Fiber-reinforced sandwich panel

Abstract

The present invention may be embodied in a sandwich panel having first and second face panels each panel having a first predetermined thickness and being formed of a fiber-reinforced cementitious material. The sandwich panel further includes support frame for supporting the first and second face panels in a spaced apart configuration. The support frame is formed of a fiber reinforced cementitious material that is continuous with the cementitious material of the first and second face panels. Blocks of rigid insulation are embedded in the sandwich panel for defining a structure of the support frame.

Description

[0001] This application is a continuation-in-part of application Ser. No. 09 / 993,374 filed on Nov. 14, 2001, the contents of which are incorporated herein by reference in their entirety.FIELD OF THE INVENTION [0002] The present invention relates to prefabricated structures, and more particularly, to fiber reinforced wall panels for ease of manufacture of prefabricated structures that can be constructed. BACKGROUND OF THE INVENTION [0003] Walls of residential and public buildings are generally expected to cover as large an area as possible with as minimum a structural weight as possible. Also, walls are expected to possess proper load bearing capacity, be economical with respect to the combination of construction labor and material costs and on-going maintenance costs, and to be adapted for prefabrication and for use in mounted constructions. Load-bearing concrete walls are generally thick, heavy, and difficult to transport. Also, an uninsulated concrete wall generally has a poor hea...

AI Technical Summary

Benefits of technology

[0011] Other embodiments of the invention include a cast wall panel that is modular and, depending on size, includes one or a plurality precast boots that are integrated with the panel. Polypropylene or polyvinyl alcohol fibers are dispersed throughout the panel thereby providing a wall panel with increased strength. The more strength needed to reinforce the panel, the more fibers that can be added. Specifically, the deflection strength of the panel is significantly higher than it would be if the reinforcing fibers were not used. Also, vibrations are reduced due to the fibers, thereby improving acoustic characteristics. The fibers serve a combination of purposes, i.e., insulation, structural and form material

Problems solved by technology

Load-bearing concrete walls are generally thick, heavy, and difficult to transport.

Also, an uninsulated concrete wall generally has a poor heat insulation value and increasing the insulation value of the concrete wall may be problematic.

Wood walls are lightweight, however, they are limited in strength.

In instances where a wall is used as a primary or secondary support member, problems occur due to large deflections / vibrations in the wall, poor fire rating, and poor thermal and acoustic properties.

Reinforcing wood walls with concrete can make up for the limited strength of wood floors; however, traditional concrete walls are heavy and labor intensive and experience problems due to crack control (flexure, shrinkage); they require steel reinforcement with a minimum slab thickness.

This of course increases the dead weight of such walls, adds to construction labor and material costs, and requires increased shoring while the concrete is curing.

Shoring adds yet further to wall construction cost and time.

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