Insulative building panel with transverse fiber reinforcement

• US 6,729,090 B2
• Filed: 05/17/2002
• Issued: 05/04/2004
• Est. Priority Date: 03/06/2002
• Status: Active Grant

• Current Assignee: Oldcastle Precast Incorporated (CRH PLC)
• Original Assignee: Oldcastle Precast Incorporated (CRH PLC)
• Inventors: Carson, John M., Fifield, John A., Messenger, Harold G., Harmon, Thomas G.
• Primary Examiner(s): Canfield, Robert
• Application Number:
  US10/150,465
• Publication Number:
  US 20030167716A1
• Time in Patent Office: 718 Days
• Field of Search: 523/097, 523/099, 523/091.1, 523/091.4, 523/091.6, 523/091.7, 524/071, 527/941
• US Class Current: 52/309.12
• CPC Class Codes: E04C 2/044 of concrete E04C2/049 takes precedence
• CPC Class Codes: E04C 2/049 completely or partially of insulating material, e.g. cellular concrete or foamed plaster
• CPC Class Codes: E04C 2/06 reinforced
• CPC Class Codes: E04C 2/288 composed of insulating material and concrete, stone or stone-like material
• CPC Class Codes: E04C 2002/045 with two parallel leaves connected by tie anchors

Abstract

An insulative panel with transverse fiber reinforcements is provided and which is adopted for use with a plurality of building materials such as concrete to create a lightweight, high strength building panel having superior insulative properties.

Claims

1. A reinforced insulative core adapted for use with at least one facing material, comprising:

an insulative material having a front surface, a back surface, a top side, a bottom side and a pair of opposing lateral edges extending therebetween;

a first plurality of fibers positioned proximate to said front surface and extending substantially between said top side, said bottom side and said pair of opposing lateral edges;

a second plurality of fibers positioned proximate to said back surface and extending substantially between said top side, said bottom side and said pair of opposing lateral edges;

at least one interwoven fiber grid extending substantially from said back surface to said front surface of said insulative material, and interconnecting said first plurality of fibers to said second plurality of fibers, wherein said insulative material, said at least one interwoven fiber grid and said first and said second plurality of fibers are operatively interconnected.

2. The apparatus of claim 1, wherein said insulative material further comprises a plurality of protuberances extending outwardly from said front surface and said back surface, wherein a space is provided between said first and said second plurality of fibers, respectively, and said front surface and said back surface.

3. The apparatus of claim 1, wherein said insulative material further comprises a plurality of ridges extending outwardly from said front surface and said back surface, wherein a space is provided between said first and said second plurality of fibers, respectively, and said front surface and said back surface.

4. The apparatus of claim 1, wherein said insulative material further comprises a plurality of channels extending into said front surface and said back surface, wherein a thickness of said substantially planar insulative material is operatively reduced in predetermined locations.

5. The apparatus of claim 1, wherein said first and said second plurality of fibers are comprised of at least one of a carbon fiber, a fiberglass, an aramid, a woven and a non-woven fiber.

6. The apparatus of claim 1, wherein said at least one fiber grid comprises a plurality of fibers oriented in a transverse pattern with respect to said front surface and said back surface of said insulative material.

7. The apparatus of claim 1, wherein said at least one fiber grid is comprised of at least one of a woven, a knitted, and a non-woven fiber which is at least partially coated with a polymer.

8. The apparatus of claim 7, wherein said polymer is at least one of a thermoset adhesive and a thermoplastic adhesive.

9. The apparatus of claim 1, wherein said substantially planar insulative material is comprised of at least one of an expanded polystyrene, a urethane, a polyolefin, a polyethylene and an ethylene propylene diene monomer.

10. The apparatus of claim 1, wherein said at least one facing material is comprised at least in part of a concrete material.

11. A building panel adapted for use with at least one facing material, comprising:

an insulative material having a front surface and a back surface;

a first plurality of interconnected fibers positioned proximate to said front surface;

a second plurality of interconnected fibers positioned proximate to said back surface;

at least one fiber grid positioned within said insulative material and having at least a portion extending transversely between said front surface and said back surface, and operably interconnecting said first plurality of interconnected fibers to said second plurality of interconnected fibers; and

a spacing means in contact with at least one of said front surface and said back surface of said insulative material to provide a separation between said first and said second plurality of fibers and said insulative material.

12. The apparatus of claim 11, wherein said spacing means comprises a plurality of protuberances extending outwardly from said insulative material.

13. The apparatus of claim 11, wherein said spacing means comprises at least one channel positioned in said insulative material, wherein said separation is filled with a cladding layer.

14. The apparatus of claim 12, wherein said spacing means comprises at least one rail extending outwardly from said insulative material.

15. The apparatus of claim 11, wherein said first and said second plurality of interconnected fibers are comprised of at least one of a carbon fiber, a fiberglass, a plastic and a woven fiber coated with a polymer.

16. The apparatus of claim 11, wherein said at least one fiber grid is comprised of a plurality of interwoven carbon fibers.

17. The apparatus of claim 11, wherein said insulative material is comprised of at least one of an expanded polystyrene, a urethane, a polyolefin, a polyethylene and an ethylene propylene diene monomer.

18. The apparatus of claim 11, wherein said insulative material has at least two distinct widths as measured between said front surface and said rear surface.

19. The apparatus of claim 11, further comprising an exterior concrete cladding material positioned adjacent said front surface and an interior concrete cladding material positioned adjacent said back surface.

20. The apparatus of claim 11, wherein said spacing means is integrally molded with said insulative material.