High performance, reinforced insulated precast concrete and tilt-up concrete structures and methods of making same

• US 8,844,227 B1
• Filed: 03/15/2013
• Issued: 09/30/2014
• Est. Priority Date: 03/15/2013
• Status: Expired due to Fees

• Current Assignee: Romeo Ilarian Ciuperca
• Original Assignee: Romeo Ilarian Ciuperca
• Inventors: Ciuperca, Romeo Ilarian
• Primary Examiner(s): Glessner, Brian
• Assistant Examiner(s): Agudelo, Paola
• Application Number:
  US13/834,574
• Publication Number:
  US 20140260034A1
• Time in Patent Office: 564 Days
• Field of Search: 526/79, 524/14, 523/099, 5230911-30912, 523/091.4, 523/091.7, 526/02, 524/26
• US Class Current: 52/309.11
• CPC Class Codes: E04B 1/04 the elements consisting of concrete, e.g. reinforced concrete, or other stone-like material
• CPC Class Codes: E04B 1/4121 with internal threads or non-adjustable captive nuts
• CPC Class Codes: E04B 2/847 the form leaf comprising an insulating foam panel
• CPC Class Codes: E04B 2001/2481 Details of wall panels
• CPC Class Codes: E04B 2001/2484 Details of floor panels or slabs
• CPC Class Codes: E04B 2001/4192 attached to concrete reinforcing elements, e.g. rods or wires
• CPC Class Codes: E04B 2103/02 of ceramics, concrete or other stone-like material
• CPC Class Codes: E04B 5/02 Load-carrying floor structures formed substantially of prefabricated units E04B5/43 - E04B5/48 take precedence
• CPC Class Codes: E04B 7/22 the slabs having insulating properties, e.g. laminated with layers of insulating material
• 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 2/205 of foamed plastics, or of plastics and foamed plastics, optionally reinforced
• CPC Class Codes: E04C 2/26 composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups of cement and mineral fibres E04C2/04
• CPC Class Codes: E04C 2/288 composed of insulating material and concrete, stone or stone-like material
• CPC Class Codes: E04C 2/296 composed of insulating material and non-metallic or unspecified sheet-material E04C2/288 takes precedence
• CPC Class Codes: E04C 5/12 Anchoring devices tools or methods for tensioning in situ E04G21/12
• CPC Class Codes: E04C 5/125 the tensile members are profiled to ensure the anchorage, e.g. when provided with screw-thread, bulges, corrugations
• CPC Class Codes: E04C 5/127 The tensile members being made of fiber reinforced plastics
• CPC Class Codes: E04C 5/16 Auxiliary parts for reinforcements, e.g. connectors, spacers, stirrups E04C5/06 takes precedence; tools connecting reinforcing elements E04G21/12
• CPC Class Codes: E04C 5/168 : Spacers connecting parts for reinforcements and spacing the reinforcements from the form
• CPC Class Codes: E04G 21/165 : specially adapted for in situ prefabricated building elements to be tilted up in position
• CPC Class Codes: F16L 59/00 : Thermal insulation in general
• CPC Class Codes: Y02A 30/00 : Adapting or protecting infrastructure or their operation
• CPC Class Codes: Y02B 30/90 : Passive houses; Double facade technology
• CPC Class Codes: Y10T 428/24504 : Component comprises a polymer [e.g., rubber, etc.]
• CPC Class Codes: Y10T 428/24512 : Polyurethane

Abstract

The invention comprises a product. The product comprises a foam insulating panel, the panel having a first primary surface and an opposite second primary surface, wherein the foam insulating panel defines at least one recessed channel in the first primary surface, the at least one recessed channel being sized and shaped to provide a mold for a structural reinforcing member. The product also comprises a concrete panel formed on the first primary surface and filling the at least one recessed channel so as to provide a structural reinforcing member for the concrete panel. The product further comprises an elongate anchor member in the foam insulating panel and extending from the first primary surface of the foam insulating panel into the concrete panel. A method of making a composite reinforced insulated concrete structure is also disclosed.

Claims

1. A product comprising:

a foam insulating panel, the panel having a first primary surface and an opposite second primary surface, wherein the foam insulating panel defines at least one recessed channel in the first primary surface, the at least one recessed channel being sized and shaped to provide a mold for a concrete structural reinforcing member, wherein the second primary surface defines a continuous plane;

a concrete panel formed on the first primary surface of the foam insulating panel and filling the at least one recessed channel so as to provide a concrete structural reinforcing member for the concrete panel, the concrete panel having a first primary surface and an opposite second primary surface; and

an elongate anchor member in the foam insulating panel and extending from the first primary surface of the foam insulating panel into the concrete panel, wherein the elongate anchor member has a definite length defined by a first end and an opposite second end, wherein the first end comprises a first enlarged portion flush with the second primary surface of the foam insulating panel and wherein the second end of the elongate anchor member is disposed between the first and second primary surfaces of the concrete panel and wherein the second end comprises a second enlarged portion such that the second end interlocks with the concrete panel.

2. The product of claim 1, wherein the foam insulating panel comprises expanded polystyrene foam, polyisocyanurate foam or polyurethane foam.

3. The product of claim 1, wherein the elongate anchor member extends through the foam insulating panel from the second primary surface to the first primary surface.

4. The product of claim 1, wherein the foam insulating panel defines a plurality of recessed channels in the first primary surface, the recessed channels being sized and shaped to provide a mold for a concrete structural reinforcing member and wherein the concrete panel fills the plurality of recessed channels providing a plurality of concrete structural reinforcing members for the concrete panel.

5. The product of claim 4, wherein the plurality of channel are formed at least around the periphery of the foam insulating panel.

6. The product of claim 5, wherein the plurality of channels include at least one intermediate horizontal channel extending the full width of the foam insulating panel.

7. The product of claim 1 further comprising a layer of reinforcing material disposed on the second primary surface of the foam insulating panel.

8. The product of claim 7 further comprising a layer of cementitious material on the layer of reinforcing material.

9. The product of claim 8, wherein the cementitious material is a polymer modified cementitious material.

10. The product of claim 1 further comprising a layer of cementitious material on the second primary surface of the foam insulating panel.

11. The product of claim 1, wherein the plurality of recessed channels are parallel to and spaced from each other.

12. A product comprising:

a concrete panel having a first primary surface and an opposite second primary surface and having at least two parallel reinforcing columns, beams or rib on the first primary surface that at least partially define a cavity therebetween;

a layer of foam insulating material having a first primary surface and an opposite second primary surface, wherein the first primary surface of the foam insulating material contacts the at least two parallel reinforcing columns, beams or rib and fills the cavity therebetween;

a layer of reinforcing material disposed on, substantially covering and adhered to the second primary surface of the layer of foam insulating material, wherein the second primary surface defines a continuous plane;

an elongate anchor member having a definite length defined by a first end and an opposite second end, a first portion of the anchor member extending from the first primary surface to the second primary surface of the layer of foam insulating material, a second portion of the anchor member extending outwardly from the first primary surface of the layer of foam insulating material and embedded in the concrete panel between the first and second primary surfaces thereof;

a first enlarged portion on the first end of the elongate anchor member, wherein at least a portion of the layer of reinforcing material is captured between the first enlarged portion and wherein the first enlarged portion is flush with the layer of reinforcing material; and

a second enlarged portion on the second end of the elongate anchor member wherein the second enlarged portion interlocks with the concrete panel.

13. The product of claim 12 further comprising a layer of cementitious material on the layer of reinforcing material.

14. The product of claim 13, wherein the cementitious material is a polymer modified cementitious material.

15. A roofing system comprising:

the product of claim 12; and

a roofing membrane disposed on and attached to the second primary surface of the layer of foam insulating material and the layer of reinforcing material.

16. The roofing system of claim 15 further comprising the concrete panel attached to a pair of horizontally disposed steel roof joists such that the concrete panel is disposed horizontally.

17. A building structure comprising:

the product of claim 12; and

a pair of vertical columns horizontally spaced from each other, whereby the precast concrete panel is attached to the pair of vertical columns such that the precast concrete panel is disposed vertically.

18. The building structure of claim 17, wherein the vertical columns are steel I-beams.

19. The building structure of claim 17, wherein the vertical columns are concrete columns.