Process for making insulated concrete tilt-up walls and resultant product
First Claim
1. An insulated tilt-up wall panel comprising:
- a. an insulating material;
b. one or more attachment grooves formed in the insulating material; and
c. concrete attached to the insulating material by the attachment grooves.
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Accused Products
Abstract
In a method of making insulated concrete tilt-up panels, an insulating material such as polystyrene is formed into a desired shape corresponding to the panel shape. Attachment grooves are formed across the surface of the insulating material. Preferably, the attachment grooves have a substantially triangular cross-section. The insulating material is laid groove-side-up in a concrete form and wet concrete is poured into the form. The concrete fills the grooves, attaching the insulation to the concrete panel. When the concrete is cured, the panel may be stood up and set in place so that the insulating material forms the exterior surface of the panel. A finishing material may be applied to the exterior surface of the panel. A panel set for use in constructing low-income residential housing includes four concrete tilt-up panels. The insulating material and concrete forms may be prepared in the quantity desired for the entire construction project and transported to a casting area at the construction site. The panels may be rapidly cast and assembled, reducing the time and labor required to complete the project.
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Citations
20 Claims
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1. An insulated tilt-up wall panel comprising:
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a. an insulating material; b. one or more attachment grooves formed in the insulating material; and c. concrete attached to the insulating material by the attachment grooves. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 15, 16, 17)
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12. A method of making an insulated tilt-up wall panel, the method comprising:
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a. forming an insulating material into a desired shape; b. forming one or more attachment grooves in the insulating material; c. placing the insulating material onto a substantially horizontal casting surface and within a concrete form such that the opening of the attachment grooves faces up; and d. pouring a desired amount of concrete into the concrete form, wherein the concrete substantially fills the attachment grooves and is attached to the insulating material when it cures. - View Dependent Claims (13, 14)
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18. A set of insulated tilt-up wall panels for building a residential structure, the set comprising:
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a. a standard panel; b. a jamb panel; c. a lintel panel; and d. a sill panel; wherein each panel comprises; i. an insulating material; ii. one or more attachment grooves formed in the insulating material; and iii. concrete attached to the insulating material by the attachment grooves. - View Dependent Claims (19, 20)
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Specification