,722,198 (filed Oct. 7, 1994) and U.S. Pat. No. 6,044,603 (filed Feb. 27, 1998) by Bader discloses a panel & method to form a metal channel and foam panel where the flanges are embedded into the sides of the foam panels. In U.S. Pat. No. 5,279,088 (filed Jan. 17, 1992), U.S. Pat. No. 5,353,560 (filed Jun. 12, 1992) and U.S. Pat. No. 5,505,031 (filed May 4, 1994) by Heydon show a wall and panel structures using overlapping foam and metal channels in various configurations.
F. Foam Tape on Studs
Foam tape is shown on metal and wood channels to reduce the conductivity between different building materials.
In U.S. Pat. No. 6,125,608 (filed Apr. 7, 1998) by Charlson shows an insulation material applied to the flange of an interior support of a building wall construction. The claims are very broad since insulating materials have been applied over interior forming structures for many years. The foam tape uses an adhesive to secure the tape to the interior building wall supports.
G. No Relationship to Invention—Appeared Significant
In U.S. Pat. No. 5,335,472 (filed Nov. 30, 1992) & U.S. Pat. No. 6,519,904 (filed Dec. 1, 2000) by Phillips initially developed a patent where a concrete wall is formed by pneumatically applying concrete to a foam panel with a wire mesh layer. A concrete column is pneumatically applied in the U.S. Pat. No. 5,335,472 and a vertically poured concrete column in the second patent using metal channels, a forming plate and pneumatically placed concrete wall as the concrete form. None of the Phillips patents relate to the pending patent.
SUMMARY OF THE INVENTION
The present invention relates to an improved wall system where a structural insulating core wall uses various wall forming structures and spacer blocks interconnecting between each other. The spacer blocks have vertical and horizontal interlocking tongue and groove connections that connect between the wall forming structure and the spacer blocks. The spacer blocks can cover the flanges of the support channels or just protrude beyond the support channels to form a thermal break.
Another variation of the invention is when the spacer blocks are wider than the support channels, and overlap the flanges of the support channels in various different ways. Beams and columns are cut into the structural insulating core and laid horizontally into a forming bead where concrete is poured over or under the structural insulating core.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an isometric view of the structural insulating wall where the spacer blocks are wider and interlock between the support channels and horizontal bracing channels and horizontal tongue fit into a trough of the spacer blocks connecting to the support channels together along with the base plate connections to the spacer blocks and support channels.
FIG. 2 shows an isometric view of a half wall and the tongue and groove connection between the spacer blocks.
FIG. 3 shows an isometric view of a concrete mold where the concrete over the structural insulating core.
FIG. 4 shows an enlarged view of the concrete beam shown in FIG. 3.
FIG. 5 shows an isometric view of a concrete mold where the concrete is below the structural insulating core.
FIG. 6 shows a wall section of the concrete mold shown in FIG. 5.
FIG. 7 is a wall section view of FIG. 2 with the concrete poured over the structural insulating core.
FIG. 8 is an isometric view of a concrete mold where concrete is pour over the structural insulating core and the support channels are separate from the concrete columns within the wall mold.
FIG. 9 is an isometric view of a concrete mold where the support channels have one flange within the spacer blocks and the remainder of the support channels is embedded within the concrete beam.
FIG. 10 is an isometric view of the concrete mold where no support channels are used and the column mold extends above the structural insulating core.
FIG. 11 is an isometric view of a lift connector embedded into the structural insulating core.
FIG. 12 shows an enlarged isometric view of the column mold extending above the structural insulating core.
FIG. 13 shows foam material installed into the holes of the hat channel.
FIG. 14 a section through a C channel where insulating foam is installed over the flange of the support channel.
FIG. 15 shows the insulating foam separated from the flange of the support channels.
FIG. 16 shows the insulating foam separated from the flange of a double flange channel or U channel.
FIG. 17 shows a front elevation of a concrete wall with grooves and recesses.
FIG. 18 shows the rear elevation of a concrete wall with the concrete columns and beams.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an isometric view a wall mold 97 comprising of a structural insulating core 111 shown in a vertical position, however the wall mold 97 is built in a horizontal position and erected vertically after concrete 39 is install. The support channels in the structural insulating core 111 are shown as C channels 42 and spacer blocks 56 fit between the C channels 42. The left side shows the wall assembled and the right side shows the various wall components separated. The right side shows the support channel as a C channel 42 with the horizontal bracing channel 150 shown as a horizontal U channel 155 passing through the hole 36 in the web 42a of the C channel 42. On both sides of the C channel 42 are spacer blocks 56 that have a trough 132 at the top of each spacer block 56. The horizontal U channel 155 fits through the hole 36 and into the troughs 132 of the spacer blocks 56. Another spacer block 56 is shown above the horizontal U channel 155 where a horizontal tongue 56t fits into the trough 132 of the spacer block 56 below. The trough 132 is deeper than the horizontal U channel 155 so to allow space for any mechanical/electric utilities to pass through. All the spacer blocks 56 are shown deeper than the length of the web 42a of the support channel so projection 56p can extend over the flanges 42b of the C channel 42. The spacer blocks 56 have a tongue shape 56a that fits between the lips 42c and abut the webs 42a and the lip 42c of the C channels 42 and a groove shape 56b where the groove shape abuts the web 42a of the C channel 42 and the projections 56p of the spacer block 56 extends over the flanges 42b of the C channel 42 abutting the adjacent spacer block 56. The base plate 120 is shown also as a horizontal U channel 155, however the web 155a is secured to a floor after the wall panel 65 is complete. When the wall mold 97 is being assembled, the webs 155b are attached to the flanges 42b of the C channel 42 and the flanges 42b also slide into a groove 121 at the bottom of the spacer block 56. The left side of FIG. 1 shows the wall panel 65 completed with the structural insulating core 111 assembled together with the concrete 39 installed over the structural insulating core 111 and a rigid board 50 installed after the wall panel 65 is erected vertically. Also installed in the structural insulating core 111 is a column mold 20 which is explained further in FIG. 3. Also shown are drainage channels 151 that protrude from the structural insulating core 111 to create an air space should the structural insulating core 111 be the exterior surface finish materials (not shown) are applied over the structural insulating core 111 and concrete 39 is the exposed surface on the interior. In addition, drainage channels 151 are shown on the exterior face of the structural insulating core 111 to allow water drainage between the structural insulating core 111 and various stucco applications. The recessed grooves 133 and drainage channels 151 can also be accents at the exterior face of the structural insulating core 111 as shown in FIGS. 16 & 17. The base plate 120 can be used as part of the wall mold 97, but is not necessary when forming a beam mold 90 as shown in some later figures.
FIG. 2 is similar to FIG. 1 except the four spacer blocks 56 of the structural insulating core 111 does not extend over both flanges, the thickness of the spacer blocks is thinner and varies in thickness as shown in FIGS. 5-9. The groove shape 56b of the spacer block 56 has a projection 56p and extension 56e that extends beyond the webs 42a of the adjoining C channels 42 enough to create a thermal break and cover the C channels 42. The open portion of the C channel 42 has a web 42a and a lip 42c where the tongue shape 56a fits against and between and a horizontal bracing channel 150 (typically used to connect adjacent C channels within the building industry) and an indentation 56i where the extension 56e fits against. FIG. 2 is similar to FIG. 1 since the isometric view a wall mold 97 is shown in a vertical position, however the wall mold 97 is built in a horizontal position and erected vertically after concrete 39 is install. Since the spacer blocks 56 overlaps the C channel 42 at the projection 56p and fits between the webs 42a, the spacer block 56, the spacer block 56 is a wall insulation as well as a support for pouring concrete 39 onto the structural insulating core. The vertical connection between the spacer blocks 56 has a horizontal tongue 56t the width of the projection 56p and extends downward into the indentation 56i of the spacer block 56 when the spacer block is narrow. FIG. 7 shows the support channels exposed and FIGS. 8 & 9 the support channels are encased in concrete 39.
FIGS. 3-6 uses a structural insulating core 111 from FIG. 1 with spacer blocks that overlap both of the flanges 42b of the C channel 42. The wall panel 65 shown in FIG. 3 is shown horizontally where the floor 175 is the bottom of the precast mold 180 and the support channels shown as C channel 42 have spacer blocks between them. A column mold 20 is shown with C channels on both sides and the C channels 42 extend into the beam mold 90. The spacer blocks are part of the precast wall mold 180 and do not extend into the beam mold. The C channels 42 within the beam mold are shown with insulating foam 100 fitting over the flanges 42b and lip 42c of the C channel 42 so drywall (not shown) or other materials can be attached after the concrete 39 has cured. In addition, ribs 124 are installed parallel to the C channel 42 and another rib 124 is installed perpendicular to the C channel 42 in the structural insulating core 111 for additional strength if required. Screws 122 or double headed fasteners (not shown) are attached through the structural insulating core 111 into the C channel 42 to secure the structural insulating core 111 to the concrete. The precast mold 180 is complete when the wall panel 65 side boards (not shown) are installed. Additional steel reinforcing (not shown) is installed in the beam molds 90 and the column mold 20 and concrete 39 is poured over and into the precast mold 180 when the precast mold 180 is in a horizontal position. Since the concrete 39 passes through the holes 36 (not shown) in the C channel 42 of the beam mold 90, the C channel 42 is secured to the structural insulating core 111. When the ribs 124 and recessed grooves 131 are added to the precast mold 180, the screws 122 securing the concrete 39 to the structural insulating core 111 might not be needed. The rigid insulation 51 shown in FIG. 1 can be used as the bottom of the precast mold 180 or a forming bed, typically used in precast construction can be used. In addition a recessed groove 131 is installed to additionally secure the structural insulating core 111 to the concrete. FIG. 4 is an enlarged view of the beam mold 90.
FIG. 5 is showing an isometric view of the same precast mold 180 as shown in FIG. 3 except the precast mold 180 is shown face down and FIG. 6 is the wall section of FIG. 5. The precast mold 180 is turned upside down so that the precast mold 180 is now placed onto a forming bed 184 and the structural insulating core 111 is suspended over the forming bed 184 so the flange 42b is set to the depth of the concrete 39 of the precast mold 180. In FIGS. 14-16 show the foam material 54 that can be used for C channels 42 or U channels 41. The foam material 54 is not necessary unless an additional material is going to be attached to the concrete 39. Holes 36 are cut into the structural insulating core 111 at the criss-crossing ribs 124 to ensure concrete 39 flows into the ribs 124. Another way to form the precast mold 180 is to install the insulating foam 100 on each of the C channels 42 along with the screws 122 and install an angle 77 connecting each C channel 42 to the desire shape of the precast mold 180. Now set the precast mold 180 over the forming bed 184 and pour the concrete 39 into the forming bed 184, beam mold 90 and into the column mold 20. After the concrete has become firm, then add the remaining foam spacer 55 to complete the structural insulating core 111. The edge forming boards of the precast mold 180 are shown in (ghost).
FIG. 7 is similar to the wall panel 65 in FIG. 2 except support channels shown as C channels 42 are horizontally on the floor 175 or forming bed 184. The precast mold 180 is above the C channels 42 since the projection 56p rest on the flange 42b of the C channels 42 and the remainder of the spacer block 56 rest on the horizontal bracing channel 155 spanning between the support channels. The beam mold 90, column mold 20 or any ribs 124 (not shown) are on the same surface as the projection 56p and the screws 122 are attached through the projection 56p of the spacer block. The concrete mold 180 is complete when steel reinforcing 60 (not shown) and concrete can then be installed over the precast mold 180. After the concrete 39 has cured, the concrete mold 90 can be tilted vertically into place. On the other hand, the precast mold 180 as described above can be assemble in place or as a precast mold and hoisted into place to become a floor 175 rather than a precast wall. Depending on the insulation requirements, the spacer block 56 can be deeper as shown dotted in FIG. 7.
FIGS. 8 & 9 are combinations of FIGS. 1 & 2 shown in a horizontal position. In FIG. 8 the spacer block 56 are wider than the C channel 42 and the projections 56p overlap both flanges 42b of the C channels 42. Screws are secured through the projections 56p with extensions 56e into the flange 42b of the top flange 42b. Two column molds 20 are shown cut into the spacer blocks to the required depth and additional ribs 124 are shown crossing the column molds 20 and extending parallel to the column molds 20. The beams molds 90 are shown at the top and bottom of the precast mold 180 similar to the profile shown in FIG. 2. Screws 122 are connected through the projections 56p or directly into the flanges 42b. After steel reinforcing 60 is added to the columns 20 and beams 90 concrete 39 can now be installed.
In FIG. 9 the spacer block uses the interlocking tongue and groove connection at the tongue side 56a and the groove side 56b at the C channels 42 at the bottom of the precast mold 180. The spacer blocks at the column mold 20 do not touch the C channel 42 but the spacer blocks form the edge of the column mold 20. Since the C channel 42 is exposed not screws 122 are needed. The beam mold 90 is formed the same way as the column mold 20 with the interlocking tongue and grooves of the spacer blocks 56. After steel reinforcing 60 is installed within the precast mold 180, concrete 39 is poured over the structural insulating core 111.
FIG. 10 is very similar to FIGS. 8 & 9 except no support channels or the C channels 42 are used since the spacer blocks 56 or the concrete 39 will be left unfinished. If the spacer blocks are a material like aerated autoclaved concrete (AAC) or cellular light weight concrete (CLC), lift connectors 221 can be embedded into either material and concrete 39 can adhere to the spacer blocks 56. One of the column molds 20 also shown in FIG. 12 has a rigid board 50 extending above the spacer blocks 56 on both sides of the column mold 20 with dovetail joints 213 to fit a connector 64 (not shown) into to maintain the spacing of the column mold 20.
FIG. 13 shows a cross-section of the insulating foam 100 installed on a hat channel 86. The foam material 54 can be installed by applying holes 36 on the face 70a of the hat channel 70 and then applying the foam material 54 into the holes 36 and then further removing the residual with a hot knife (not shown). The foam material 54 shown here has a thermal break at the flat edge of the foam material 54 and can be used on any metal channel needed a thermal break.
In FIG. 14 shows a cross section of a C channel 42 with different insulating foam 100 wrapped around the flange 42b of the C channel 42. The insulating foam 100 has a thickness t which is constant as it wraps around the flange 42b. The C channel 42 also has a lip 42c at the end of the flange 42b. The insulating foam 100 extends the length of the flange 42b shown as 100a, then around the lip 42c over the back side of the flange 42b shown as 100a′ and stops at the web 42a. The lip 42c and the friction of the flange 42b allow the insulating foam 100 to adhere to the C channel 42. The insulating foam 100 is shown in FIG. 15 and in FIG. 16 for a straight flange connection like a U channel 41.
FIG. 15 shows the front elevation of a wall panel 65 and FIG. 16 shows the rear of the same wall panel 65. An isometric view of the rear view of a similar wall panel 65 is shown in FIG. 10. Since a wall panel 65 can be at least 10 feet wide by 35 feet tall, smaller aerated autoclave concrete sections of the spacer block 56 can be used to form the beam molds 90 and column molds 20 are formed to complete the wall mold 181. In FIGS. 3, 8 & 9 concrete 39 is poured over the various wall molds, however when the concrete 39 is eliminated and the spacer block 56 is exposed, ribs 124 are required at the joints between the spacer block 56 wall sections. The front elevation shown in FIG. 15 has various architectural reliefs shown in FIG. 1 as a protruding drainage channel 151 or a recessed groove 133. The architectural reliefs can be installed in the aerated concrete prior to autoclaving when the aerated concrete is soft and can be cut by wire or pressed into the desired shape or can be cut after autoclaving by cutting with a saw or by hot wire cutting.
CONCLUSION AND SCOPE OF INVENTION
A structural insulating core consisting of structural support members and spacer blocks that fit between the structural support members. The spacer blocks are thermal blocks that are wider than the support members that interlock between other spacer blocks and structural support members which when assembled together form a wall. Many types of support members such as metal channels can fit between the support members and interlock together with a tongue and groove connections both vertically and horizontally. Horizontal bracing channels interlock between the support members and spacer blocks along with the horizontal tongue and trough connects interlock the spacer blocks together. The tongue and groove connections allow the spacer blocks to just slide together without fasteners or mortar to hold them in place. When the structural insulating core is placed horizontally, column molds, beam molds, plus rib and grooves are added so when concrete is poured into the wall mold a precast concrete wall is formed.
A structural insulating core where the thickness can vary which changes the shape and function of the precast molds. The precast molds can be poured face up or face down into a forming bed. Different recesses or grooves can be installed as accents on the spacer blocks or within the concrete facing.
A structural insulating core where the concrete is poured over the wall mold to form a concrete flooring system.
It is understood that the invention is not to be limited to the exact details of operation or structures shown and describing in the specification and drawings, since obvious modifications and equivalents will be readily apparent to those skilled in the art. The flexibility of the described invention is very versatile and can be used in many different types of building applications.
Patent Application
20120144767
