Structural composite insulated panel and method of manufacturing
a technology of structural composite insulation panels and manufacturing methods, which is applied in the field of structural panels, can solve the problems of high inability to manufacture panels in a sufficiently compact and compressed manner for easy handling and installation, and is practically impossible to meet the requirements of construction and construction. the effect of improving the quality control of the plaster shell, reducing the cost of implementing scips, and improving the quality of the plaster shell
Inactive Publication Date: 2009-01-08
KESHISHIAN PETROS +1
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Benefits of technology
"The present invention is a structural composite insulated panel that includes truss members and an insulating member. The panel also has two side panels and two end panels, which are perpendicular to each other and the truss members. The panel also includes a pair of prismatic members and a pair of locking members that provide compressive locking tension to the insulating members and trusses. The invention also includes a plastering control gauge that simplifies the plastering process and increases quality control of the plaster shell. The technical effects of the invention include improved insulation, simplified construction, and increased quality control of the plaster shell."
Problems solved by technology
Disadvantageously, the cost of implementing SCIPs can become high due to costs associated with meeting building code requirements, fabrication and construction costs.
The '248 and '712 patents disclose a method of fabrication that has several disadvantages which makes the panels inferior to the competing panels on the market.
The main disadvantage of the panels in the '248 and '712 patents is that it is practically impossible to manufacture the panels in a sufficiently compact and compressed manner for easy handling and installation without the panels falling part.
Specifically, such panels tend to suffer from the defect of having the foam blocks sliding off the panels due to insufficient compression holding the panels together.
In other words, although the '248 and '712 patents claim that the panel should be compressed and restrained in that compressed position by means of attaching wire meshes on both sides, this is in practice very difficult to achieve.
The problem lies in the fact that the wire mesh is attached to the trusses 1 or 1a using C-rings, which are not as tight as a weld.
This is not always possible and this results in panels manufactured with inconsistent levels of tightness and gaps.
So the restraining stiffness of the wire mesh is limited by the bending stiffness of the trusses 1 or 1a that cantilever out from the foam to reach the wire mesh.
For the typical type of wire trusses 1 or 1a that are practical to be used in these panels their out of plane bending stiffness is very limited and therefore the system of the compressing the panels through wire mesh and cantilever portion of the trusses 1 or 1a is limited.
Another disadvantage of the panels described in '248 and '712 patents is that although such patents teach that the truss spacing is arbitrary, this is not accurate.
It appears that the truss spacing is limited by a multiple of the size of the wire mesh that is used to hold the panel in compression.
Another disadvantage of the panels described in '248 and '712 patents is that the wire mesh, which is an integral part of the panel that holds it together in the '712 patent, is one of the most expensive components in the manufacturing of the panel.
Since wire meshes is typically manufactured in limited widths (usually 4 feet), the width of a panel constructed according to the '712 patent would be limited by the available wiremesh in practice.
Producing larger panels could result in efficiencies realized during installation of the panels at the job site.
Thus, use of the wire mesh alone creates this cumbersome task for installation of such utilities and it would be beneficial to replace the wiremesh with some structure that does not impede such installation.
Another disadvantage of the '248 and '712 patents is that during installation the panels, the wire mesh on both sides of the panels have to be stitched together by overlaying an additional strip of wire mesh over the connection line of neighboring panels and attached to both panels by C-rings, which adds to the cost of construction.
A further disadvantage of the '712 patent is that the installation of the panel requires skilled and expensive labor due to the use of plastering.
Such application of plastering can vary and be inconsistent since there is nothing provided in the panel for preserving the exact thickness of plastered shells.
Such thickness is a critical value for engineering these panels and there is thus a tendency to have low quality control during installation of the panels.
Additionally, the issue of out-of-plain resistance of the panels is not properly resolved in the '712 patent.
Another cost increasing component in SCIP construction is the problem of splicing the SCIPs to cover long spans or construction of tall walls.
Finally, the method of the construction with SCIPs is not developed sufficiently to cover all outstanding issues.
Particularly, the issue of joints of wall to floor connection and development of bond beams is not properly resolved during fabrication and is being done at the jobsite but melting the foam and trying to accommodate the rebar and panels creating problems during the construction.
Method used
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Embodiment Construction
[0039]A novice structural panel with one or more layers of insulation sandwiched between two or more layers of shell is introduced. The layers of insulation and layers or shell are in alternating order and connected to each other by steel wire trusses that are partially embedded in the shells while passing through the layer(s) of insulation. The insulation layer is usually comprised of rigid foam block, and the shell layers are made of concrete plaster or similar. The panel can be used in residential, commercial and industrial construction for walls as well as floor and roof slabs. They possess with high insulating and soundproofing characteristics, are resilient to mold and mildew.
[0040]The present invention relates to the prefabricated structural panels that are erected on site and concrete or other cementitious material is applied to create one or more layers of shell that are interconnected with wire trusses or similar. The panels can be used but are not limited to wall, floor, ...
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A structural composite insulated panel having a plurality of truss members arrayed in substantially parallel relation at a substantially equal interval so as to define a plurality of cells therebetween. The panel has an insulating member disposed in each of the cells, the panel has two opposing elongated side panel surfaces defined by side surfaces of the cells, and two opposing end panel surfaces defined by the respective end surfaces of two outermost cells of the panel, the two side panel surfaces are substantially perpendicular to the two end panel surfaces and the plurality of truss members. The panel has a pair of prismatic members, each parallely engaged to the respective side panel surfaces. The panel has a pair of locking members, each at the respective end panel surfaces and engaged thereat to the prismatic members to provide compressive locking tension to the insulating members and the trusses in the panel.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application claims priority to provisional patent application No. 60 / 891,496, provisional patent application No. 60 / 891,494, and provisional patent application 60 / 909,419, which are hereby incorporated by reference.DESCRIPTION[0002]1. Field of the Invention[0003]The present invention generally relates to the field of structural panels and more specifically to panel composition, manufacturing process and installation and construction with those panels.[0004]2. Background of the Invention[0005]Structural Concrete Insulating Panels (SCIP) are typically composed of two or more structural shells that are separated with an insulating material and connected via steel trusses 1 or 1a. In a typical SCIP panel, the shells are fabricated from concrete, the insulating material is foam and the trusses 1 or 1a are composed of steel wire. Such SCIPs are used in building homes and other structures, by relatively unskilled laborers, and are pre-fabri...
Claims
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IPC IPC(8): E04C2/34
CPCE04C2/044
InventorKESHISHIAN, PETROSMARTIROSSYAN, ARMEN
OwnerKESHISHIAN PETROS