Insulation sheet structure and concrete sandwich wall panel assembly constructed therewith

• US 20060080923A1
• Filed: 10/14/2004
• Published: 04/20/2006
• Est. Priority Date: 10/14/2004
• Status: Abandoned Application

• Current Assignee: Peter Fleischhacker
• Original Assignee: Peter Fleischhacker
• Inventors: Fleischhacker, Peter
• Application Number:
  US10/965,049
• Publication Number:
  US 20060080923A1
• Time in Patent Office: Days
• US Class Current: 52/403.100
• CPC Class Codes: E04C 2/288 composed of insulating material and concrete, stone or stone-like material

Abstract

An insulation sheet for concrete sandwich wall panels comprising a sheet base composed substantially of expanded cellular foam and having opposed base surfaces. Protrusions integral with the sheet base extend from each of the base surfaces from a footprint at the base surface to a distal surface away from the base surface. Each of the protrusions has a cross-sectional shape such that a width of the distal surface is greater than a width of the footprint, that is, mushroom-shaped. Narrow ducts extend through the insulation sheet. Optionally, the protrusion distal surfaces are rounded.

Claims

1. An insulation sheet comprising:

(a) a sheet base composed substantially of expanded cellular foam and having opposed base surfaces;

(b) a plurality of protrusions integral with said sheet base and extending from each of said base surfaces from a footprint at said base surface to a distal surface away from said base surface; and

(c) each of said plurality of protrusions having a cross-sectional shape such that a width of said distal surface is greater than a width of said footprint.

2. The insulation sheet of claim 1 wherein said distal surfaces have shapes and the smallest of said distal surfaces is larger than the largest area between said distal surfaces.

3. The insulation sheet of claim 1 wherein said distal surfaces are rounded.

4. The insulation sheet of claim 1 wherein said sheet includes ducts that extend through said insulation sheet.

5. The insulation sheet of claim 1 wherein said expanded cellular foam is selected from the group consisting of expanded polystyrene, expanded polypropylene, expanded polyethylene, and expanded copolymers.

6. An insulation sheet comprising:

(a) a sheet base composed substantially of expanded cellular foam and having opposed base surfaces;

(b) a plurality of protrusions integral with said sheet base and extending from each of said base surfaces from a footprint at said base surface to a distal surface away from said base surface;

(c) each of said plurality of protrusions having a cross-sectional shape such that a width of said distal surface is greater than a width of said footprint;

(d) said distal surfaces being rounded and having shapes, the smallest of said distal surfaces being larger than the largest area between said distal surfaces; and

(e) said sheet including ducts that extend through said insulation sheet.

7. The insulation sheet of claim 6 wherein said expanded cellular foam is selected from the group consisting of expanded polystyrene, expanded polypropylene, expanded polyethylene, and expanded copolymers.

8. A concrete sandwich assembly comprising a first concrete layer, a second concrete layer, and an insulation sheet therebetween, said insulation layer comprising:

(a) a sheet base composed substantially of expanded cellular foam and having opposed base surfaces;

(b) a plurality of protrusions integral with said sheet base and extending from each of said base surfaces from a footprint at said base surface to a distal surface away from said base surface; and

(c) each of said plurality of protrusions having a cross-sectional shape such that a width of said distal surface is greater than a width of said footprint.

9. The insulation sheet of claim 8 wherein said distal surfaces have shapes and the smallest of said distal surfaces is larger than the largest area between said distal surfaces.

10. The insulation sheet of claim 8 wherein said distal surfaces are rounded.

11. The insulation sheet of claim 8 wherein said sheet includes ducts that extend through said insulation sheet.

12. The insulation sheet of claim 8 wherein said expanded cellular foam is selected from the group consisting of expanded polystyrene, expanded polypropylene, expanded polyethylene, and expanded copolymers.

13. A concrete sandwich assembly comprising a first concrete layer, a second concrete layer, and an insulation sheet therebetween, said insulation layer comprising:

(a) a sheet base composed substantially of expanded cellular foam and having opposed base surfaces;

(b) a plurality of protrusions integral with said sheet base and extending from each of said base surfaces from a footprint at said base surface to a distal surface away from said base surface;

(c) each of said plurality of protrusions having a cross-sectional shape such that a width of said distal surface is greater than a width of said footprint;

(d) said distal surfaces being rounded and having shapes, the smallest of said distal surfaces being larger than the largest area between said distal surfaces; and

(e) said sheet including ducts that extend through said insulation sheet.

14. The insulation sheet of claim 13 wherein said expanded cellular foam is selected from the group consisting of expanded polystyrene, expanded polypropylene, expanded polyethylene, and expanded copolymers.

15. A method of constructing a concrete sandwich assembly comprising the steps of:

(a) providing an insulation sheet comprising a sheet base composed substantially of expanded cellular foam and having opposed base surfaces, a plurality of protrusions integral with said sheet base and extending from each of said base surfaces from a footprint at said base surface to a distal surface away from said base surface, each of said plurality of protrusions having a cross-sectional shape such that a width of said distal surface is greater than a width of said footprint;

(b) pouring a first concrete layer into a form;

(c) pushing said protrusions of a first of said opposed base surfaces of said insulation sheet into said first concrete layer; and

(d) pouring a second concrete layer onto a second of said opposed base surfaces of said insulation sheet.

16. The method of claim 15 wherein said distal surfaces have shapes and the smallest of said distal surfaces is larger than the largest area between said distal surfaces.

17. The method of claim 15 wherein said distal surfaces are rounded.

18. The method of claim 15 wherein said sheet includes ducts that extend through said insulation sheet.

19. The method of claim 15 wherein said expanded cellular foam is selected from the group consisting of expanded polystyrene, expanded polypropylene, expanded polyethylene, and expanded copolymers.