Non-flammable net zero energy building system

Abstract

Methods, systems, and apparatus for building shingles and buildings are disclosed. The shingle may include: a fiber reinforced concrete layer (104) including concrete having an interwoven fiber material; a thermal insulation layer (102); and a connector (106). A thermal insulation layer is sandwiched between the fiber reinforced concrete layers, and a connector extends through the thermal insulation layer and the concrete layers to create a composite action between the thermal insulation layer and the concrete layers.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. patent application serial number 17 / 982,428 filed on November 7, 2022, which claims priority to U.S. provisional patent application serial number 63 / 344,757 filed on May 23, 2022. Technical Field

[0002] The present disclosure relates generally to non-combustible building systems in the residential and commercial construction industries. Background Art

[0003] Problems with conventional building materials and processes are related to fire damage and energy efficiency in residential and commercial structures, both of which represent major concerns throughout the construction industry in general and in California in particular. In addition to direct fire exposure, the heat of combustion at 600 degrees Fahrenheit can cause building structures to ignite, and because conventional wood materials are highly flammable and combustible, these materials generally offer little protection from structural burning.

[0004] There is no solution to these problems that is fully solved yet. Some attempted solutions include simple mitigation strategies, such as thickened plaster, closing vents, and keeping brushes away from homes, but these solutions focus on mitigating direct fire exposure rather than fire and combustion resistance and prevention. Other solutions have attempted to use concrete instead of wood for building walls, but concrete is a heavy material and is prone to cracking. Some concrete solutions attempt to place insulation between thick concrete layers, but these thick concrete layers usually require steel reinforcements, which makes concrete even heavier and more expensive. There is a demand for a lightweight, cost-effective solution that provides fire and combustion resistance and energy efficiency to residential and commercial building structures. Summary of the invention

[0005] The present disclosure describes insulated concrete wall panels for residential and commercial structures. The systems described herein can be used to prevent structural fires and combustion damage, and in addition, to provide energy savings and net zero energy results for residential and commercial buildings.

[0006] Embodiments of the present disclosure provide sandwich wall panels having an insulating layer between two layers of concrete. Unlike existing sandwich wall constructions that use steel reinforced concrete for the outer layer, the present disclosure describes the use of fiber reinforced concrete, which is lighter, stronger, and more fire resistant. Concrete is known throughout the construction industry to have high strength under compression but relatively low strength under tension.

[0007] Large amounts of concrete (e.g., concrete slabs, foundations, or wall panels) often require reinforcements to help the concrete maintain its shape (especially when exposed to tension). Traditionally, steel cages have been used to reinforce concrete, but steel reinforcements add weight to the concrete and require thickening of the concrete to protect the steel from rust and corrosion. In contrast, the present disclosure describes mixing fiber materials (e.g., fiberglass, polypropylene, nylon) with concrete to create a fiber-reinforced concrete composite. The addition of fibers interwoven and embedded within the concrete provides many of the benefits discussed below, including tensile strength, lighter weight, fire resistance, and energy efficiency.

[0008] Generally, the innovative aspects of the subject matter described in this specification can be embodied in a wall panel comprising: at least two fiber reinforced concrete layers, the at least two fiber reinforced concrete layers comprising concrete with interwoven fiber material; an insulation layer; and a connector. The insulation layer is sandwiched between the at least two fiber reinforced concrete layers, and the connector extends through the insulation layer and the concrete layer to create a composite effect between the insulation layer and the concrete layer. Other embodiments of this aspect include corresponding systems, devices, and methods.

[0009] In another general aspect, the innovative aspects of the subject matter described in this specification can be embodied in a method comprising the following acts: providing a pre-set mold having a length in a first transverse dimension and a width in a second transverse dimension; forming a first concrete layer by pouring a wet concrete mixture containing a fiber material into the pre-set mold; installing an insulation layer and one or more connectors while the concrete mixture is still wet so that the insulation layer and the connectors are embedded in the first concrete layer in the pre-set mold; forming a second concrete layer by pouring the concrete mixture containing the fiber material over the insulation layer and the connectors in the pre-set mold; and allowing the first and second concrete layers to dry, thereby forming a sandwich wall panel by composite action between the first and second concrete layers, the insulation layer and the connectors. The length of the insulation layer is less than the width of the pre-set mold, the width of the insulation layer is less than the width of the pre-set mold, or both.

[0010] In another general aspect, the innovative aspects of the subject matter described in this specification can be embodied in a building system comprising: a plurality of wall panels, each wall panel comprising: a first concrete layer and a second concrete layer, each of the first concrete layer and the second concrete layer comprising fiber reinforced concrete, the fiber reinforced concrete comprising concrete embedded with interwoven fiber material; an insulation layer disposed between the first concrete layer and the second concrete layer; 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, the insulation layer being recessed at the first region to form a first zone of solid fiber reinforced concrete extending between the first concrete layer and the second concrete layer; and a second region at a lower end of the wall panel, the insulation layer being recessed at the second region to form a second zone of solid fiber reinforced concrete extending between the first concrete layer and the second concrete layer, the second region being sized to receive at least two tapcon anchors. The peripheral edge of the thermal insulation layer is inserted from the corresponding peripheral edges of the first concrete layer and the second concrete layer, and the entire peripheral edge of the thermal insulation layer is covered by a cap of fiber-reinforced concrete.

[0011] In another general aspect, the innovative aspects of the subject matter described in this specification can be embodied in a method comprising the following acts: forming a first sandwich wall panel from a first predetermined mold and forming a second sandwich wall panel from a second predetermined mold; and bolting the first sandwich wall panel to the second sandwich wall panel by drilling at least one large diameter tapcon anchor through the solid fiber reinforced concrete portions of the first sandwich wall panel and the second sandwich wall panel. Each of the first sandwich wall panel and the second sandwich wall panel comprises: two fiber reinforced concrete layers; an insulation layer between the two fiber reinforced concrete layers; at least one connector extending through the insulation layer and the concrete layer; and a solid fiber reinforced concrete portion.

[0012] These and other implementations can each optionally include one or more of the following features.

[0013] In some embodiments, the fiber reinforced concrete layer is no greater than about two inches thick.

[0014] In some embodiments, the insulation layer is at least about four inches thick.

[0015] In some embodiments, the fiber reinforced concrete layer includes polypropylene fibers, polyethylene fibers, or both.

[0016] In some embodiments, the wall panel comprises a solid concrete portion covered with an insulation layer. In some embodiments, the solid concrete portion comprises a fiber reinforced concrete material. In some embodiments, the solid concrete portion comprises at least one large diameter tapcon anchor.

[0017] In some embodiments, the fiber material in the concrete layer is configured to form air pockets when exposed to heat.

[0018] In some embodiments, the wall panels do not include reinforcing steel material.

[0019] In some embodiments, the wall panel comprises a solid fiber reinforced concrete portion without an insulation layer. In some embodiments, the solid concrete portion comprises at least one large diameter tapcon anchor.

[0020] In some embodiments, the pre-set mold includes an opening. In some embodiments, the action includes forming a window or door in the sandwich wall panel from the opening in the pre-set mold.

[0021] In some embodiments, the action includes lifting the sandwich wall panel from a predetermined mold.

[0022] In some embodiments, the sandwich wall panel includes a solid fiber reinforced concrete portion.

[0023] In some embodiments, the actions include adding a fiber reinforced concrete portion over the insulation layer such that the solid concrete portion completely covers the insulation layer.

[0024] In some embodiments, the length of the insulation layer is 2 inches less than the length of the intended mold, the width of the insulation layer is 2 inches less than the width of the intended mold, or both.

[0025] In some embodiments, the preset mold has a length in a first lateral dimension and a width in a second lateral dimension, and wherein the length of the insulation layer is less than the width of the preset mold, the width of the insulation layer is less than the width of the preset mold, or both are true.

[0026] In some embodiments, the first concrete layer does not include steel reinforcements extending entirely within a plane defined by the first concrete layer.The second concrete layer does not include steel reinforcements extending entirely within a plane of the second concrete layer.

[0027] In some embodiments, at least one of the plurality of wall panels includes: a conduit box embedded in the first concrete layer; and a conduit connected to the conduit box embedded in the first concrete layer.

[0028] In some embodiments, the actions include: positioning a first set of wall panels at a first elevation; installing a bottom panel on the first set of wall panels after positioning the first set of wall panels; lifting and positioning a second set of wall panels on the first set of wall panels at a second elevation higher than the first elevation after installing the bottom panel; and installing a top panel on the second set of wall panels after lifting and positioning the second set of wall panels. The first set of wall panels includes a first sandwich wall panel and a second sandwich wall panel.

[0029] Particular implementations of the subject matter described in this specification can be implemented so as to realize one or more of the following advantages.

[0030] High-strength concrete is non-flammable and non-combustible, providing superior fire resistance over conventional wood materials. Additionally, high-quality concrete with an insulated core stores and releases thermal energy, allowing for lower usage of HVAC systems to maintain desired temperatures, providing a more affordable net-zero energy outcome. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 is a perspective cutaway view of an exemplary embodiment of a wall panel construction according to the present disclosure. The illustrated embodiment includes an insulation layer sandwiched between two concrete layers, with a plurality of connectors joining the wall layers.

[0032] Figure 2 is a cross-sectional end view of one embodiment of a wall panel construction according to the present disclosure.

[0033] Figure 3 is a cross-sectional elevation view of one embodiment of a wall panel according to the present disclosure.

[0034] Figures 4 to 6 An on-site molding and lifting process for manufacturing wall panels according to the present disclosure is shown. Pre-set molds (e.g., "racks") are shown that can be reused without having to be set up before each use, which reduces the need for highly skilled on-site labor.

[0035] Figure 7 A bolted connector for use with a wall panel according to the present disclosure is shown.

[0036] Figures 8 to 9 A wall panel according to the present disclosure is shown after being erected and bolted.

[0037] FIG. 10A to FIG. 10C Depicts the successive layers of a building being constructed.

[0038] Fig.11 is a flow chart of the process used to construct the wall panels.

[0039] Fig.12 is a flow chart of a process 1200 for constructing a building. DETAILED DESCRIPTION

[0040] Embodiments of the present disclosure include a unique building system having fiber-reinforced insulated concrete wall panels for fire and combustion protection and energy efficiency.

[0041] Figure 1 is a perspective cutaway view of one embodiment of a wall panel construction 100 according to the present disclosure. The illustrated embodiment includes an insulation layer 102 sandwiched between two concrete layers 104, with a plurality of connectors 106 spaced throughout the wall panel construction 100. The connectors 106 join the wall layers by extending from a first concrete layer to a second concrete layer. Figure 2 is a cross-sectional end view of one embodiment of a wall panel construction 200 according to the present disclosure.

[0042] Some embodiments may include a structural composite wall panel construction having multiple layers used as a single wall. Some portions of the wall panel construction 100 include an insulation layer 102 on either side sandwiched between two concrete layers 104, such as Figure 1 In other parts, the wall panel can be solid concrete without insulation. In some embodiments, the insulation layer 102 can have a certain thickness (e.g., at least about four inches), and each concrete layer 104 can have a certain thickness (e.g., about two inches or less), thereby forming, for example, a 2"-4"-2" wall panel configuration 200, such as Figure 2 . The sandwich wall panel may include connectors 106 that pass through the layers, which create a composite action between the layers (e.g., strongly bond the layers together so that they structurally function together as a single unit). The combination of composite materials creates a composite mold effect, meaning that once a binder (e.g., solid concrete 206) is applied, the combination of composite connectors 106 and interwoven composite reinforcing fibers work together structurally. In some embodiments, a majority of the wall panel material is composite material (e.g., about 70% composite material and about 30% concrete). Note that while in Figure 1 to Figure 2 Two layers of concrete are shown in FIG, but the insulation layer 102 may be sandwiched between more than two layers of concrete, and there may be more than one insulation layer.

[0043] The solid concrete 206 can allow a solid portion of the wall panel to provide a structural insert for lifting and attaching the panel during assembly of the building. In some embodiments, the "top" (e.g., the area of ​​the wall panel that will be the highest after assembly) can include a structural attachment point (e.g., a lifting anchor) recessed in the solid concrete 206 area of ​​the wall panel 200 that does not include the insulation layer 102. The lifting anchor can be a metal tab with a loop at the edge of the wall panel that has a hook cable to facilitate lifting of the wall panel. The "bottom" (e.g., the area of ​​the wall panel that will be the lowest after assembly) can have an attachment anchor in the solid concrete 206. In some embodiments, the attachment anchor loop captures a wider range of orientations of the wall panel than can allow when the wall panel is lifted and assembled.

[0044] The presence of solid concrete 206 around the perimeter of the wall panel can also prevent fire or water from penetrating into the insulation layer 102 or the interior of the assembled building. For example, such a solid concrete perimeter can improve the safety and stability of a family home compared to a family home with exposed insulation.

[0045] Standard concrete used in home construction generally has an ideal temperature range, assuming that concrete is prone to cracking at extreme temperatures (e.g., greater than 120°F and less than 10°F) (given its different coefficients of expansion and contraction). On the other hand, the disclosed combination of composite materials (e.g., fiber-reinforced concrete) is less likely to crack under extreme conditions (e.g., fluctuating temperatures in extreme climates, large temperature differences between the interior and exterior of a building, and tensile or compressive stresses and strains).

[0046] The presence of the composite connector 106 can have beneficial effects on the structural stability of the building, such as transferring shear stress and deflection loads from one layer of concrete to another. For example, during an earthquake, forces from ground shaking on the building can be transferred from one layer of concrete to another, thereby preventing one particular layer from exceeding a threshold force that causes damage. In some embodiments, the composite connector 106 is a fiber reinforced rebar.

[0047] Figure 1 Also shown is an optional solid concrete section 110 on top of the wall panel. The solid concrete section 110 can have a certain thickness (e.g., about two inches thick or less) and can extend along the entire length of all panel edges where the insulation layer 102 will be exposed. The solid concrete section 110 can: protect the insulation layer 102 from burning or direct fire exposure, and seal the wall from water damage and moisture so that no water or moisture reaches and damages the insulation layer 102. The solid concrete section 110 can be made of a similar concrete mix discussed above that includes fiber materials, which provide additional strength and protection against thermal cracking.

[0048] In some embodiments, the concrete layer 104 is made of a fiber reinforced concrete composite material, which avoids the need to use heavier steel reinforcements. The fibers are interwoven into the concrete and may include, but are not limited to, polypropylene, polyethylene macrofibers, or a combination thereof. Additionally, the insulation layer 102 may be, but is not limited to, a foam material such as extruded polystyrene.

[0049] Reinforced concrete allows the concrete layer 104 to be thinner (e.g., about two inches) without losing shape and form, and reinforcing the concrete with fiber materials allows the concrete layer 104 to be lighter than a steel reinforced concrete layer. Despite being thinner and lighter, fiber reinforced concrete is also stronger than steel reinforced concrete. Lighter wall panels provide many benefits during construction, such as the ability to use smaller equipment, ship more products per square foot, provide safer working conditions, and reduce the need for reinforcement of the foundation system (e.g., in soft ground conditions, less material is required to reinforce the house against sliding). In addition, providing a thinner concrete layer allows a thicker insulation layer 102 within standard wall thickness parameters (e.g., four inches of insulation within a standard eight-inch wall panel), which provides increased energy efficiency by preventing heat from being transferred from one concrete layer 104 to another. More specifically, the concrete layer 104 does not have steel reinforcements (e.g., rebar) that extend within the plane defined by the concrete layer 104 and are fully embedded in the layer. However, as described above, some embodiments may include composite connectors 106 made of fiber reinforced steel bars that extend between panels 104 in a direction along the thickness of the panels so as to join the two panels 104 .

[0050] Fiber reinforced concrete is stronger than steel reinforced concrete under tension. The increased tensile strength provides benefits particularly during shipping and installation (e.g., when lifting panels and preventing wall panels from buckling under pressure). In addition, the reinforcing fibers in the composite concrete material create air pockets when exposed to heat and fire, which slows heat transfer through the wall panel and provides additional fire and burn resistance. The fibers also help strengthen the bond between the concrete layer 104, the insulation layer 102, and the adjoining connectors 106, thereby strengthening the composite action in the wall panel.

[0051] The lifting anchors 202 can lift the wall panel construction 200. In some embodiments, the lifting anchors 202 can be connected to a portion of the concrete layer 104 through hairpin rebars 204. In some embodiments, the lifting anchors 202 can lift weights up to several tons (e.g., four tons). In some embodiments, each panel can include one or more (e.g., two to four) lifting anchors 202 depending on the weight of the panel, and the lifting anchors can be evenly spaced to keep the panel level. In some embodiments, the lifting anchors can span about three feet.

[0052] Additionally, fiber reinforced concrete provides additional fire resistance to wall panels, where the reinforcing fibers create air pockets when exposed to heat and fire, which slows heat transfer through the wall.

[0053] Figures 4 to 6 An on-site molding and lifting process for manufacturing wall panels according to the present disclosure is shown. Pre-set molds (e.g., "racks") are shown that can be reused without having to be set up before each use, which reduces the need for highly skilled on-site labor.

[0054] In the home construction industry, wall panels are often custom made, e.g., not made using a preset mold. The disclosed preset molds can be reused in a modular manner. For example, a particular preset mold can be used for any floor of a house or for different floor layouts. The mold can be made of steel, concrete, a composite material, or a combination thereof. In some embodiments, the wall panels are formed by pouring a fiber concrete mix, bolting steel together, or a combination of both. In some embodiments, the preset mold can be formed by welding down steel.

[0055] like Figures 3 to 6 As shown in, embodiments of the present disclosure also include on-site molding and lifting methods and processes for manufacturing the wall panels disclosed herein. These processes greatly reduce the need for skilled labor by using pre-set molds (e.g., "racks"). These methods standardize the construction process and therefore standardize the wall panels for each corresponding building.

[0056] Fig.11 is a flow chart of a process 1100 for building a wall panel. For example, a building system 400 ( Figure 4 ) is capable of performing process 1100.

[0057] The building system 400 can provide a preset mold (1110). In some embodiments, the preset mold includes an opening. In some embodiments, the preset mold rests on a substantially horizontal plane.

[0058] The building system 400 can form a first concrete layer. For example, the concrete layer can be formed by pouring a concrete mixture (such as concrete mixture 406) containing a fiber material into a preset mold (such as preset mold 402). Figure 4 (1120). In some embodiments, the concrete mixture as a fluid flows to fill the total area within the pre-set mold. Therefore, it can have the same lateral dimensions as the pre-set mold, for example, the same height and width in a rectangular pre-set mold.

[0059] In some embodiments, the final wall panel will include electrical wiring or sleeves for water supply and drainage. For example, a standard conduit box with one or two outlets can be embedded in the first layer of concrete, and the conduit, such as a wire with a width of 0.5-0.75 inches, can extend vertically through the wall panel so that the conduits of the first wall panel and the second wall panel will be aligned in the assembled building. In some embodiments, the electrical wiring in the wall panel is achieved by placing a spacer in a preset mold before pouring the concrete mixture. The spacer provides a cavity for a standard conduit box. The junction box can be a flesh added to the surface of the wall panel. In some embodiments, the sleeve can be placed in a preset mold before pouring the concrete mixture. When the concrete mixture is dry, the concrete layer includes a cavity through which the water supply and drainage pipe can extend. A similar approach can also be used for outdoor hoses.

[0060] While the concrete mix is ​​still wet, the building system 400 can install the insulation layer and one or more connectors, such as connector 410, so that the insulation layer and connectors are embedded in the wet concrete in the preset mold 402 (1130). In some embodiments, the insulation layer is shorter than the first layer of concrete in one or more dimensions, for example, 97% of the length of the first concrete layer. For example, in a rectangular mold, the length of the insulation layer can be 2 inches less than the length of the first concrete layer, which can be determined by the length of the preset mold. In more complex shapes, such as a pentagon forming the side of a house, the insulation layer can have a shape similar to the preset mold, but have its lateral dimensions reduced in size. In some embodiments, the peripheral edge 112 of the insulation layer can be inset from the corresponding peripheral edge 114 of the first concrete layer 104 and the second concrete layer 104.

[0061] Leaving a gap in the insulation at this stage in the process 1100 results in a height gap between the first layer of concrete and the top of the insulation at the edge of the intended mold. In some embodiments, the gap is filled with concrete in the process 1100. The concrete filling the gap can form a perimeter around the wall panel.

[0062] The thickness of the insulation layer can depend on the environment and heating or cooling requirements of the building that the wall panel is constructed for. In some embodiments, the wall panel can provide as much or more insulation than a conventional wall panel with continuous barrier insulation because more of a standard eight-inch thick wall can be used for insulation, for example, a thick (about four inches) insulation sandwiched by a thin (about two inches) concrete wall.

[0063] The building system 400 can form a second concrete layer (1140) by pouring a concrete mixture containing fiber material over the insulation layer and connectors in a pre-set mold. In some embodiments, the second concrete layer can have approximately the same dimensions as the first concrete layer and be larger than the insulation layer in one or more dimensions.

[0064] In embodiments where the insulation layer is shorter than the first layer of concrete in one or more dimensions, there will be a height gap between the first concrete layer and the insulation layer, which is filled by step 1140. Filling this gap can create a solid concrete section as the wall panel is driven. The solid concrete section formed in this manner is less likely to crack compared to how typical non-fiber reinforced concrete would behave in process 1100. Therefore, including a solid concrete perimeter is not an industry standard.

[0065] The building system 400 can allow the first concrete layer and the second concrete layer to dry so as to form a sandwich wall panel 502 (1150) from the building system 500 by composite action between the first concrete layer and the second concrete layer, the insulation layer, and the connector, such as Figure 5 In some embodiments, the edge of the wall panel may include a solid concrete perimeter. Figures 3 to 6 As shown in FIG. 4 , openings 504 may be formed in a preset mold 402 to create windows, doors, or other building features.

[0066] In some embodiments, process 1100 may include additional steps, fewer steps, or some steps may be divided into multiple steps. For example, building system 400 may: form windows in a sandwich wall panel from openings in a predetermined mold; form doors in a sandwich wall panel from openings in a predetermined mold; place electrical wiring within one or more of the concrete layers; provide conduits for water and drainage through the wall panel; or a combination of two or more of these.

[0067] In some embodiments, process 1100 includes lifting a sandwich wall panel from a pre-set mold. In some embodiments, process 1100 includes forming a fiber reinforced concrete solid portion, such as a "cap," in which the insulation layer is not connected to the concrete layer, such that the cap 116 completely covers the entire peripheral edge 112 of the insulation layer from the outside of the wall panel.

[0068] Figure 3300 according to the present disclosure. The wall panel 300 may include a portion corresponding to the slab connector 302, a lifting anchor 304, which may be surrounded by a solid concrete area 306 without foam. The solid concrete area 306 may be formed in the area where the recess 312 is formed in the insulation layer 106. The solid concrete area 306 at the bottom of the wall panel 300 may be sized to receive two or more tapcon anchor bolts for the slab connector 302. As described above, the peripheral edge 112 of the insulation panel 106 can be inserted from the peripheral edge of the concrete layer 114. In some embodiments, the opening 308 may be surrounded by a zone with a suppression foam 310, the perimeter being marked by a dotted line. In some embodiments, the wall panel 300 may be approximately ten feet by ten feet. In some embodiments, the opening 308 may be a window, such as a four foot by six foot window.

[0069] like Figures 5 and 6 As shown in , once dried to a desired amount, the sandwich wall panel 502 can be lifted from the mold and erected to form a section 602 of a building wall.

[0070] The process disclosed herein for casting wall panels from a preset mold allows the same mold to be reused multiple times without requiring skilled labor to dismantle and re-set the mold, as opposed to conventional construction processes where each panel is different, requiring additional setup and removal of the mold each time a panel is cast. The process disclosed herein is more efficient and quicker to accomplish, in part, by using a fiber concrete mix rather than conventional reinforcing steel that requires manual installation on a chairlift and tying the steel together with wire tires.

[0071] The process described herein eliminates the need for structural steel inserts to weld panels together; instead, embodiments of the present disclosure rely on specifically designed "solid sections" of concrete, allowing for on-site drilling into the panels and bolting them together. In these solid sections, the fibers create structural strength and eliminate concerns about thermal cracking.

[0072] The fiber reinforced wall panels also provide sufficient strength for a variety of top and bottom plate options and systems. For example, the wall panels disclosed herein can be used with a steel joist and deck top and bottom plate system. In addition, the wall panels can be used with wood-based systems, steel stud systems, concrete bottom and top plate panels, and cast-in-place concrete top and bottom plate systems. The top and bottom plate system can also include preset molds so that the walls, top and bottom plates can be assembled without skilled labor or the need for field measurements because all attachments (wall to wall, wall to bottom plate, and wall to top plate) are predetermined and anchored and bolted in place in a pre-formatted interlocking system.

[0073] Figure 7 A bolted connector 700 is shown for use with wall panels 702 and 708 according to the present disclosure. Such a bolted connector 700 avoids the need for conventionally installed welded plates and reduces the need for highly skilled field labor. In the portion of the wall panel 702 having the bolted connector 700, the insulation layer is reduced or eliminated to create a solid concrete section that can be drilled into and secured with a large diameter tapcon (LDT) anchor 706. For example, the LDT can be sized to meet the necessary seismic shear strength requirements (e.g., approximately 5 / 8" x 6" or 5 / 8" x 8"). Figures 8 to 9 Wall panels 702 and 708 are shown after being erected and bolted with LDT anchors 706 .

[0074] The preset mold system and wall panels disclosed herein allow a building to be constructed floor by floor, so that a first set of wall panels can be positioned to form a perimeter at a first elevation (e.g., ground level), and a second set of wall panels can be lifted and positioned to form a perimeter above the first set of wall panels at a higher second elevation (e.g., second, third, or fourth floor). The bottom plate for each floor can be laid after each set of wall panels is positioned; for example, the bottom plate for the second floor can be laid on top of the first set of wall panels before the second set of wall panels is positioned. The top plate can then be applied upon completion of positioning the last set of wall panels on the top floor of the building.

[0075] Fig.12 is a flow chart of process 1200 for constructing a building. For example, building system 600 can perform process 1200. FIG. 10A to FIG. 10C Depicts the successive layers of a building being constructed.

[0076] The building system 600 can form a first sandwich wall panel from a first predetermined mold and form a second sandwich wall panel from a second predetermined mold (1210). Each of the first sandwich wall panel and the second sandwich wall panel, such as wall panels 702 and 708, can include: two fiber reinforced concrete layers, such as concrete layer 104; an insulation layer between the two fiber reinforced concrete layers, such as insulation layer 102; at least one connector extending through the insulation layer and the concrete layer, such as connector 106; and a solid fiber reinforced concrete portion.

[0077] Building system 600 can bolt a first sandwich wall panel to a second sandwich wall panel by drilling at least one large diameter tapcon anchor through the solid fiber reinforced concrete portion of the first sandwich wall panel and the second sandwich wall panel (1220). Step 1220 can result in building system 600 forming a corner of a building such as Figure 8 The corner wall 800 is, for example, where the two walls 702 and 708 meet at an angle above the bottom plate 604. Fig. 9 Another perspective view of corner wall 800 is provided.

[0078] In some embodiments, building system 600 bolts more than two sandwich wall panels together to form a complete wall around the perimeter of a building. Fig. 10A A number of wall panels 1010a - e that together form the exterior of the ground floor of the building 1000 are included.

[0079] In some embodiments, the process continues with building system 600 positioning a first set of wall panels at a first elevation (1230). The first set of wall panels may include a first sandwich wall panel and a second sandwich wall panel. Fig. 10A The ground floor level of a building 1000 is shown, which may include a first set of panels 1010a-e at a first elevation 1020 marked by a dashed line. Although reference is made to only five panels in the first set of panels 1010a-e, there may be any number, such as ten or fifty wall panels. The panels may include openings 1030 for windows 1030a, garage doors 1030b, entry doors 1030c, interior windows 1030d and interior doors 1030e in the building, and the like.

[0080] After positioning the first set of wall panels, building system 600 can install a base plate over the first set of wall panels (1240). Fig. 10B Shown is building 1040, which has been added to Fig. 10A The building 1040 has a floor 1052 above the first set of wall panels 1010.

[0081] After installing the floor, the building system 600 can lift and position the second set of wall panels above the first set of wall panels and at a second elevation higher than the first elevation (1250). The building 1040 includes a second set of wall panels 1050a-e at a second elevation 1060 marked by a dashed line. Although reference is made to only five panels in the second set of panels 1050a-e, there may be any number, such as ten or fifty wall panels. The second elevation 1060 is greater than the first elevation 1020, as measured from the ground.

[0082] After lifting and positioning the second set of wall panels, building system 600 can install a top panel over the second set of wall panels (1260). Fig. 10B and Fig. 10C All show the top plate. Fig. 10B A top plate 1070 is shown above a portion of the first set of wall panels 1010. Fig. 10C A building 1080 is shown, which is located in the Fig. 10B A portion of the building 1040 has a roof 1090 above it. In this example, the roof 1090 passes over the second set of wall panels 1050.

[0083] In some embodiments, process 1200 may include additional steps, fewer steps, or some steps may be divided into multiple steps. For example, for more than two sandwich wall panels, step 1220 may be repeated multiple times, depending on how many wall panels form the floors of the building. Steps 1250 and 1260 may be repeated multiple times for different portions of the building to create a structure having a top plate at multiple heights above different portions of the building (such as at a height from Fig. 10C A building 1080 having roof panels 1070 and 1090) on it.

[0084] The manufacturing process according to the present disclosure eliminates the need to cast in structural steel to weld the panels together, as described above, eliminating this need can help prevent fires. Due to the preset mold process described herein, all wall panel coordinates can be predetermined by engineering and cast accordingly. This allows the wall panels to be produced without the need for skilled labor, and also allows the wall panels and structural steel bottom and top plates to be erected and bolted together without the use of measuring tools (e.g., tape measures) or the use of a "stringer layout." This again reduces or eliminates the need for skilled labor on the construction site and standardizes and simplifies the construction building process.

[0085] Embodiments of the present disclosure may be used for a variety of residential building structures, including but not limited to single-family homes, multi-family homes, apartments, and condominiums. In addition, embodiments may be used for commercial and other structures, such as car washes, storage garages, cladding panels for high-rise buildings, low-rise cold storage rooms, low-rise office buildings, medical and dental clinics, strip malls, schools, hotels, manufacturing centers, data centers, shooting ranges, retail centers, municipal buildings, low-rise warehouses, grocery stores, beverage packaging rooms and production buildings, restaurants, and basements. Some or all windows, doors, and machinery (e.g., electrical and water supply and drainage systems) for these residential and / or commercial structures may be cast into the wall during the manufacturing and construction process.

[0086] Many variations and other embodiments of the present disclosure set forth herein will be desirable to those skilled in the art, for whom these inventions are suitable for the benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it should be understood that the present disclosure is not limited to the specific embodiments disclosed, and is intended to include variations and other embodiments within the scope of the appended claims. In addition, although the foregoing description and the associated drawings describe example embodiments in the context of certain example combinations of elements and / or functions, it should be understood that different combinations of elements and / or functions may be provided by alternative embodiments without departing from the scope of the appended claims. In this regard, for example, combinations of elements and / or functions different from those elements and / or functions explicitly described above are also considered, as may be set forth in some of the appended claims. Although specific terms are employed herein, they are used only in a general and descriptive sense, not for the purpose of limitation.

Claims

1. A wall panel, comprising: at least two fiber reinforced concrete layers, the at least two fiber reinforced concrete layers comprising concrete having interwoven fiber material; Insulation layer; as well as Connectors, wherein the thermal insulation layer is sandwiched between the at least two fiber reinforced concrete layers, and wherein the connector extends through the insulation layer and the concrete layer to create a composite effect between the insulation layer and the concrete layer.

2. The wall panel according to claim 1, wherein: The fiber reinforced concrete layer is no greater than about two inches thick.

3. The wall panel according to claim 2, wherein: The insulation is at least about four inches thick.

4. The wall panel according to claim 1, wherein: The fiber reinforced concrete layer includes polypropylene fibers.

5. The wall panel according to claim 1, wherein: The fiber reinforced concrete layer includes polyethylene fibers.

6. The wall panel of claim 1, further comprising a solid concrete portion covering the insulation layer.

7. The wall panel according to claim 6, wherein: The solid concrete portion comprises a fiber reinforced concrete material.

8. The wall panel according to claim 6, wherein: The solid concrete portion includes at least one large diameter tapcon anchor.

9. The wall panel according to claim 1, wherein: The fiber material in the concrete layer is configured to form air pockets when exposed to heat.

10. The wall panel according to claim 1, wherein: The wall panels do not include reinforcing steel material.

11. A building system, comprising: A plurality of wall panels, each wall panel comprising: a first concrete layer and a second concrete layer, each of the first concrete layer and the second concrete layer comprising fiber reinforced concrete including concrete embedded with an interwoven fiber material; an insulating layer disposed between the first concrete layer and the second concrete layer, wherein a peripheral edge of the insulating layer is inserted from respective peripheral edges of the first concrete layer and the second concrete layer, and the entire peripheral edge of the insulating layer is covered by a cap of fiber-reinforced concrete; a plurality of connectors spaced apart 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 where the insulation layer is recessed to form a first zone of solid fiber reinforced concrete extending between the first and second concrete layers; and At a second region at a lower end of the wall panel, the insulation layer is recessed at the second region to form a second zone of solid fiber reinforced concrete extending between the first and second concrete layers, the second region being sized to receive at least two tapcon anchors.

12. The building system according to claim 11, wherein: The first concrete layer includes no steel reinforcement extending entirely within a plane defined by the first concrete layer, and wherein the second concrete layer includes no steel reinforcement extending entirely within a plane of the second concrete layer.

13. The building system of claim 11, wherein: At least one of the plurality of wall panels includes: a conduit box embedded in the first concrete layer; and a conduit connected to the conduit box embedded in the first concrete layer.

14. A method for constructing a wall panel, the method comprising: providing a predetermined mold having a length in a first transverse dimension and a width in a second transverse dimension; forming a first concrete layer by pouring a wet concrete mixture containing a fiber material into the predetermined mold; While the concrete mixture is still wet, installing an insulation layer and one or more connectors so that the insulation layer and the connectors are embedded in the first concrete layer in the predetermined mold, wherein the length of the insulation layer is less than the width of the predetermined mold, the width of the insulation layer is less than the width of the predetermined mold, or both; Forming a second concrete layer by pouring the concrete mixture containing the fiber material onto the insulation layer and the connector in the preset mold; and The first and second concrete layers are allowed to dry, thereby forming a sandwich wall panel by composite action between the first and second concrete layers, the insulation layer, and the connector.

15. The method according to claim 14, wherein: The preset mold includes an opening.

16. The method of claim 15, further comprising forming windows in the sandwich wall panel from the openings in the predetermined mold.

17. The method of claim 14, further comprising lifting the sandwich wall panel from the predetermined mold.

18. The method according to claim 14, wherein: The sandwich wall panel comprises a solid fiber reinforced concrete portion.

19. The method of claim 14, further comprising adding a fiber reinforced concrete portion on the insulation layer such that the solid concrete portion completely covers the insulation layer.

20. The method according to claim 14, wherein: The preset mold has a length in a first transverse dimension and a width in a second transverse dimension, and wherein the length of the insulation layer is smaller than the width of the preset mold, the width of the insulation layer is smaller than the width of the preset mold, or both are true.

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