Concrete composite wall panel

• US 7,681,368 B1
• Filed: 08/21/2007
• Issued: 03/23/2010
• Est. Priority Date: 08/21/2007
• Status: Active Grant

• Current Assignee: Edward Rubio
• Original Assignee: Edward Rubio
• Inventors: Rubio, Edward
• Primary Examiner(s): Chilcot, Jr.; Richard E
• Assistant Examiner(s): AKBASLI, ALP A
• Application Number:
  US11/842,182
• Time in Patent Office: 945 Days
• Field of Search: 523/097, 523/099, 523/091.1, 523/091.2, 523/091.6, 523/091.7, 523/092, 527/941
• US Class Current: 52/309.12
• CPC Class Codes: E04C 2/044 of concrete E04C2/049 takes precedence

Abstract

A composite wall panel for exterior walls of a structure includes a polymeric foam core having a C-stud framing system embedded therein and an exterior and/or interior facing formed of a reinforced concrete bonded to the core surface and mechanically attached to the studs thereby providing increased strength, insulation and resistance to environmental conditions.

Claims

1. A composite wall panel comprising:

a rectangular foam core having transversely spaced vertical interior and exterior planar surfaces, horizontally spaced vertical planar end surfaces and vertically spaced transverse upper and lower horizontal planar surfaces;

a plurality of C-studs, each of said studs characterized by a transverse base wall terminating at outer ends with lateral inner and outer side walls, said side walls terminating at outer ends with inwardly turned flanges;

a plurality of vertically extending slots formed in said foam core between said end surfaces, each of said slots having a transverse portion slidably engaging a portion of said base wall of a stud and an internal end section slidably engaging one of said flanges of said stud whereby a remaining portion of said base wall and the other of said flanges extends outwardly from said interior surface of said core;

a reinforcing mesh on said exterior surface of said core and fastened to said flanges of said one of said studs;

upper and lower U-shaped track members each having a base and turned inner and outer legs, said bases engaging said top and bottom surfaces of said foam core, and said outer leg retained in a lateral slot in the top and bottom surfaces of said core adjacent said outer flanges of said studs and fastened thereto;

an outer facing of concrete material embedding said reinforcing mesh and bonded to said exterior surface of said core; and

an inner wall panel fastened to said inner flanges of said stud.

2. The composite wall panel as recited in claim 1 wherein said foam core is comprised of a plurality of abutting lateral sections.

3. The composite wall panel as recited in claim 2 wherein said wall panel includes an opening partially framed by laterally spaced studs.

4. The composite wall panel as recited in claim 1 wherein said core is formed of an expanded polystyrene material.

5. The composite panel as recited in claim 4 wherein said slots are formed by locally melting said expanded polystyrene material.