Static structures (e.g. – buildings) – With synthetic resinous component – Foam
Reexamination Certificate
1998-10-27
2001-03-20
Friedman, Carl D. (Department: 3635)
Static structures (e.g., buildings)
With synthetic resinous component
Foam
C052S309400, C052S309700, C052S309120, C052S309160, C052S309170, C052S309150, C052S281000, C052S379000, C052S745090, C052S745190
Reexamination Certificate
active
06202375
ABSTRACT:
BACKGROUND—FIELD OF INVENTION
The present invention relates in general to the field of buildings and more particularly to composite panels for concrete buildings.
BACKGROUND—DESCRIPTION OF PRIOR ART
Conventional concrete building panels are typical simple concrete slaps with imbedded reinforcement members in order to use the high compression strength from concrete together with the tensile strength of the reinforcing members.
Concrete by itself has relatively poor insulative properties although building panels have been developed in with the structural strength of concrete and reinforcing members have been combined with insulative properties.
In recent years, various techniques are developed for composite panels by combining outside concrete layers with inside insulation core and using structural members to connect them. By narrowing the methods to advanced techniques, three basic methods are found.
First, three dimensional welded wire space frame with an insulated core flanked by wire mesh connected with wire welded to the outer wire mesh layer and using field applied shotcrete This panel is manufactured by a machine which forces the wire in an angle through the insulated core and welded the wire to the flanked wire mesh. The fabricating of panels in the plant with expensive machinery is only possible by a uniform producing with high sales volume and high transport cost through an extended market. Changes of the panels are very cost-intensive.
Secondly, a three-dimensional wire frame is constructed in assembling insulated blocks in layers with wire trusses between each layer; the outer wire mesh then is clamped to the truss wire. Concrete can be field applied by shotcrete. U.S. Pat. No. 4,297,820 discloses a building structure as afore described.
Thirdly, a connector is forced through an insulation core or a prescribed pattern of holes is drilled through an insulation core through which connector rods are inserted to connect the outside concrete layers. The concrete is precast in a manufacturing plant or cast in the field in forms, or cast in form horizontal and erected in tilt up system. More advanced systems using plastic connector. U.S. Pat. No. 4,829,733 discloses a plastic shear connector with a relatively difficult method to manufacturing and use. U.S. Pat. No. 5,519,973 discloses a plastic connector that is used to connect the outer layers of concrete through an insulation core with no direct connection to the reinforcement. Both disclosures need form applied concrete.
But nevertheless, all closures heretofore known suffer from a number of disadvantages.
Steel connections like wire, truss wire or connectors, function as “thermal bridges” and can eliminate the R-value of the insulation core of up to 70%. In addition to the loss of insulation value, there is another important problem—cold spots—which can cause freeze-thaw and condensation problems.
The crack control of the concrete outer layer is preformed by wire mesh space mostly 2×2 inches for cracking, up to maximum 9 gage. This limits the structural strength for the concrete layers if formless concrete is used.
The applying technique such as field casting or precasting is complicated costly and time consuming.
The factors for the valuation of panels in these groups are high insulation value, structural strength, crack control, flexible design, easy to assemble in producing of the panels, lightweight to transport, easy to assemble on construction site, formless concrete application.
OBJECT AND ADVANTAGES OF THE INVENTION
The object of the present invention is to provide a composite panel with a method for fabricating composite panels using an improved design plastic connector and assemble them at the construction site to a structure which will be shotcreted on both sides to a concrete building which is highly insulated, provide a thermal wall storage that is fire and termite proof, hurricane, earthquake and flood resistant and fulfills the requirement for flexible design.
Still further objects and advantages will become apparent from a consideration of the ensuing description and accompanying drawings.
Building System
1—The panel is fast and easy to assemble in the plant; no expensive machinery is required: only hand tools are used. The lightweight of the panel makes the transport and unloading on to the construction site fast and efficient.
2—All material is readily available everywhere.
3—The shotcrete application has all the advantages of concrete but does not require timely construction of forms and only one finish process is required, but with many variations.
4—Multiple additives for the concrete mixtures are possible for protection or design.
5—The addition of fiber to the concrete limits the need of secondary reinforcement and use the reinforcement only for structural purpose. This allows variation of structural design.
6—Another feature of the system, lightweight steel-framing members can be assembled together in various combinations to provide efficient, versatile and structurally sound framing for non and load bearing insidewalls, floors and roofs. They offer many opportunities for savings in material cost, structural requirements, and construction time. The steel can be 100% recycled.
Connectors
1—The connector in design makes all the advantages of the panel system possible. The connector is easy to insert in the foam core of the panel, the stops and the snap connector on both sides of the connector shaft hold the connector in position for mounting the wire mesh in the required distance to the foam core for the reinforcement of the later shotcrete application.
2—The connector form with the wire mesh of the outside layers a tri-dimentional lightweight structural system that is strong for transport of any distance.
3—The high insulation value of the plastic connector and foam core allow the on-site applicated interior layer of the concrete to be a thermal storage.
4—The training time for the assembling crews for the plant and construction site is reduced to a minimum.
BRIEF SUMMARY OF THE INVENTION
The present invention comprises a composite panel with a method for fabricating composite panels using an improved design plastic connector and assembles them at the construction site to a structure, which will be shotcreted on both sides to a concrete building.
Composite Panels
Each panel has on the two major surfaces of the panel a square-welded mesh pattern of longitudinal and transverse wires of the same diameter “Welded Wire Mesh” diagonally extended highly insulative connectors spaced as required through the panel insulation core are continuously attached to the welded wire mesh using the snap connection on both ends of the connector, so they form a tri-dimentional system which greatly increases the panel strength. The snap connections at the end of connectors are designed to be inserted in a 90-degree or 45-degree angle to the wire mesh, depending on the required structural function.
The insulation core is held in the required space from each face of the wire frame to permit the wire mesh to be embedded in an application of concrete mixture including an application of fiber as for shrinkage and cracking. This replaces the welded wire fabric used for secondly reinforing and has the wire mesh reinforcing only related to the structural strength of the composite panel.
This results in the advantage for the flexible selecting of the diameter and spacing of the wire mesh only for the structural strength of a composite panel. The insulation core provides a high insulation value without thermo bridging which is increased in combination with an interior thermo storage of the interior concrete layer. The insulation core also functions as a back surface for the formless shotcrete application to receive a sprayed coating for better bonding of the concrete application to the foam core.
Method and Design of Manufacturing a Highly Insulated Connector
In a preferred design, the connector has a central shaft having at each end a snap connection for connecting the welded wire mesh with the required distance of the wi
Friedman Carl D.
Thissell Jennifer I.
LandOfFree
Method for concrete building system using composite panels... does not yet have a rating. At this time, there are no reviews or comments for this patent.
If you have personal experience with Method for concrete building system using composite panels..., we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Method for concrete building system using composite panels... will most certainly appreciate the feedback.
Profile ID: LFUS-PAI-O-2440220