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

• US 9,982,433 B2
• Filed: 08/08/2017
• Issued: 05/29/2018
• 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): Agudelo, Paola
• Application Number:
  US15/671,986
• Publication Number:
  US 20170370101A1
• Time in Patent Office: 294 Days
• 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 method comprising:

positioning a foam insulating panel on a horizontal surface, the foam insulating 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, wherein a plurality of elongate anchor members positioned in the foam insulating panel extend outwardly from the first primary surface of the foam insulating panel, wherein each of the elongate anchor members has 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 comprises a second enlarged portion and wherein the second primary surface is adjacent the horizontal surface; and

placing a quantity of plastic concrete on the first surface of the foam insulating panel so that the second end of each of the elongate anchor members is disposed within the quantity of plastic concrete and the plastic concrete fills the at least one recessed channel.

2. The method of claim 1 further comprising positioning a layer of insulating material on a surface of the quantity of plastic concrete opposite the foam insulating panel.

3. The method of claim 2, wherein the layer of insulating material comprises polystyrene foam, polyisocyanurate foam or polyurethane foam.

4. The method of claim 2, wherein the layer of insulating material has an R-value of greater than 4.

5. The method of claim 2, wherein the layer of insulating material has an R-value of greater than 8.

6. The method of claim 1, wherein the foam insulating panel further comprising a layer of reinforcing material disposed on, substantially covering and adhered to the second primary surface of the foam insulating material, wherein the layer of reinforcing material is at least partially disposed between the first enlarged portion of each of the elongate anchor members and the second primary surface of the foam insulating panel.

7. The method of claim 6, wherein the layer of reinforcing material is adhered to the foam insulating material by a polymeric, elastomeric material.

8. The method of claim 1, wherein the foam insulating panel comprises polystyrene foam, polyisocyanurate foam or polyurethane foam.

9. A method comprising:

positioning a foam insulating panel on a horizontal surface, the foam insulating 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, wherein a plurality of elongate anchor members positioned in the foam insulating panel extend outwardly from the first primary surface of the foam insulating panel, wherein each of the elongate anchor members has 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, wherein the second end comprises a second enlarged portion and wherein the second primary surface is adjacent the horizontal surface, wherein the foam insulating panel has an R-value of greater than 4;

placing a quantity of plastic concrete on the first surface of the foam insulating panel so that the second end of each of the elongate anchor members is disposed within the quantity of plastic concrete and the plastic concrete fills the at least one recessed channel;

positioning a layer of insulating material on a surface of the quantity of plastic concrete opposite the foam insulating panel, wherein the layer of insulating material has an R-value of greater than 4; and

leaving the plastic concrete on the foam insulating panel and under the layer of insulating material so that the plastic concrete at least partially cures.

10. The method of claim 9 further comprising removing the layer of insulating material.

11. The method of claim 10 further comprising raising the at least partially cured concrete and attached foam insulating panel to a vertical position.

12. The method of claim 11, wherein the layer of insulating material comprises polystyrene foam, polyisocyanurate foam or polyurethane foam.

13. The method of claim 12, wherein the foam insulating panel comprises polystyrene foam, polyisocyanurate foam or polyurethane foam.