Prefabricated wall panels

• US 8,844,223 B2
• Filed: 08/24/2010
• Issued: 09/30/2014
• Est. Priority Date: 08/24/2010
• Status: Active Grant

• Current Assignee: Empire Technology Development LLC (Allied Inventors Management, LLC)
• Original Assignee: Empire Technology Development LLC (Allied Inventors Management, LLC)
• Inventors: Zhong, Hai
• Primary Examiner(s): Wendell, Mark
• Assistant Examiner(s): Minter, Keith
• Application Number:
  US13/203,837
• Publication Number:
  US 20120047816A1
• Time in Patent Office: 1,498 Days
• Field of Search: 522/50, 522/52, 522/59, 522/61, 522/62, 522/64, 522/65, 522/67, 522/68, 522/69, 522/70, 522/201, 524/15, 524/16, 524/17, 524/18, 524/19, 524/20, 249/42, 249/40, 249/194
• US Class Current: 52/259
• CPC Class Codes: B28B 1/29 by profiling or strickling the material in open moulds or on moulding surfaces in rotary moulds B28B1/02; by means of profiled rollers B28B3/12, B28B3/123
• CPC Class Codes: B28B 19/0053 to tiles, bricks or the like
• CPC Class Codes: E04B 1/161 with vertical and horizontal slabs, both being partially cast in situ
• CPC Class Codes: E04B 1/164 with vertical and horizontal slabs, only the horizontal slabs being partially cast in situ
• CPC Class Codes: E04B 1/165 with elongated load-supporting parts, cast in situ E04B1/161, E04B1/163 and E04B1/164 take precedence
• CPC Class Codes: E04B 2/10 by filling material with or without reinforcements in small channels in, or in grooves between, the elements
• CPC Class Codes: E04B 2/562 with fillings between the load-bearing elongated members
• CPC Class Codes: E04B 2/68 made by filling-up wall cavities E04B2/24, E04B2/38, E04B2/52 take precedence
• CPC Class Codes: E04B 2/8647 with ties going through the forms
• CPC Class Codes: E04B 2002/0286 Building elements with coatings
• CPC Class Codes: E04B 2002/0293 solid material
• CPC Class Codes: E04C 2/205 of foamed plastics, or of plastics and foamed plastics, optionally reinforced
• CPC Class Codes: E04C 2/288 composed of insulating material and concrete, stone or stone-like material
• CPC Class Codes: E04C 3/20 of concrete or other stone-like material, e.g. with reinforcements or tensioning members reinforcing elements E04C5/00
• CPC Class Codes: E04C 3/34 of concrete other stone-like material, with or without permanent form elements, with or without internal or external reinforcement, e.g. metal coverings E04C3/36 takes precedence
• CPC Class Codes: E04G 9/05 the form surface being of plastics

Abstract

A prefabricated wall panel includes molds for casting reinforced concrete (RC) elements. The prefabricated wall panel includes foam boards, foam glass panels fixed to the foam boards, fabric mesh fixed to the foam glass panels, wire mesh fixed to the fabric mesh, and an exterior wall finish fixed to the wire mesh. Spaces defined by the foam boards and the foam glass panels form the molds for casting RC columns and beams.

Claims

1. A prefabricated wall panel, comprising:

foam boards;

foam glass panels with interior surfaces fixed to the foam boards, wherein spaces defined by the foam boards and the foam glass panels form reinforced concrete column molds;

fabric mesh fixed to exterior surfaces of the foam glass panels;

wire mesh fixed to the fabric mesh; and

exterior wall finish fixed to the wire mesh.

2. The prefabricated wall panel of claim 1, wherein the reinforced concrete column molds include column molds comprising frame column molds and dense column molds having a smaller cross-sectional than the frame column molds.

3. The prefabricated wall panel of claim 2, wherein the prefabricated wall panel has a standard depth w, and a dense column mold has a width h and a depth b, where 100 mm≦

b≦

300 mm, b<

w, and 1≦

h/b≦

3.

4. The prefabricated wall panel of claim 3, wherein a frame column mold has a width k and a depth z that is equal to or greater than depth w.

5. The prefabricated wall panel of claim 4, wherein adjacent column molds are separated by a distance equal to or less than 1,250 mm.

6. The prefabricated wall panel of claim 2, wherein the frame column molds comprise L-shaped and T-shaped frame column molds have an exterior width k and a thickness z, where 1<

k/z≦

4, k≧

500 mm, and 200 mm≦

z≦

300 mm.

7. The prefabricated wall panel of claim 1, wherein the spaces further form L-shaped and T-shaped shear wall molds have a width k and a thickness z, where k/z≧

5.

8. The prefabricated wall panel of claim 1, wherein a mortar fixes the wire mesh under tension to the wire mesh.

9. The prefabricated wall panel of claim 1, wherein the foam boards are spaced apart along a length of the prefabricated wall panel to define one or more widths of the reinforced concrete column molds.

10. The prefabricated wall panels of claim 9, wherein a thickness of the foam boards defines a depth of the column molds.

11. The prefabricated wall panel of claim 1, wherein the foam glass panels extend above the foam boards to form a reinforced concrete beam mold.

12. The prefabricated wall panel of claim 11, wherein the foam glass panels form an L-shaped angle above the foam boards on one side of the prefabricated wall panel to form the reinforced concrete beam mold.

13. The prefabricated wall panel of claim 11, wherein the foam glass panels is taller on one side of the prefabricated wall panel than the other to form a floor slab mold above the reinforced concrete beam mold.

14. The prefabricated wall panel of claim 11, wherein notches are formed in the foam glass panels above the foam boards on one side of the prefabricated wall panel to provide access to other reinforced concrete beam molds.

15. The prefabricated wall panel of claim 11, further comprising bolts passing through the prefabricated wall panel within the reinforced concrete beam mold.

16. The prefabricated wall panel of claim 15, further comprising an internally and externally threaded sleeve fitted to an end of each bolt.

17. The prefabricated wall panel of claim 1, further comprising bolts passing through the prefabricated wall panel alongside the reinforced concrete column molds.

18. The prefabricated wall panel of claim 17, further comprising a washer fitted to one end of each bolt, the washer having holes tied by wires to the wire mesh.

19. The prefabricated wall panel of claim 1, wherein the foam glass panels form a vertical U-channel along a space between two foam boards to form a reinforced concrete column mold.

20. The prefabricated wall panel of claim 19, wherein the vertical U-channel includes a vertical slot to provide access to a shear wall.

21. The prefabricated wall panel of claim 1, wherein the wire mesh extends over the top of the foam glass panels.

22. The prefabricated wall panel of claim 1, wherein the foam glass panels forms a cantilevered slab mold to cast a cantilevered slab from one side of the prefabricated wall panel.

23. The prefabricated wall panel of claim 1, wherein the foam glass panels form a U-channel against a foam board at a lateral end of the prefabricated wall panel to form a reinforced concrete window column mold to cast a window column, the reinforced concrete window column mold including a top opening to receive a protruding tab from an adjoining upper prefabricated wall panel and a lower opening to provide access to another mold in an adjoining lower prefabricated wall panel for forming part of the window column.

24. The prefabricated wall panel of claim 1, wherein another space between the foam boards and the foam glass panels form a reinforced concrete shear wall mold.

25. The prefabricated wall panel of claim 1, wherein the reinforced concrete column molds include a portion to cast capitals to support a precast floor slab.

26. The prefabricated wall panel of claim 1, further comprising a conduit holder.

27. The prefabricated wall panel of claim 1, further comprising a foam U-channel fixed near the top of one side of the prefabricated wall panel, the U-channel forming a cornice with a rain gutter.

28. The prefabricated wall panel of claim 1, further comprising a foam core fixed near the bottom of one side of the prefabricated wall panel, the foam core forming an architrave.

29. The prefabricated wall panel of claim 28, wherein a bottom of the architrave comprises a drip line.

30. The prefabricated wall panel of claim 1, wherein the exterior wall finish includes at least one of a faux column, a relief, and a cornice line.