Insulated tilt-up wall panel

A tilt-up wall panel formed on a horizontal support surface within a form comprises an outer foam layer having a top surface, and an outer surface with an outer finish layer applied thereto. An intermediate concrete layer having a bottom surface and a top surface is applied, at the bottom surface thereof, to the top surface of the outer foam layer. An intermediate foam layer having a bottom surface and a top surface is applied, at the bottom surface thereof, to the top surface of the intermediate concrete layer. A concrete inner layer having a bottom surface and a top surface is applied, at the bottom surface thereof, to the top surface of the intermediate foam layer. The tilt-up wall panel is then raised to a vertical position to form part of a wall of a building. Methods of forming the tilt-up wall panel are disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable.

Not Applicable.

FIELD OF THE INVENTION

This invention relates to building materials, and more particularly to an insulated tilt-up wall panel.

BACKGROUND

Tilt-up concrete wall panels are well known in the art and comprise a large percentage of industrial, warehouse, and other buildings. Concrete, however, is relatively dense and as n such has a relatively high thermal and sound transmission rate. For example, concrete formed with a sand and gravel aggregate has an R-Value of 0.13-0.64. Polystyrene foam boards, on the other hand, have R-Values of between 3.6 and 5.4. Yet polystyrene foam by itself is not nearly strong enough to be used as a wall panel for a building.

Therefore, there is a need for a tilt-up wall panel that has the strength of concrete but insulating and sound absorbing qualities that are similar to polystyrene. Such a needed invention would allow for a plurality of different outer finish layers to provide a variety of finished appearances. Such a needed wall panel would be relatively inexpensive, and would require a process similar to that of concrete tilt-up panels to lift and affix to a building structure. The present invention accomplishes these objectives.

SUMMARY OF THE INVENTION

The present device is a tilt-up wall panel formed on a horizontal support surface within a form. Such a horizontal support surface may be a smooth concrete slab prepared to be a casting surface for the tilt-up wall panel, for example, and may later be used as a floor of a building formed with a plurality of the tilt-up wall panels.

The tilt-up wall panel comprises an outer foam layer having a top surface, and an outer surface with an outer finish layer applied thereto. Such an outer finish layer may include stucco, brick facia, stone, vinyl-style siding, or other surface treatments as desired.

An intermediate concrete layer having a bottom surface and a top surface is applied, at the bottom surface thereof, to the top surface of the outer foam layer. An intermediate foam layer having a bottom surface and a top surface is applied, at the bottom surface thereof, to the top surface of the intermediate concrete layer. A concrete inner layer having a bottom surface and a top surface is applied, at the bottom surface thereof, to the top surface of the intermediate foam layer. When the tilt-up wall panel is raised to a vertical position, the top surface of the inner layer defines an inside surface of the tilt-up wall panel that is exposed to an interior portion of the building.

Steps required for forming the tilt-up wall panel include first providing the horizontal support surface suitable for use as a casting surface for concrete. The outer foam layer is in laid onto the support surface within the form, and then the intermediate concrete layer is poured into the form onto the top surface of the outer foam layer. Then, before the intermediate concrete layer cures, the intermediate foam layer is applied to the top surface of the intermediate concrete layer. Then, either immediately or sometime later, the concrete inner layer is poured over the top surface of the intermediate foam layer. When the concrete inner layer cures, the tilt-up wall panel may be raised up to a vertical position to form part of a building structure, as is known in the art.

In an alternate method of forming the tilt-up wall panel, the concrete inner layer is formed first, poured onto the horizontal support surface within the form. In such an embodiment a release agent may be applied to the horizontal support surface first, so that the concrete of the concrete inner layer is inhibited from bonding to the horizontal support surface, as is known in the art. Before the concrete inner layer cures, the intermediate foam layer is applied to the bottom surface of the concrete inner layer. Then, either immediately or sometime later, the intermediate concrete layer is poured onto the bottom surface of the intermediate foam layer, and the outer foam layer is applied to the bottom surface of the intermediate concrete layer. When the intermediate concrete layer cures, the tilt-up wall panel may be raised up to a vertical position to form part of a building structure, as is known in the art.

The present invention is a tilt-up wall panel that has the strength of concrete but insulating and sound absorbing qualities that are closer to polystyrene. The present invention allows for a plurality of different outer finish layers to provide a variety of finished appearances. The present wall panel is further relatively inexpensive, and requires a process similar to that of concrete tilt-up panels to tilt-up and affix to a building structure. Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS.1-3illustrate a tilt-up wall panel10formed on a horizontal support surface15within a form16. Such a horizontal support surface may be a smooth concrete slab prepared to be a casting surface for the tilt-up wall panel10, for example, and may later be used as a floor of a building (not shown) formed with a plurality of the tilt-up wall panels10.

The tilt-up wall panel10comprises an outer foam layer20having a top surface28, and an outer surface22with an outer finish layer21applied thereto. Such an outer finish layer21may include stucco, brick facia, stone, vinyl-style siding, or other surface treatments as desired. When the tilt-up wall panel10is lifted away from the horizontal support surface15and properly placed, it is intended that the outer finish layer21is visible from outside of the building (not shown). Various styles and materials can be used for the outer finish layer21. The outer foam layer20is preferably made with a polystyrene or similar foam material having a relatively high R-Value for providing excellent insulation.

An intermediate concrete layer30having a bottom surface32and a top surface38is applied, at the bottom surface32thereof, to the top surface28of the outer foam layer20. The intermediate concrete layer30is preferably made with an aggregate concrete that includes pebbles or sand, as is known in the art.

An intermediate foam layer40having a bottom surface42and a top surface48is applied, at the bottom surface42thereof, to the top surface38of the intermediate concrete layer30. The intermediate foam layer40is preferably made with a polystyrene or similar foam material having a relatively high R-Value for providing excellent insulation.

A concrete inner layer50having a bottom surface52and a top surface58is applied, at the bottom surface52thereof, to the top surface48of the intermediate foam layer40. When the tilt-up wall panel10is raised to a vertical position, the top surface58of the inner layer50defines an inside surface58of the tilt-up wall panel10that is exposed to an interior portion of the building (not shown). The concrete inner layer50is preferably made with an aggregate concrete that includes pebbles or sand, as is known in the art.

Steps required for forming the tilt-up wall panel10include first providing the horizontal support surface15suitable for use as a casting surface for concrete (FIG.1). The outer foam layer20is laid onto the support surface15within the form16, and then the intermediate concrete layer30is poured into the form onto the top surface28of the outer foam layer20. Then, before the intermediate concrete layer30cures, the intermediate foam layer40is applied to the top surface38of the intermediate concrete layer30. Then, either immediately or some time later, the concrete inner layer50is poured over the top surface48of the intermediate foam layer40. When the concrete inner layer50cures, the tilt-up wall panel10may be raised up to a vertical position to form part of a building structure, as is known in the art.

In an alternate method of forming the tilt-up wall panel10, the concrete inner layer50is formed first, poured onto the horizontal support surface within the form16. In such an embodiment a release agent17(FIG.2) may be applied to the horizontal support surface15first, so that the concrete of the concrete inner layer50is inhibited from bonding to the horizontal support surface15, as is known in the art. Before the concrete inner layer50cures, the intermediate foam layer40is applied to the bottom surface52of the concrete inner layer50. Then, either immediately or sometime later, the intermediate concrete layer30is poured onto the bottom surface42of the intermediate foam layer40, and the outer foam layer20is applied to the bottom surface32of the intermediate concrete layer30. When the intermediate concrete layer30cures, the tilt-up wall panel10may be raised up to a vertical position to form part of a building structure, as is known in the art.

In some embodiments the outer foam layer20includes a keyed recess60into which concrete of the intermediate concrete layer30flows. Once cured the outer foam layer20is fixed or locked with the intermediate concrete layer30. In a similar manner the keyed recess60may be formed into either side of the intermediate foam layer40to lock the intermediate foam layer40to either the intermediate concrete layer30or the concrete inner layer50.

In some embodiments, a malleable wire mesh70is fixed with the bottom surface42of the intermediate foam layer40, the top surface48of the intermediate foam layer40, or both, such that either the intermediate concrete layer30or the concrete inner layer50, or both, are locked together with the intermediate foam layer40. Similarly, the wire mesh70can be fixed with the top surface28of the outer foam layer20to lock the outer foam layer20to the intermediate concrete layer30.

While a particular form of the invention has been illustrated and described, it will be apparent that various modifications can be made without departing from the spirit and scope of the invention. For example, additional layers of foam or concrete may be utilized. Accordingly, it is not intended that the invention be limited, except as by the appended claims.