Abstract:
The present invention provided a precast modular concrete wall panel having a rectangular wall body with an upper slot and two side slots, and the wall body can further include an insulating layer and a decorative layer, and can contain a sandwich layer embedded in the concrete structure. The wall panels may be used with wall columns, wall corners and other components to form a wall panel system and further to form a building of frame structure or frame-share wall structure. Such wall panels have advantageous structural features and thus can be cost effectively prefabricated, and the construction process using such panel system can be performed with high efficiency.

Description:
FIELD OF THE INVENTION 
     The present invention generally relates to the field of architectural construction and, more particularly, to a precast modular concrete wall panel, system of such wall panels, and method of construction. 
     BACKGROUND OF THE INVENTION 
     Frame wall and frame-shear wall structures are common structural types in architectural design and construction. For constructing such structures, conventional processes of concrete casting often require on-site reinforcement bar wiring, template or mould assembling and dissembling prior and after concrete casting step. Such on-site processes are rather labor intensive and time consuming. 
     Precast modular units may be used for improve the efficiency of fabrication and construction. However, current art has not provided precast modular concrete wall panels and system with the structural features and process convenience as disclosed herein. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to provide a precast modular concrete wall panel, system thereof, and method of construction. 
     The present invention provided a precast modular concrete wall panel, comprising: a rectangular body, having a first face and a second face, an upper end and a lower end, and a first side and a second side, wherein an upper slot is formed along the upper end, and a first and second side slots are respectively formed along the first and second sides, and the body has a concrete structure with a plurality of steel bars for reinforcement. 
     The precast modular concrete wall panel may further comprise an insulating layer attached on the second face, and a decorative layer attached on the insulating layer. 
     The precast modular concrete wall panel may further comprise a sandwich layer, embedded in the concrete structure between the first face and the second face. 
     The present invention provided also a modular concrete wall panel system, comprising: a plurality of modular concrete wall panels, wall columns, floor templates and other components. 
     The present invention provided also a method for fabricating the modular concrete wall panels, the wall panel system, and buildings of frame structure or frame-share wall structure. 
     The precast modular concrete wall panels, as described herein, have advantageous structural features and thus can be cost effectively prefabricated. The on-site construction process of the wall panel system and corresponding building structure can be performed with high efficiency and low costs. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A-1F  are respectively front view, side view, top view, cross-section view, bottom view, and perspective view of a precast modular concrete wall panel in accordance with an embodiment of the present invention, wherein the wall panel has an upper slot and two side slots. 
         FIGS. 2A-2F  are respectively a front view, side view, top view, cross-section view, bottom view, and perspective view of a precast modular concrete wall panel in accordance with another embodiment of the present invention, wherein the wall panel, as compared to that of  FIGS. 1A-1F , further includes an insulating layer and a decorative layer. 
         FIGS. 3A-3F  are respectively a front view, side view, top view, cross-section view, bottom view, and perspective view of a precast modular concrete wall panel in accordance with yet another embodiment of the present invention, wherein the wall panel, as compared to that of  FIGS. 2A-2F , further includes a sandwich layer embedded therein but with exposure of all four edges, i.e., two end edges and two side edges. 
         FIG. 3G  is a cross-section view of a precast modular concrete wall panel in accordance with yet another embodiment of the present invention, wherein, as compared to the wall panel shown in  FIG. 3D , the sandwich layer has exposure of only two side edges. 
         FIG. 3H  is a perspective view of a unit of sandwich layer. 
         FIG. 4A  is a cross-section view showing a precast modular concrete wall panel of  FIGS. 1A-1F  connected side by side with a wall column. 
         FIG. 4B  is a cross-section view showing a precast modular concrete wall panel of  FIGS. 1A-1F  connected side by side with a shear wall. 
         FIG. 4C  is a cross-section view showing a precast modular concrete wall panel of  FIGS. 1A-1F  connected through the upper slot upwardly with a floor structure. 
         FIG. 5A  is a schematic perspective view of a building with a frame structure including a modular concrete wall panel system having a plurality of modular concrete wall panels, wall columns and floor structure. 
         FIG. 5B  is a schematic perspective view of a building with a frame-shear structure including a modular concrete wall panel system having a plurality of modular concrete wall panels, shear wall structure, wall columns and floor structure. 
         FIG. 6A  is a cross-section view of a building with a frame structure including precast concrete wall panels, wall columns and floor. 
         FIG. 6B  is a cross-section view of a building with a frame-shear wall structure including precast concrete wall panels, shear walls, wall columns and floor structure. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     Representative embodiments of the invention are explained below in detail. It is to be understood, however, that the present invention is not limited in its scope explained in the description or illustrated in the drawings. In the drawings, for convenience, similar components or parts have been marked with similar numerals. 
       FIGS. 1A-1F  illustrates an embodiment of the invention, the precast modular concrete wall panel  100 , comprising: a rectangular body, having a first face  110   a  and a second face  110   b , an upper end  120   a  and a lower end  120   b , and a first side and a second side, wherein an upper slot  130  is formed along the upper end  120   a , and a first and second side slots  140  are respectively formed along the first and second sides, and the body has a concrete structure with a plurality of steel bars therein for reinforcement. 
     The upper slot  130  runs through the entire length of the upper end  120   a , the side slots  140  run through the entire length of the sides, respectively, such that the upper slot  130  is connected to each of the side slots  140 . 
     The width and depth of the slots may vary based on actual needs. In a preferred embodiment, the upper slot  130  is greater in the depth of slot comparing to the side slots  140 . 
     The upper slot  130  and the side slots  140  have independently a cross-section shape of, for example, trapezoidal, rectangular, circular or triangular. 
       FIGS. 2A-2F  illustrates another embodiment, the precast modular concrete wall panel  200 , further comprising: an insulating layer  260  attached on the second face  110   b , and a decorative layer  270  attached on the insulating layer  260 , in addition to the components shown in  FIGS. 1A-1F . 
     In two sides of the insulating layer  260  are formed two side grooves  265 , which have a cross-section shape of, for example, semicircular, rectangular, trapezoidal or triangular. 
     The insulating layer  260  can be made of any insulating or anti-flaming materials, preferably polystyrene or phenol formaledlyde foam. 
     The decorative layer  270  can be made of any materials which have functions for decoration or for both decoration and insulation. 
       FIGS. 3A-3F  illustrates another embodiment of the invention, the precast modular concrete wall panel  300 , further comprising: a sandwich layer  345 , in addition to the components shown in  FIGS. 2A-2F . 
     The sandwich layer  345  is embedded in the concrete structure between the first face  110   a  and the second face  110   b , and can be positioned across the entire body of the panel (see  345  in  FIG. 3E ) or positioned across only a partial body of the panel (see  345 ′ in  FIG. 3G ). 
     Preferably, as shown in  FIG. 3H , a plurality of longitudinal dovetail grooves  347  are formed in two faces of the sandwich layer  345 , such that, during the prefabricating process, concrete can be poured into the grooves for a tight binding. 
     The sandwich layer  345  can be formed of any suitable lightweight materials, preferably, having insulating function, such as, polystyrene or phenol formaledlyde foam. 
       FIG. 4A  illustrates a precast modular concrete wall panel  410  connected side by side with a wall column  450 . A side of the wall panel  410  is positioned next to a side of the wall column  450  forming a channel there between, and the channel can be installed with a plurality of steel bars extending upwardly and poured into with concrete to secure a solid connection. 
       FIG. 4B  illustrates a precast modular concrete wall panel  410  connected side by side with a shear wall unit  460 . A side of the wall panel  410  is positioned next to a side of shear wall unit  460  forming a channel there between, the channel can be installed with a plurality of steel bars extending upwardly, and into the channel is poured with concrete to secure a solid connection. 
       FIG. 4C  illustrates a precast modular concrete wall panel  410  connected through the upper slot upwardly with a floor structure  470 . The steel bars placed in the upper slot of the wall panel  410  can be coupled with the steel bars of the floor unit  470  and poured into with concrete to secure a solid connection. 
     In the illustration of drawings, the components are marked with some particular sizes. In the embodiment of  FIG. 1C , for example, the wall panel is marked with a width of 600 mm. It is understood that, however, the width may be changed or modified if needed to any suitable ones, for example, 1,200 mm. 
       FIGS. 5A and 5B  illustrate embodiments of buildings of a frame structure  500   a  and a frame-shear wall structure  500   b , respectively. Such building includes a modular concrete wall panel system and floor structure. 
     The modular concrete wall panel system comprises: a plurality of modular concrete wall panels  510 , which are placed upwardly with the lower end setting on a structural base (floor component  570 , for example), a side of each panel is positioned next to a side of an adjacent panel or a wall column  550  or a shear wall panel  560 , the side slot of the each wall panel forming a channel between the each wall panel and the adjacent wall panel or the wall column or the shear wall panel; wherein, the channel is installed there through a plurality of steel bars extending upwardly and poured into the channel with concrete to secure a solid connection of the wall panel system. 
     In the modular concrete wall panel system, the wall panels can be complemented with certain special components such as door frames, window frames and corner components. As shown in  FIGS. 5A and 5B , for example, the wall panels  510  are complemented with a lintel  530  for window frame. 
       FIG. 6A  illustrates a building  600   a  with a frame structure including precast concrete wall panels  610 , wall columns  650 , lintel  630  and floor. 
       FIG. 6B  illustrates a building  600   b  with a frame-shear wall structure including precast concrete wall panels  610 , shear walls  660 , wall columns  650 , lintel  630  and floor. 
     The modular concrete wall panel system can be used to construct a single story structure by placing steel bars pouring concrete in the groove formed by the upper slots of the wall panels. As needed, such structure can be constructed as a frame structure or a frame-shear wall structure. 
     The single story structure can be as one story unit or a single story building. Based on architectural needs, such one story unit can be used as the base to construct multistory unit and further to a multistory building. 
     In one embodiment, for constructing a building having the modular concrete wall panel system, comprising the steps of: 
     (1) prefabricating a plurality of the modular concrete wall panels by using a mould, including for each of the wall panels: forming a body frame with a plurality of steel bars, configuring the upper slot and the side slots, installing the insulating layer, placing the decorative layer, and pouring concrete to form the modular concrete wall panel having the rectangular body, the insulating layer and the decorative layer; 
     (2) assembling the modular concrete wall panel system by positioning a plurality of modular concrete wall panels upwardly with the lower ends setting on a structural base, a side of each panel being positioned next to a side of an adjacent panel or wall column or shear wall panel, the side slot of the each panel forming a channel between the each panel and the adjacent panel or the wall column or the shear wall panel; 
     (3) setting up a floor template by positioning the floor template horizontally on top of the wall panels and wall columns to form a structure with the wall panels and the floor template; 
     (4) constructing an integrated wall panel system by placing through the channel between adjacent wall panels a plurality of steel bars extending upwardly on the structural base, and placing an insulating or sealing material through the longitudinal void formed by the side grooves of adjacent installing layers; 
     (5) constructing a beam structure by placing a plurality of steel bars in the groove formed by the upper slots of the plurality of modular concrete wall panels, and coupling the steel bars in the groove with structure of the floor template; and 
     (6) pouring concrete into the channels, the grooves and the floor template to form a single story building as a frame structure or a frame-shear wall structure. 
     The concrete used for the body of the wall panels can be regular concrete, lightweight aggregate concrete, or concrete blended or reinforced with fiber materials. 
     In another embodiment, the method further comprises: repeating the steps (1) through (5), on the basis of the single story building, to form a multi-story building as a frame structure or a frame-shear wall structure. 
     The foregoing description and drawings are provided only for the purpose of explanation and illustration of the present invention. The invention can be practiced through other embodiments or configured in various shapes, sizes, materials, and arrangements. As one of ordinary skill in the art would appreciate, the invention may be practiced with all suitable modifications and equivalents which still remain within the spirit and scope of the present invention.