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US 2024/0117633 A1Published application
Non-Combustible, Net-Zero Energy Building Systems
AssigneeKlrh, LLC
InventorsScott Long, Manoj Krishan
Life of this patent
Estimating the term…
Abstract
Methods, systems, and apparatus for constructing a wall panel and building are disclosed. The wall panel can include: fiber-reinforced concrete layers including concrete with interwoven fibrous materials; an insulation layer; and a connector. The insulation layer is sandwiched between the fiber-reinforced concrete layers, and the connector extends through the insulation layer and concrete layers to create composite action between the insulation layer and the concrete layers.
Claims20
A method comprising:
- providing a preset mold having a length in a first lateral dimension and a width in a second lateral dimension;
- forming a first concrete layer by pouring a wet concrete mix containing fibrous material into the preset mold;
- while the concrete mix is still wet, installing an insulation layer and one or more connectors such that the insulation layer and connectors embed into the first concrete layer in the preset mold, where a length of the insulation layer is less than the length of the preset mold, a width of the insulation layer is less than the width of the preset mold, or both;
- forming a second concrete layer by pouring the concrete mix containing a fibrous material over the insulation layer and the connectors in the preset mold;
- and
- allowing the first and second concrete layers to cure to form a sandwich wall panel with composite action between the first and second concrete layers, the insulation layer, and the connectors.
3 more elements
A construction method using concrete composite wall panels, the method comprising:
- obtaining a plurality of concrete composite wall panels (CCWP), each CCWP comprising:
- a first concrete layer and a second concrete layer,
- an insulation layer disposed between the first concrete layer and the second concrete layer, where a perimeter edge of the insulation layer is inset from respective perimeter edges of the first and second concrete layers and an entirety of the perimeter edge of the insulation layer is covered by a cap of concrete,
- a plurality of connectors spaced throughout the wall panel, each connector extending from the first concrete panel through the insulation layer and into the second concrete panel,
- a lifting anchor embedded in a first region at an upper end of the wall panel at which the insulation layer is recessed further inward than the inset, thereby forming a first area of solid concrete extending between the first and second concrete layers;
- and
- a second region at a lower end of the wall panel at which the insulation layer is recessed further inward than the inset, thereby forming a second area of solid concrete extending between the first and second concrete layers, the second region sized to accept at least two tapcon anchors;
- positioning a first CCWP adjacent to a second CCWP using respective lifting anchors of each CCWP;
- and
- securing the respective lower end of each of the first CCWP and the second CCWP to tapcon anchors in a foundation, where the tapcon anchors are secured within the respective second region of each CCWP.
7 more elements
Dependencies are inferred from the claim text.