Insulative concrete building panel with carbon fiber and steel reinforcement

• US 6,898,908 B2
• Filed: 04/24/2003
• Issued: 05/31/2005
• Est. Priority Date: 03/06/2002
• Status: Active Grant

• Current Assignee: Oldcastle Precast Incorporated (CRH PLC)
• Original Assignee: Oldcastle Precast Incorporated (CRH PLC)
• Inventors: Lorah, Douglas L., Messenger, Harold G., Baur, Kenneth, Graziano, Gary C., Harmon, Thomas G.
• Primary Examiner(s): Glessner, Brian E.
• Assistant Examiner(s): KATCHEVES, BASIL S
• Application Number:
  US10/423,286
• Publication Number:
  US 20040065034A1
• Time in Patent Office: 768 Days
• Field of Search: 523/091.1, 522/68, 523/097, 523/091.4, 523/091.2, 523/091.7, 524/061
• US Class Current: 52/268
• 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 2/2885 with the insulating material being completely surrounded by, or embedded in, a stone-like material, e.g. the insulating material being discontinuous
• CPC Class Codes: E04C 2002/045 with two parallel leaves connected by tie anchors
• CPC Class Codes: E04C 2002/046 Flat anchors

Abstract

An insulative, lightweight concrete building panel is provided with one or more fiber or steel reinforcements which are manufactured in a controlled environment and can be easily transported and erected at a building site.

Claims

1. A carbon fiber reinforced concrete building panel, comprising:

a substantially planar concrete panel comprising an inner surface, an outer surface, an upper end and a lower end, and a substantially longitudinal axis defined between said upper end and said lower end;

a first carbon fiber grid positioned within said substantially planar concrete panel between said upper end and said lower end and positioned proximate to said inner surface;

a foam core having an inner surface and an outer surface positioned within said substantially planar concrete panel and extending substantially between said upper end and said lower ends of said substantially planar concrete panel;

at least one carbon fiber shear strip extending through said foam and oriented in a substantially linear direction between said upper end and said lower ends of said substantially planar concrete panel;

at least one first reinforcing bar positioned proximate to said at least one carbon fiber shear strip, and extending substantially between said upper end and said lower end of said substantially planar concrete panel; and

a wire mesh material positioned above said upper surface of said foam core and proximate to said outer surface of said substantially planar concrete panel.

2. The carbon fiber reinforced concrete building panel of claim 1, wherein said at least one carbon fiber shear strip is comprised of an interwoven grid of individual carbon fibers.

3. The carbon fiber reinforced concrete building panel of claim 1, further comprising at least one lifting anchor interconnected to at least one of said upper end, said lower end, said outer surface and said inner surface.

4. The carbon fiber reinforced concrete building panel of claim 1, wherein said foam core is comprised of a plurality of individual foam core panels.

5. The carbon fiber reinforced concrete building panel of claim 1, further comprising a second reinforcing bar positioned above said at least one first reinforcing bar and positioned proximate to said wire mesh.

6. The carbon fiber reinforced concrete building panel of claim 1, wherein said at least one carbon fiber shear strips are prefabricated into individual sections of foam panels which have a thickness less than said foam core.

7. The carbon fiber reinforced concrete building panel of claim 1, further comprising a spacer positioned between said foam core and said wire mesh material, wherein a layer of concrete is provided between an outer surface of said foam core and said wire mesh material.

8. The carbon fiber reinforced concrete building panel of claim 1, further comprising a second reinforced section having at least one reinforcing bar oriented in a direction substantially perpendicular to said substantially longitudinal axis to define at least a portion of a window or a door.

9. The carbon fiber reinforced concrete building panel of claim 1, wherein said at least one first reinforcing bar is comprised of a metallic rod having a diameter of at least about 0.50 inches.

10. The carbon fiber reinforced concrete building panel of claim 1, further comprising a third reinforcing bar which is positioned proximate to at least one of a plurality of perimeter edges of said substantially planar concrete panel.

11. The carbon fiber reinforced concrete building panel of claim 1, further comprises a second carbon fiber sheer strip positioned proximate to at least one of a plurality of perimeter edges of said substantially planar concrete panel.

12. The carbon fiber reinforced concrete building panel of claim 1, further comprising at least one spacer positioned at least partially around at least one first reinforcing bar, wherein there is a predetermined amount of separation between said foam core and said at least one first reinforcing bar.

13. A reinforced concrete building panel having an upper end, a lower end, and lateral edges extending therebetween, comprising:

a first layer of concrete having a first reinforcing grid positioned therein;

a second layer of concrete having a second reinforcing grid positioned therein;

a foam core comprised of a plurality of individual panels having at least one beveled edge which defines a groove for receiving at least one reinforcing rod positioned between said first layer of concrete and said second layer of concrete;

a plurality of third reinforcing grids positioned within said foam core and extending between said first layer of concrete and said second layer of concrete, said plurality of third reinforcing grids oriented in a substantially linear direction and extending between said upper end and said lower end of said building panel, wherein said at least one reinforcing rod is positioned proximate to said plurality of third reinforcing grids; and

a plurality of spacers interconnected to said at least one reinforcing rod to provide separation between said at least one reinforcing rod and said foam core.

14. The reinforced concrete building panels of claim 13, wherein said first reinforcing grid is comprised of a carbon fiber material.

15. The reinforced concrete building panels of claim 13, wherein said second reinforcing grid is comprised of a wire mesh material.

16. The reinforced concrete building panels of claim 13, wherein said plurality of third reinforcing grids is comprised of a carbon fiber material.

17. The reinforced concrete building panels of claim 13, wherein said third reinforcing grid is comprised of at least one of a plastic material, a metal material and a fiberglass material.

18. The reinforced concrete building panels of claim 13, wherein said second reinforcing grid is comprised of a least one of a plastic material, a metal material and a fiberglass material.

19. The reinforced concrete building panel of claim 13, further comprising a metallic reinforcing rod positioned substantially parallel to said at least one reinforcing rod.

20. The reinforced concrete building panel of claim 13, further comprising a lifting anchor interconnected to at least one of said upper end, said lower end, an interior surface and an exterior surface of said reinforced concrete building panel.

21. The reinforced concrete building panel of claim 13, further comprising a spacer positioned between said foam core and said second reinforcing grid.

22. The reinforced concrete building panel of claim 13, wherein said foam is comprised of an expanded polystyrene material.

23. The reinforced concrete building panel of claim 13, wherein said reinforced concrete building panel has a density of no greater than about 41 pounds per square foot.

24. The reinforced concrete building panel of claim 13, further comprising at least one reinforcing bar positioned along at least one perimeter edge of said reinforced concrete building panel.