PREFABRICATED WALL PANELS

• US 20120047816A1
• Filed: 08/24/2010
• Published: 03/01/2012
• Est. Priority Date: 08/24/2010
• Status: Active Grant

• Current Assignee: Empire Technology Development LLC (Allied Inventors Management, LLC)
• Original Assignee: Empire Technology Development LLC (Allied Inventors Management, LLC)
• Inventors: Zhong, Hai
• Granted Patent: US 8,844,223 B2
• Time in Patent Office: Days
• US Class Current: 52/11
• CPC Class Codes: B28B 1/29 by profiling or strickling the material in open moulds or on moulding surfaces in rotary moulds B28B1/02; by means of profiled rollers B28B3/12, B28B3/123
• CPC Class Codes: B28B 19/0053 to tiles, bricks or the like
• CPC Class Codes: E04B 1/161 with vertical and horizontal slabs, both being partially cast in situ
• CPC Class Codes: E04B 1/164 with vertical and horizontal slabs, only the horizontal slabs being partially cast in situ
• CPC Class Codes: E04B 1/165 with elongated load-supporting parts, cast in situ E04B1/161, E04B1/163 and E04B1/164 take precedence
• CPC Class Codes: E04B 2/10 by filling material with or without reinforcements in small channels in, or in grooves between, the elements
• CPC Class Codes: E04B 2/562 with fillings between the load-bearing elongated members
• CPC Class Codes: E04B 2/68 made by filling-up wall cavities E04B2/24, E04B2/38, E04B2/52 take precedence
• CPC Class Codes: E04B 2/8647 with ties going through the forms
• CPC Class Codes: E04B 2002/0286 Building elements with coatings
• CPC Class Codes: E04B 2002/0293 solid material
• CPC Class Codes: E04C 2/205 of foamed plastics, or of plastics and foamed plastics, optionally reinforced
• CPC Class Codes: E04C 2/288 composed of insulating material and concrete, stone or stone-like material
• CPC Class Codes: E04C 3/20 of concrete or other stone-like material, e.g. with reinforcements or tensioning members reinforcing elements E04C5/00
• CPC Class Codes: E04C 3/34 of concrete other stone-like material, with or without permanent form elements, with or without internal or external reinforcement, e.g. metal coverings E04C3/36 takes precedence
• CPC Class Codes: E04G 9/05 the form surface being of plastics

Abstract

A prefabricated wall panel includes molds for casting reinforced concrete (RC) elements. The prefabricated wall panel includes foam boards, foam glass panels fixed to the foam boards, fabric mesh fixed to the foam glass panels, wire mesh fixed to the fabric mesh, and an exterior wall finish fixed to the wire mesh. Spaces defined by the foam boards and the foam glass panels form the molds for casting RC columns and beams.

Claims

1. :

A prefabricated wall panel with molds for casting reinforced concrete elements, comprising;

foam boards;

foam glass panels fixed to the foam boards, wherein spaces defined by the foam boards and the foam glass panels form molds for casting reinforced concrete elements;

fabric mesh fixed to the foam glass panels;

wire mesh fixed to the fabric mesh; and

exterior wall finish fixed to the wire mesh.

2. :

The prefabricated wall panel of claim 1, wherein the reinforced concrete elements include frame columns and dense columns having a smaller cross-sectional than the frame columns.

3. :

The prefabricated wall panel of claim 2, wherein the prefabricated wall panel has a standard depth w, and a dense column mold has a width h and a depth b, where 100 mm≦

b≦

300 mm, b<

w, and 1≦

h/b≦

3.

4. :

The prefabricated wall panel of claim 3, wherein a frame column mold has a width k and a depth z that is equal to or greater than depth w.

5. :

The prefabricated wall panel of claim 4, wherein adjacent molds are separated by a distance equal to or less than 1,250 mm.

6. :

The prefabricated wall panel of claim 2, wherein L-shaped and T-shaped frame column molds have an exterior width k and a thickness z, where 1<

k/z≦

4, k≧

500 mm, and 200 mm≦

z≦

300 mm.

7. :

The prefabricated wall panel of claim 1, wherein L-shaped and T-shaped shear wall molds have a width k and a thickness z, where k/z≧

5.

8. :

The prefabricated wall panel of claim 1, wherein a mortar fixes the wire mesh under tension to the wire mesh.

9. :

The prefabricated wall panel of claim 1, wherein the foam boards are spaced apart along a length of the prefabricated wall panel to define one or more widths of the molds for casting the columns.

10. :

The prefabricated wall panels of claim 9, wherein a thickness of the foam boards define a depth of the molds for casting the columns.

11. :

The prefabricated wall panel of claim 1, wherein the foam glass panels extend above the foam boards to form a mold for casting a reinforced concrete beam.

12. :

The prefabricated wall panel of claim 11, wherein the foam glass panels form an L-shaped angle above the foam boards on one side of the prefabricated wall panel to form the mold for casting the beam.

13. :

The prefabricated wall panel of claim 11, wherein the foam glass panels is taller on one side of the prefabricated wall panel than the other to form another mold for casting a floor slab above the mold for casting the beam.

14. :

The prefabricated wall panel of claim 11, wherein notches are formed in the foam glass panels above the foam boards on one side of the prefabricated wall panel to provide access to other RC beams.

15. :

The prefabricated wall panel of claim 11, further comprising bolts passing through the prefabricated wall panel within the mold for casting the beam.

16. :

The prefabricated wall panel of claim 15, further comprising an internally and externally threaded sleeve fitted to an end of each bolt.

17. :

The prefabricated wall panel of claim 1, further comprising bolts passing through the prefabricated wall panel alongside the molds for casting the columns.

18. :

The prefabricated wall panel of claim 17, further comprising a washer fitted to one end of each bolt, the washer having holes tied by wires to the wire mesh.

19. :

The prefabricated wall panel of claim 1, wherein the foam glass panels form a vertical U-channel along a space between two foam boards to form a mold for a reinforced concrete column.

20. :

The prefabricated wall panel of claim 19, wherein the U-channel includes a vertical slot to provide access to a shear wall.

21. :

The prefabricated wall panel of claim 1, wherein the wire mesh extends over the top of the foam glass panel.

22. :

The prefabricated wall panel of claim 1, wherein the foam glass panels forms a mold for a cantilevered slab from one side of the prefabricated wall panel.

23. :

The prefabricated wall panel of claim 1, wherein the foam glass panels form a U-channel against a foam board at a lateral end of the prefabricated wall panel to form a mold for casting a reinforced concrete window column, the mold including a top opening for receiving a protruding tab from an adjoining upper prefabricated wall panel and a lower opening for providing access to another mold in an adjoining lower prefabricated wall panel for forming part of the window column.

24. :

The prefabricated wall panel of claim 1, wherein another space between the foam boards and the foam glass panels form another mold for casting a reinforced concrete shear wall.

25. :

The prefabricated wall panel of claim 1, wherein the molds include a portion for casting capitals to support a precast floor slab.

26. :

The prefabricated wall panel of claim 1, further comprising a conduit holder.

27. :

The prefabricated wall panel of claim 1, further comprising a foam U-channel fixed near the top of one side of the prefabricated wall panel, the U-channel forming a cornice with a rain gutter.

28. :

The prefabricated wall panel of claim 1, further comprising a foam core fixed near the bottom of one side of the prefabricated wall panel, the foam core forming an architrave.

29. :

The prefabricated wall panel of claim 28, wherein a bottom of the architrave comprises a drip line.

30. :

The prefabricated wall panel of claim 1, wherein the exterior wall finish includes at least one of a faux column, a relief, and a cornice line.

31. :

A prefabricated wall panel system, comprising;

full-height prefabricated wall panels;

a less-than-full-height upper prefabricated wall panel fixed between the full-height prefabricated wall panels to define a window or a door opening below the less-than-full-height upper prefabricated wall panel and between the full-height prefabricated wall panels;

wherein at least one of the full-height and the less-than-full-height upper prefabricated wall panel comprises;

one or more foam boards;

foam glass panels fixed to the one or more foam boards;

fabric mesh fixed to the foam glass panels;

wire mesh fixed to the fabric mesh; and

exterior wall finish fixed to the wire mesh.

32. :

The system of claim 31, wherein spaces defined by the one or more foam boards and the foam glass panels form molds for casting reinforced concrete elements.

33. :

The system of claim 31, wherein each full-height prefabricated wall panels is selected from the group consisting of straight and L-shaped corner prefabricated wall panels.

34. :

The system of claim 31, further comprising a less-than-full-height lower prefabricated wall panel fixed between the full-height prefabricated wall panels below the less-than-full-height upper prefabricated wall panel to define the window opening.

35. :

The system of claim 34, wherein the less-than-full-height upper and lower prefabricated wall panel are selected from the group consisting of rectilinear and polygonal less-than-full-height upper and lower prefabricated wall panels.