High performance, lightweight precast composite insulated concrete panels and high energy-efficient structures and methods of making same

• US 9,809,981 B2
• Filed: 11/03/2014
• Issued: 11/07/2017
• Est. Priority Date: 09/25/2012
• Status: Active Grant

• Current Assignee: Romeo Ilarian Ciuperca
• Original Assignee: Romeo Ilarian Ciuperca
• Inventors: Ciuperca, Romeo Ilarian
• Primary Examiner(s): Agudelo, Paola
• Application Number:
  US14/531,644
• Publication Number:
  US 20150118393A1
• Time in Patent Office: 1,100 Days
• Field of Search: 52679, 52414, 5274505, 527422
• CPC Class Codes: B32B 13/02 with fibres or particles being present as additives in the layer
• CPC Class Codes: B32B 13/12 of synthetic resin
• CPC Class Codes: B32B 13/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 15/046 of foam
• CPC Class Codes: B32B 15/14 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/54 Yield strength; Tensile strength
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 3/266 characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 5/028 Net structure, e.g. spaced apart filaments bonded at the crossing points
• CPC Class Codes: B32B 7/027 Thermal properties
• CPC Class Codes: B32B 7/08 by mechanical means
• CPC Class Codes: E04B 5/02 Load-carrying floor structures formed substantially of prefabricated units E04B5/43 - E04B5/48 take precedence
• CPC Class Codes: E04C 2/044 of concrete E04C2/049 takes precedence
• 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 2002/047 Pin or rod shaped anchors
• CPC Class Codes: E04F 13/02 of plastic materials hardening after applying, e.g. plaster surface treatment in painting technique B44D; inorganic or bituminous masses C04B; organic plastics C08L ; implements for applying plasticised materials E04F21/02
• CPC Class Codes: E04F 2203/00 Specially structured or shaped covering, lining or flooring elements not otherwise provided for
• CPC Class Codes: Y10T 428/2495 Thickness [relative or absolute]
• CPC Class Codes: Y10T 428/24967 Absolute thicknesses specified
• CPC Class Codes: Y10T 428/249923 : Including interlaminar mechanical fastener

Abstract

The invention comprises a relatively lightweight cementitious-based material panel. The cementitious-based material panel comprises a foam insulating panel having a first surface and a second surface; a first structural layer of cementitious-based material formed on the first surface of the foam insulating panel and affixed thereto; and a second non-structural layer of cementitious-based material formed on the second surface of the foam insulating panel and affixed thereto. The second non-structural layer of cementitious-based material is substantially thinner than the first structural layer of concrete. The second non-structural layer of cementitious-based material is preferably formed from polymer modified concrete, plaster or mortar. A method of making the cementitious-based material panel is also disclosed.

Claims

1. A method of forming a composite insulated concrete panel comprising:

placing a foam insulating panel on a flat horizontal surface, the foam insulating panel having a first primary surface and an opposite second primary surface, 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 foam insulating panel, a second portion of the anchor member extending outwardly from the second primary surface of the foam insulating panel, an enlarged portion on the first end of the elongate anchor member, the enlarged portion contacting the first primary surface of the foam insulating panel, wherein the enlarged portion is flush with the first primary surface of the foam insulating panel;

placing a quantity of plastic cementitious-based material on the second primary surface of the foam insulating panel;

forming the quantity of plastic cementitious-based material into a structural layer having a first primary surface and an opposite second primary surface such that the second end of the anchor member is embedded in the structural layer of cementitious-based material intermediate the first and second primary surfaces of the structural layer of cementitious-based material; and

allowing the structural layer of plastic cementitious-based material to at least partially cure.

2. The method of forming a composite insulated concrete panel of claim 1 comprising raising the foam insulating panel and attached structural layer of cementitious-based material to a vertical position.

3. The method of forming a composite insulated concrete panel of claim 2 comprising applying an architectural non-structural layer of cementitious-based material to the first primary surface of the foam insulating panel.

4. The method of forming a composite insulated concrete panel of claim 3, wherein the structural layer of cementitious-based material is approximately 2 to approximately 8 inches thick.

5. The method of forming a composite insulated concrete panel of claim 3, wherein the architectural non-structural layer of cementitious-based material is approximately ⅛

inch to 2 inches thick and is less than 50% the thickness of the structural layer of cementitious-based material.

6. The method of forming a composite insulated concrete panel of claim 1 further comprising a layer of mesh disposed on and attached to the first primary surface of the foam insulating panel such that at least a portion of the layer of mesh is disposed between the enlarged portion on the elongate anchor member and the first primary surface of the foam insulating panel.

7. The method of forming a composite insulated concrete panel of claim 1, wherein the foam insulating panel is approximately 1 inch to approximately 8 inches thick.

8. A method of forming a composite insulated concrete panel comprising:

placing a foam insulating panel on a flat horizontal surface, the foam insulating panel having a first primary surface and an opposite second primary surface, 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 foam insulating panel, a second portion of the anchor member extending outwardly from the second primary surface of the foam insulating panel, a first enlarged portion on the first end of the elongate anchor member, the first enlarged portion contacting the first primary surface, wherein the first enlarged portion is flush with the first primary surface of the foam insulating panel, a second enlarged portion on the elongate anchor member intermediate the first and second ends thereof, the second enlarged portion contacting the second primary surface;

placing a quantity of plastic cementitious-based material on the second primary surface of the foam insulating panel;

forming the quantity of plastic cementitious-based material into a structural layer having a first primary surface and an opposite second primary surface such that the second end of the anchor member is embedded in the structural layer of cementitious-based material intermediate the first and second primary surfaces of the structural layer of cementitious-based material; and

allowing the structural layer of plastic cementitious-based material to at least partially cure.

9. The method of forming a composite insulated concrete panel of claim 8 comprising raising the foam insulating panel and attached structural layer of cementitious-based material to a vertical position.

10. The method of forming a composite insulated concrete panel of claim 8 comprising applying an architectural non-structural layer of cementitious-based material to the first primary surface of the foam insulating panel.

11. The method of forming a composite insulated concrete panel of claim 10, wherein the architectural non-structural layer of cementitious-based material is approximately ⅛

inch to 2 inches thick and is less than 50% the thickness of the structural layer of cementitious-based material.

12. The method of forming a composite insulated concrete panel of claim 8, wherein the structural layer of cementitious-based material is approximately 2 to approximately 8 inches thick.

13. The method of forming a composite insulated concrete panel of claim 8 further comprising a layer of mesh disposed on and attached to the first primary surface of the foam insulating panel such that at least a portion of the layer of mesh is disposed between the enlarged portion on the elongate anchor member and the first primary surface of the foam insulating panel.

14. The method of forming a composite insulated concrete panel of claim 13, wherein the layer of mesh made from carbon fiber, fiberglass, basalt fiber, aramid fibers, polypropylene, polystyrene, vinyl, polyvinyl chloride or nylon.

15. The method of forming a composite insulated concrete panel of claim 8, wherein the foam insulating panel is approximately 1 inch to approximately 8 inches thick.

16. A method of forming a composite insulated concrete panel comprising:

forming an architectural non-structural layer of plastic cementitious-based material on a horizontal surface;

applying to the architectural non-structural layer of plastic cementitious-based material a foam insulating panel having a first primary surface and an opposite second primary surface, 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 foam insulating panel, a second portion of the anchor member extending outwardly from the second primary surface of the foam insulating panel, a first enlarged portion on the first end of the elongate anchor member, and a layer of reinforcing material substantially covering and adhered to the first primary surface of the foam insulating panel, wherein at least a portion of the layer of reinforcing material is captured between the first enlarged portion and the first primary surface of the foam insulating panel, and wherein the layer of reinforcing material contacts the architectural non-structural layer of plastic cementitious-based material such that the layer of reinforcing material is at least partially embedded in the architectural non-structural layer of plastic cementitious-based material;

placing a quantity of plastic cementitious-based material on the second primary surface of the foam insulating panel and forming it into a structural layer having a first primary surface and an opposite second primary surface such that the second end of the anchor member is embedded in the structural layer of cementitious-based material intermediate the first and second primary surfaces of the structural layer of cementitious-based material; and

allowing the architectural and structural layers of plastic cementitious-based material to at least partially cure.

17. The method of forming a composite insulated concrete panel of claim 16 comprising raising the foam insulating panel and attached structural layer of cementitious-based material to a vertical position.

18. The method of forming a composite insulated concrete panel of claim 16, wherein the architectural non-structural layer of cementitious-based material is approximately ⅛

inch to 2 inches thick and is less than 50% the thickness of the structural layer of cementitious-based material.

19. The method of forming a composite insulated concrete panel of claim 16, wherein the architectural non-structural layer of cementitious-based material is approximately ⅛

inch to 2 inches thick and is less than 50% the thickness of the structural layer of cementitious-based material.

20. The method of forming a composite insulated concrete panel of claim 16, wherein the layer of reinforcing material is a discontinuous layer or mesh made from carbon fiber, fiberglass, basalt fiber, aramid fibers, polypropylene, polystyrene, vinyl, polyvinyl chloride or nylon.