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

• US 9,290,939 B2
• Filed: 04/13/2015
• Issued: 03/22/2016
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• 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:
  US14/684,899
• Publication Number:
  US 20150218809A1
• Time in Patent Office: 344 Days
• Field of Search: 523/099, 523/091.1, 523/091.4, 523/091.7, 523/091.2, 526/02
• US Class Current: 1/1
• 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: H05K 999/99 : dummy group
• 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 roofing system comprising:

a foam insulating panel, the panel having a first primary surface and an opposite second primary surface;

a concrete panel formed on the first primary surface, the concrete panel having a first primary surface and an opposite second primary surface;

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 and wherein the first end comprises a first enlarged portion flush with the second primary surface of the foam insulating panel and the second end is disposed between the first and second primary surfaces of the concrete panel;

at least one concrete reinforcing portion extending outwardly from the concrete panel into the foam insulating panel;

a layer of reinforcing material disposed on and attached to the second primary surface of the foam insulating panel by a roofing membrane primer material, wherein at least a portion of the reinforcing material is disposed between the first enlarged portion of the elongate anchor member and the second primary surface of the concrete panel; and

a roofing membrane disposed on the layer of reinforcing material.

2. The roofing system of claim 1, wherein the roofing membrane is a fluid applied roofing membrane.

3. The roofing system of claim 2, wherein the roofing membrane is a sheet of polymeric roofing membrane.

4. The roofing system of claim 3, wherein the sheet of polymeric roofing membrane is made from ethylene propylene diene monomer rubber, polyvinyl chloride or thermoplastic polyolefin.

5. The roofing system of claim 3, wherein the sheet of polymeric roofing membrane is made from thermoplastic polyolefin.

6. A roofing system comprising:

a foam insulating panel having a first primary surface and an opposite second primary surface;

a concrete panel formed on the first primary surface, the concrete panel having a first primary surface and an opposite second primary surface;

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 first end and an opposite second end and wherein the first end comprises a flange extending radially outwardly and the second end of the elongate anchor member is disposed between the first and second primary surfaces of the concrete panel;

a layer of reinforcing material disposed on and attached to the second primary surface of the foam insulating panel by a polymeric material, wherein at least a portion of the reinforcing material is disposed between the first enlarged portion of the elongate anchor member and the second primary surface of the concrete panel; and

a layer of cementitious material disposed on the layer of reinforcing material; and

a first roofing membrane disposed on the layer of cementitious material.

7. The roofing system of claim 6, wherein the first roofing membrane is a fluid applied roofing membrane.

8. The roofing system of claim 6 further comprising a second roofing membrane disposed on the first roofing membrane.

9. The roofing system of claim 8, wherein the first and second roofing membranes are fluid applied roofing membranes.

10. The roofing system of claim 8, wherein the second roofing membrane is a sheet of polymeric roofing material.

11. The roofing system of claim 10, wherein the sheet of polymeric roofing material is made from ethylene propylene diene monomer rubber, polyvinyl chloride or thermoplastic polyolefin.

12. The roofing system of claim 10, wherein the sheet of polymeric roofing material is made from thermoplastic polyolefin.

13. A roofing system comprising:

a foam insulating panel, the panel having a first primary surface and an opposite second primary surface;

a concrete panel formed on the first primary surface, the concrete panel having a first primary surface and an opposite second primary surface;

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 first end and an opposite second end and wherein the first end comprises a flange extending radially outwardly and the second end of the elongate anchor member is disposed between the first and second primary surfaces of the concrete panel; and

a layer of reinforcing material disposed on and attached to the second primary surface of the foam insulating panel by a roofing membrane primer material, wherein at least a portion of the reinforcing material is disposed between the first enlarged portion of the elongate anchor member and the second primary surface of the concrete panel, wherein the layer of reinforcing material is discontinuous or a mesh;

a layer of cementitious material disposed on the layer of reinforcing material; and

a first roofing membrane disposed on the layer of cementitious material.